| Summary: | 碩士 === 國立成功大學 === 工學院工程管理專班 === 91 === Most of production losses in chemical plants were cause by equipment failures. Arrangements shall be implemented to ensure that any item of plant or equipment, which failure would adversely affect the level of safety. ‘Safety Critical’ equipment arrangements shall be implemented to ensure a high level of integrity is assured throughout the life cycle of the equipment, the extent of arrangements should be appropriate and in proportion to its contribution to the overall safety risk. That is the concept of MI.
In the Study, we used PHA、HAZOP、FMEA、RBI, a set of studies carried out to ensure that Naphtha cracking plant’s hazards are identified and understood, properly controlled to minimize risks, and eliminated if practicable. The scope of the Naphtha cracking plant risk analysis included three process units, more than 1894 vessels. The process units assessed were：（1）master unit（2）Acetylene reuse unit（3）Ethylene storage tank unit. These units were representative of the vessels in the plant and the potential failure modes that could be expected. In 3 years HAZOP program, the plant has increase the reliability of vessels from 88.2﹪ to 98.1﹪.That is, the equipment that accounted for likelihood-of-failure values of 3 and 4 have shifted to likelihood-of-failure values of 4 and 5.
The application of risk-based prioritization for scheduling maintenance and NDT activities can yield significant economic advantages. In this study, the plant creates a relative risk ranking. Reliable data analysis and a commitment to a strategy also could reduce the furnace shutdown times from 3 times/per year to 0, and reduce the loss caused by furnace shutdown from NT$11,900,000/ per year to 0.
The risk-based effort has resulted in an inspection program with improved performance and reliability at a lower production loss and documented risk.
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