非恒定故障率安全联锁系统执行机构的时变竞争失效研究

doi:10.11949/0438-1157.20240531

摘要/Abstract

摘要：

安全联锁系统（SIS）在防止化工装置发生危险事故方面发挥着重要作用，但由于复杂的工作环境，SIS执行机构不可避免地受到老化退化以及外界需求冲击的影响，造成传统可靠性模型中的恒定故障率假设不再适用。为此针对具有非恒定故障率的执行机构，基于失效模式以及失效机理，考虑退化过程的时变特性，引入退化速率加速因子、退化突增量系数以及时变硬失效阈值，提出了N取K结构（KooN）通用的退化、冲击相互依赖竞争失效模型DCFP-TVC，并将该模型应用于风力发电制氢氧纯度联锁回路。实例表明，相比恒定故障率模型、其他竞争失效模型，所提模型可有效解决非恒定故障率执行机构可靠性分析精度低的难点，并且以重要退化参数进行灵敏度分析，说明其对可靠性、失效时间分布的影响效果，提出调整验证测试间隔的建议，实现执行机构非周期检测的风险管控。

关键词: 安全联锁系统, 竞争失效, 过程控制, Monte Carlo模拟, 制氢

Abstract:

The safety interlock system (SIS) plays an important role in preventing hazardous accidents in chemical plants. Due to the complex working environment, SIS actuators are inevitably affected by aging degradation and external demand shocks, resulting in the assumption of constant failure rate in traditional reliability models no longer being applicable. To this end, based on failure modes and mechanisms, considering the time-varying characteristics of the degradation process, a universal dependent competing failure processes considering time-varying characteristics (DCFP-TVC) for KooN structures was proposed by introducing degradation rate acceleration factor, degradation sudden increment coefficient, and time-varying hard failure threshold to achieve stochastic failure process modeling of non-constant failure rate actuators. The application of this model to the hydrogen oxygen purity interlocking circuit of wind power generation shows that compared to the constant failure rate model and other competing failure models, the proposed model can effectively solve the difficulties in reliability analysis of non-constant failure rate actuators, and the sensitivity analysis is carried out with important degradation parameters to illustrate its influence on reliability and failure time distribution, and the suggestion of adjusting the proof test interval is proposed to realize the risk control of non-periodic detection of actuators.

Key words: safety interlock system, competing failure, process control, Monte Carlo simulation, hydrogen production

中图分类号:

X 937

孙冰颜, 王海清, 张玉涛, 汪肆杰. 非恒定故障率安全联锁系统执行机构的时变竞争失效研究[J]. 化工学报, 2024, 75(12): 4646-4653.

Bingyan SUN, Haiqing WANG, Yutao ZHANG, Sijie WANG. Research on time-varying competitive failure of safety interlock system actuators with non-constant failure rate[J]. CIESC Journal, 2024, 75(12): 4646-4653.

图/表 8

图1 考虑时变退化速率、退化突增量及冲击失效阈值的竞争失效过程

Fig.1 Dependent competing failure processes considering time-varying characteristics

图2 一般竞争失效模型与DCFP-TVC模型

Fig.2 General DCFP model and DCFP-TVC model

图3 氧纯度联锁回路

Fig.3 Oxygen purity interlock circuit

表1 DCPF-TVC竞争失效模型中涉及的参数值

Table 1 Parameter values involved in DCFP-TVC

参数	数值	参数	数值	参数	数值
H	1.25×10^{-3 [18]}	a₁	4.0×10^-2（假设）	β₀	~N( $μ_{β_{0}}, σ_{β_{0}}^{2}$ ); $μ_{β_{0}}$ =8.4823×10^-9； $σ_{β_{0}}$ =6.0016×10^{-10 [18]}
λ_de	5.0×10^-5 h^-1	a₂	-1.5×10^-2（假设）	β₀
D₀	1.5G^[18]	a₃	5.0×10^{-2 [14]}	W_j	~N( $μ_{W}, σ_{W}^{2}$ ); $μ_{W}$ =2.0×10^-2； $σ_{W}$ =1.5×10^-2（假设）
$φ$	0^[18]	b₁	8.0×10^-2（假设）	Y_j	~N( $μ_{Y}, σ_{Y}^{2}$ ); $μ_{Y}$ =1.0×10^-4； $σ_{Y}$ =2.0×10^{-5 [18]}
α	300^[19]	b₂,b₃	0^[14]	τ	8760 h

表1 DCPF-TVC竞争失效模型中涉及的参数值

Table 1 Parameter values involved in DCFP-TVC

参数	数值	参数	数值	参数	数值
H	1.25×10^{-3 [18]}	a₁	4.0×10^-2（假设）	β₀	~N( $μ_{β_{0}}, σ_{β_{0}}^{2}$ ); $μ_{β_{0}}$ =8.4823×10^-9； $σ_{β_{0}}$ =6.0016×10^{-10 [18]}
λ_de	5.0×10^-5 h^-1	a₂	-1.5×10^-2（假设）	β₀
D₀	1.5G^[18]	a₃	5.0×10^{-2 [14]}	W_j	~N( $μ_{W}, σ_{W}^{2}$ ); $μ_{W}$ =2.0×10^-2； $σ_{W}$ =1.5×10^-2（假设）
$φ$	0^[18]	b₁	8.0×10^-2（假设）	Y_j	~N( $μ_{Y}, σ_{Y}^{2}$ ); $μ_{Y}$ =1.0×10^-4； $σ_{Y}$ =2.0×10^{-5 [18]}
α	300^[19]	b₂,b₃	0^[14]	τ	8760 h

图4 各模型可靠性曲线对比

Fig.4 Comparison of reliability curves for various models

图5 DCFP-TVC/NTVC的PFDavg对比结果

Fig.5 Comparison of PFDavg between DCFP-TVC /NTVC

图6 退化参数对可靠性和失效时间分布的影响

Fig.6 Impact of degradation parameters on reliability and failure time distribution

表2 不同a3下的测试间隔更新结果

Table 2 Update results of test intervals under different a3

参数	第一测试间隔	第二测试间隔	第三测试间隔	第四测试间隔	第五测试间隔
a₃=0.05	(0,3τ)	(3τ,6τ)	(6τ,7.15τ)	(7.15τ,7.28τ)	(7.28τ,7.38τ)
a₃=0.50	(0,3τ)	(3τ,6τ)	(6τ,6.43τ)	(6.43τ,6.64τ)	(6.64τ,6.78τ)
a₃=1.50	(0,3τ)	(3τ,5.05τ)	(5.05τ,5.36τ)	(5.36τ,5.55τ)	(5.55τ,5.72τ)
a₃=2.50	(0,3τ)	(3τ,3.82τ)	(3.82τ,4.43τ)	(4.43τ,4.91τ)	(4.91τ,5.25τ)

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