近年來國內外石化廠頻傳工安事故，其中爆炸事件的關鍵因素往往與製程設備發生局部開裂破壞，抑或銲道裂縫有關，由於石化廠管線設備複雜，廠務人員在日常維修過程中極易漏檢細微的破壞，也因而經常造成意外的爆炸。因此，引用更科學而有效的方法與技術，解決設備及管線老化而衍生的裂縫問題，對提昇製程設備安全，避免災害發生，是關乎石化業的永續經營、國際競爭力與環境生態保護，實是當前政府最須重視的課題之一。本研究計畫結合國立中央大學與工業技術研究院的技術與經驗，依據美國石油協會頒佈的API RP 579- Fitness for Service(FFS)規範，採用先進的非破壞檢測配合高空繩索技術(Rope Access Technology)，針對桃園煉油廠製程設備進行裂縫檢測、材質評估與量化損傷分析，落實設備適用性評估，再透過失效機率(POF)與引致損失(COF)估算損害機制以進行風險分析，進而針對高風險的構件運用自行研發的藍芽智慧貼片來長期監測。監測的結果可利用貝氏定理結合先前計算之失效機率並更新為事後機率(posterior probability) ，最後再以風險基準檢測法(RBI)歸納出石化廠管線設備的系統性風險，提供石化業者設備維護管理的創新技術，協助石化業主管機關制定更嚴謹的檢驗標準與作業規定，達到快速提昇石化廠設備安全的目的。 ;In recent years, industrial safety accidents have frequently occurred in the petrochemical plants in the whole world. The major factors of the explosion incidents are mostly related to cracks on the process facilities or the weldment. Due to the process complication in the petrochemical plants, facilities are never easy to maintain for engineers to detect subtle cracks thoroughly. Hence, most explosion occurred unexpectedly. So it is crucial in employing more advanced and effective technologies to solve the crack problems due to facilities aging, to improve process safety, and to avoid industrial disasters. Such action really matters for the sustainable operation of the petrochemical industry to enhance international competitiveness and environmental protection. The government should pay great attention and set up proper regulations to guarantee it.This project integrates National Central University’s academical knowledge and Industrial Technology Research Institute’s expertise and extensive technologies. Based on the API RP 579- Fitness for Service (FFS) specification issued by the American Petroleum Institute, advanced non-destructive methods will be utilized together with rope access technology to conduct crack inspection. Material evaluation and quantitative damage analyses for the process equipment in the Taoyuan Refinery. Actual fitness of the facilities will be well assessed. This research will conduct risk analyses through the damage mechanism calculations using the methodologies of probability of failure (POF) and consequences of failure (COF). For high risk facilities, self-developed bluetooth smart tags will then be applied for long-term monitoring. In addition, Bayesian theory is adopted to combine the information collected from monitoring and prior probability forming a terminal of posterior probability of POF. Eventually, risk-based inspections (RBI) program will be proposed to summarize the systematical risks about facilities in the petrochemical plant and to provide innovative technologies for the management of plant maintenance. The results would be helpful for the petrochemical plant to meet the requirements of more stringent inspection standards and operational regulations set up by the regulatory authority to improve facility safety.
