焦炭塔自动顶盖机与底盖机故障类型及故障频率分析

Analysis of types of failures of coke drum unheading devices and failure frequency

通过调研,搜集了两家大型石化公司12家企业的43台法兰密封型顶盖机、22台法兰密封型底盖机、7台平板式阀门底盖机的180起故障,并进行了统计分析,比较和分析了法兰密封型自动顶盖机和底盖机的故障情况,以及法兰密封技术和阀门密封技术的优缺点,提出了建议措施:建议有关企业加强顶/底盖机设备的维护保养能力,提高维保人员的素质,加强监测,有效降低故障频率;在关键设备的设计、制造、采购和安装全过程,实施严格的质量保证措施,做到全面质量管理,确保产品生产的全过程质量处于受控状态;加强技术人员和操作人员在顶/底盖机设备结构、运行原理、操作技能方面的培训,正确处理生产中出现的问题;建议在顶盖机锁环部位设置开关位回讯信号,接入DCS系统联锁,将此信号与四通阀进行联锁,同时加机械确认装置,确保锁环到位,防止出现类似事故;加强平板闸阀结构的自动顶/底盖机的研发,加快国产化速度,加强设备可靠性、安全性分析。

A survey has been performed to collect information on 180 failures occurred on 43 flange-seal top unheading devices,22 flange-seal bottom unheading devices and 7 plate valve bottom unheading devices in 12 large petrochemical plants. A statistical analysis was conducted on those failures. The failures of flange-seal top unheading device and bottom unheading device were analyzed and compared, and recommendations were proposed, such as： the maintenance capability for top/bottom unheading divices should be enhanced, the tech-nical skills of maintenance people should be improved, and unit operation should be strictly monitored to effec- tively reduce the occurrences of failures. In the process of design, fabrication, procurement and installation of equipment, effective quality control measures must be taken to ensure that the quality of equipment was completely under control in the whole production process. The technical training should be strengthened for operators on the equipment construction, operating mechanisms and operating skills in operation of top/bottom unheading devices so as to be able to handle various problems arising in unit operation. The position signal shall be provid- ed for the interlock of unheading devices, which is connected with the interlock of DCS system and the interlock of 4-way valve. When the interlock is not completely closed, the 4-way valve can not be switched over. The re- search and development of automatic top/bottom unheading device of plate gate valve construction shall be strengthened to accelerate the domestic fabrication and strengthen the analysis of reliability and safety.