Research On Key Technology Of Asset Integrity Management For Mechanical Equipment On The Offshore Platform Based On RCM

With the change of the world energy supply structure,especially the international oil prices continue to slump in recent years,the need for enterprises to control production costs and enhance production safety management has become increasingly prominent.At present,Asset Integrity Management(AIM)has gradually become the core technology of equipment management in high-risk enterprises,in order to reduce the occurrence of major accidents,reduce equipment maintenance costs,improve enterprise economic benefits.As the offshore platform equipment automation,integration and refinement is more and more high,in the process of operation,the important function of equipment failure will cause unplanned downtime,resulting in significant loss of production and high maintenance costs,and even lead to serious safety accidents and environmental pollution.Then,for the offshore platform equipment assets with high risk,CNOOC oil and gas enterprises have gradually started the research and application of the AIM technology in recent years.However,due to the complex structure,changing operating conditions,various fault modes,high risk of failure of the offshore platform equipment,there is no set of mature,systematic AIM system,but also the lack of scientific supporting key technologies.Therefore,in order to realize the dynamic scientific management of equipment on offshore platform,to ensure the safe operation of the equipment moving and reduce maintenance cost,this paper carried out the research of equipment integrity management dynamic ocean platform based on Reliability-Centered Maintenance(RCM).The purpose of this study is to form a number of independent intellectual property rights of the AIM key technologies to break the monopoly of foreign AIM technology and services,improve the international competitiveness of China's offshore oil and oil companies.The main research contents and results are as follows.(1)Based on the PDCA cycle and the existing AIM methods,an Integrity Management System of the offshore platfonn mechanical equipment with RCM was established in this paper by analyzing its current situation about application,maintenance and management.In addition,taking the characteristics of offshore platform mechanical equipment and development trend of maintenance management into consideration,a reinforced RCM(RRCM)was put forward in this paper to solve the application problems and deficiencies of traditional RCM.Meanwhile,combined with the ABC classification method and RCM maintenance logical decisions figure,a classification maintenance logic decision method was proposed in this paper to meet the demand of RRCM analysis in order to achieve a scientific decision-making of maintenance methods for the mechanical equipment.(2)By considering the operating characteristics of offshore platform mechanical equipment,including high risk,high cost and other factors,a kind of classification method of the offshore platform mechanical equipment was presented based on their risk level and importance degree level.Firstly,the low risk matrix was used to quickly screen out non-risk products and risk products from a large number of products.Secondly,the multistage risk matrix was applied to rescreen out the risk products,then low risk products and medium&high risk products were accurately distinguished.The screening process effectively reduced the number of the evaluation objectes of importance evaluation process.Moreover,in order to realize the importance of quantitative evaluation,importance evaluation index and scoring standard of the mechanical equipment was established.Thne a combination and group method on the importance evaluation was proposed to ensure rationality and scientificity of the results of importance evaluation based on Fuzzy Borda method and AHP method.The Monte Carlo Simulation was used to eliminate the influence of subjective factors in the importance evaluation process.Finally,taking the mud pump as an example to validate the methods above,their analysis results were in line with the engineering practice.(3)According to the analysis on the modeling purpose and requirement of the maintenance decision of the offshore platform mechanical equipment,the computing method of maximum likelihood estimation was put forward to determine cumulative failure distribution function.In this paper,the economy,task and safety were considered as the scheduled maintenance strategy optimization index,and its cost model,availability model and risk model were established respectively.And then the chain of Mud Pump was taken as an example to verify the regular maintenance model.Meanwhile the task and economy were determined as the optimization index of the hidden failure detection strategy,and the availability model and cost model were established respectively,then the safety valve of Mud Pump was taken as an example to verify the hidden failure detection model.Moreover,with the RRCM maintenance decision method,the formulation and optimization method of maintenance program of the offshore platform mechanical equipment was proposed,and then the optimization method of maintenance program was verified by taking the crane as an example.(4)On the basis of traditional FMECA method,a streamlined FMECA(SFMECA)was put forward in this paper,which provided more detailed data for the subsequent risk assessment and maintenance decision.In order to realize the quantitative evaluation of the failure risk,a kind of risk evaluation method of failure mode was put forward based on the Fuzzy Set,Grey Correlation Degree and a developed Borda method.Then risk value and risk grade of the A-shape frame and the hoisting system in a crane were quantitatively evaluated,which reduced the risk node effectively.Moreover,an multi-layer Borda sequence value method was put forward for multi-level evaluation problem in this paper.The quantitative comprehensive evaluation for the equipment/parts risk was achieved.Then the main structure system of the truss crane was evaluated to get the risk value and risk grade of its components and subsystems.(5)The characteristic state space was used in mechanical equipment health condition recognizing,the relative impainnent grade was used for characterization of the state of degradation,and the calculation formula of relative deterioration degree of characteristic quantity was also determined.For realizing the integrity evaluation of mechanical equipment,a kind of fuzzy evaluation method for health condition of mechanical equipment was put forward in this paper.The feasibility of this method was verified in a mud pump power end.This method realize the evaluating effects by defining the occurrence probability of failure mode and the full-degradation probability of the characteristic quantity,as well as the variable weight synthesis theory and fuzzy theory.Moreover,a time series prediction model for mechanical equipment health condition based on LS-SVR was proposed in this paper by considering the time history of characteristic quantity.The health condition prediction and residual life evaluation of the mechanical equipment had come true.And the method was verified with a cross and guide component,which showed that the prediction error was tiny,and the problems of characteristic quantity redundancy and huge calculation were effectively avoid.(6)The operability and practicability must be guaranteed for the key technologies of mechanical equipment integrity management in this paper.In this case,the analysis software for the RRCM of mechanical equipment on offshore platform was developed.This software was developed by using C#language based on B/S structure.The function of the software includes system setting,project&index management,importance degree evaluation,SFMECA analysis,risk evaluation,maintenance decision and optimization,report exporting etc.and the software has easy operation,strong interactivity,data sharing,rapid upgrading,etc.The software was strictly tested within F-1300 mud pump.The analysis process and results showed that the software enhanced the practicality and maneuverability of RRCM analysis method,reduced the repeated work effectively,improved the efficiency of the overall analysis and decreased the cost analysis.