原料油增压泵风险分析技术研究

发布时间：2018-05-04 09:02

本文选题：HAZOP + 风险评估　；参考：《北京化工大学》2015年硕士论文

【摘要】：原料油增压泵是渣油加氢装置中的重要设备之一,其是否安全稳定运行对整套装置有重要影响。进行泵运行过程风险分析,辨识自身故障和系统原因导致的异常状态及其对整个过程造成的影响是石化装置泵运行过程状态监测、故障预警和事故防控的前提,也可为操作人员处理故障或事故提供参考依据。为了对原料油增压泵风险进行分析和辨识,本文综合风险分析、故障辨识、后果模拟以及流体力学模拟等方法,研究并提出了原料油增压泵风险分析技术。首先应用危险与可操作性(Hazard and Operability Analysis,简称HAZOP)分析方法,对原料油增压泵所处过程系统进行了定性风险分析,分析了系统原因导致异常工况、故障或事故,得出原料油增压泵潜在的高风险事件及不稳定事件,辨识了其自身故障原因,计算了失效概率；其次,针对HAZOP分析辨识得到的高风险泄漏事件,采取定量风险计算方法计算由于多原因耦合导致的泵故障率和失效后果；再次,针对HAZOP分析辨识得到泵效率低的不稳定事件,基于参数敏感性分析方法研究转速、叶轮直径等因素对泵效率的影响。主要工作和结论如下：(1)对原料油增压泵所处的工艺单元进行HAZOP定性分析,识别设备潜在风险,评定原因事件的风险等级,得到系统潜在的高风险事件和不稳定事件,分析发现：泄漏事故和泵效率低是原料油增压泵所处工艺单元过程的重要潜在风险。(2)针对原料油增压泵泄漏事故进行定量风险分析,建立原料油增压泵所处节点的泄漏事故树,转化为贝叶斯网络模型,定量计算事故的可能性概率；分析泄漏事故后果模式,应用PHAST软件定量计算泄漏事故后果严重度；综合可能性和严重度等级划分,构建风险矩阵,确定泄漏原因事件风险。分析发现：安装或维护不当是导致泄漏事故的高风险事件,异常振动、机械密封异常磨损导致泄漏事故的风险等级较高。定量分析得到的结论可用于泄漏事故风险预防措施和应急预案的确定。(3)针对原料油增压泵效率低事件进行参数敏感性分析,设计单因素影响试验和正交试验分别研究效率影响因素的局部敏感性和全局敏感性。应用FLUENT软件完成试验设计计算,分析效率影响因素的重要度排序。研究发现：电机转速和介质粘度对泵运行效率有显著影响,叶轮磨损量、介质密度及出口压力等因素对效率影响较低。利用参数敏感性分析得到的结论可用于泵高效运行措施的提出。本文依据原料油增压泵风险辨识、风险分析和参数敏感性分析,提出事故预防、应急处理及提高运行效率措施,对提高设备安全管理效率,保障原料油增压泵安全高效运行有非常重要的实际意义。
[Abstract]:Feedstock booster pump is one of the important equipment in residue hydrogenation unit, and its safe and stable operation has an important effect on the whole unit. Risk analysis of pump operation process, identification of abnormal state caused by self-fault and system reason and its influence on the whole process are the premise of monitoring, fault warning and accident prevention and control of pump operation process in petrochemical plant. It can also provide reference for operators to deal with faults or accidents. In order to analyze and identify the risk of feedstock booster pump, the risk analysis technology of feedstock booster pump is studied and put forward in this paper, such as risk analysis, fault identification, consequence simulation and hydrodynamic simulation. Firstly, the hazard and maneuverability Hazard and Operability Analysis, (HAZOPP) analysis method is used to analyze qualitatively the risk of the process system of the feedstock booster pump, and the system causes of abnormal working conditions, faults or accidents are analyzed. The potential high risk events and unstable events of the feedstock booster pump are obtained, the causes of its own faults are identified, and the failure probability is calculated. Secondly, aiming at the high risk leakage events identified by HAZOP analysis, Quantitative risk calculation method is adopted to calculate the failure rate and failure consequence of the pump caused by multi-cause coupling. Thirdly, the rotational speed is studied based on the parameter sensitivity analysis method in view of the unstable events with low pump efficiency obtained by HAZOP analysis. The influence of impeller diameter and other factors on pump efficiency. The main work and conclusions are as follows: (1) HAZOP qualitative analysis of the process unit of the feedstock booster pump, identification of the equipment potential risk, assessment of the risk grade of the cause event, obtaining the potential high risk events and unstable events of the system. It is found that the leakage accident and low pump efficiency are important potential risks in the process of the process unit of the feedstock booster pump. (2) quantitative risk analysis is carried out for the leakage accident of the feedstock booster pump, and the leakage accident tree of the node of the feedstock booster pump is established. Transform into Bayesian network model, calculate probability probability of accident quantitatively; analyze the model of leakage accident consequence, use PHAST software to calculate the severity of leakage accident consequence quantitatively; divide synthetically possibility and severity grade, construct risk matrix, Determine the risk of leakage events. It is found that improper installation or maintenance is a high risk event leading to leakage accident, and abnormal vibration and abnormal wear of mechanical seal lead to high risk of leakage accident. The conclusion of quantitative analysis can be used to determine the risk of leakage accident and the emergency plan. (3) the parameter sensitivity analysis of low efficiency events of feedstock booster pump can be carried out. The local sensitivity and global sensitivity of the influencing factors of efficiency were studied by single factor test and orthogonal test respectively. FLUENT software is used to complete the design and calculation of the experiment, and the importance ranking of the influencing factors of efficiency is analyzed. It is found that motor speed and medium viscosity have significant influence on pump efficiency, while impeller wear, medium density and outlet pressure have little effect on efficiency. The conclusions obtained from the parameter sensitivity analysis can be used to put forward the efficient operation measures of the pump. According to the risk identification, risk analysis and parameter sensitivity analysis of feedstock booster pump, this paper puts forward the measures of accident prevention, emergency treatment and improving operation efficiency, which can improve the efficiency of equipment safety management. It is of great practical significance to ensure the safe and efficient operation of the feedstock booster pump.
【学位授予单位】：北京化工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TE96

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