4 API RP 581 Code를 기반.hwp

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1 CORROSION SCIENCE AND TECHNOLOGY, Vol.11, No.5(2012), pp.179~183 API RP 581 Code 를기반으로한 LNG 플랜트의 Risk-Based Inspection(RBI) 기술개발 최송천 최재붕 1 황인주 2 한국가스안전공사가스안전연구원, 1 성균관대학교기계공학부, 2 한국건설기술연구원 (2012 년 4 월 26 일접수, 2012 년 10 월 16 일수정, 2012 년 10 월 16 일채택 ) Development of Risk-Based Inspection(RBI) Technology for LNG Plant Based on API RP581 Code Song-Chun Choi, Jae-Boong Choi 1, and In-Ju Hawang 2 Korea Gas Safety Corporation, Institute of Gas Safety R&D, Siheung , Korea 1 School of Mechanical Engineering, Sungkyunkwan University, Suwon , Korea 2 Korea Institute of Construction Technology, Ilsan , Korea (Received April 26, 2012; Revised October 16, 2012; Accepted October 16, 2012) As one of promising solutions to overcome high oil price and energy crisis, the construction market of high value-added LNG plants is spotlighted world widely. The purpose of this study is to introduce LNG-RBI system to develop risk assessment technology with RAM(Reliability, Availability, Maintainability) modules against overseas monopolization. After analyzing relevant specific features and their technical levels, risk assessment program, non-destructive reliability evaluation strategy and safety criteria unification class are derived as core technologies. These IT-based convergence technologies can be used for enhancement of LNG plant efficiency, in which the modular parts are related to a system with artificial optimized algorithms as well as diverse databases of facility inspection and diagnosis fields. Keywords : information technology, LNG plant, reliability, risk based inspection, risk assessment 1. 서론 세계적인에너지위기및고유가를극복하기위해고부가가치의 LNG 플랜트건설시장이최근해외건설시장에서각광을받고있다. LNG 플랜트의경우다른중요기간산업설비와마찬가지로설계시부터안전성이확보되어야하므로, 해외선진기업은안전성평가전문기업으로부터고액의컨설팅을받아시공, 관리, 운영등을수행하고있다. 1) 본연구의목적은 LNG 플랜트의위험도기반진단기술 (Risk Based Inspection: RBI) 평가기술에대한현재까지의개발현황을소개하기위한것으로써, LNG 플랜트설비및배관계통도에대하여 API RP 581 Code를기반으로인공지능을내재한웹기반의최적화위험도평가모듈을개발하여 RAM(Reliability, Availability, Maintainability) 기반의 LNG 플랜트모듈화기술에접목시키고자한다. 이를위해엔지니어링효율성개선기술과연계하여운전전후및유지관리를위한검사 진단분야에서도활용할수있도록시스 Corresponding author: scchoi@kgs.or.kr 템을구축하기위한 LNG-RBI 시스템의소프트웨어에대한기본설계내용을소개하고자한다. 2. Risk 개념정의및적용분야위험요소 (hazard) 는사람, 재산또는환경에피해를미칠수있는잠재성을가진고유한물리적, 화학적특성을말한다. 위험도 (risk) 는어떠한기회에의해서사람또는설비에손상을입히는데원인이되는잠재적인위험성또는유해성이사고로이어질수있는빈도 (frequency) 와사고결과 (consequence) 의곱으로이루어지는시나리오시스템으로정의된다. 2) 또한신뢰성 (reliability) 은주어진시간내에파손이발생하지않을확률을의미하며, 유지관리성 (maintainability) 은주어진시간내에보수 수리를수행할확률을의미한다고할수있다. 위험도기반의진단및관리 (Risk-Based Inspection & Management: RBIM) 기술은기존의시간에기초한검사와는달리 Fig. 1에나타낸바와같이개개의설비와관련된위험도를파손확률 (likelihood of failure: LOF) 과피해결 179

2 SONG-CHUN CHOI, JAE-BOONG CHOI, AND IN-JU HAWANG 과 (consequence of failure: COF) 에의해측정가능한손실비용 (Risk=LOF COF) 으로계량화함으로써, 잠재적으로위험도가높은설비에초점을집중하여검사및보수의우선순위를결정하는기술이다. 특히, RBI 기술은압력용기를포함하여 pump seal 부분의파손까지도포함하고있다. 3) 또한검사의우선순위를결정함으로서산업현장에서의고위험군에속하는장치에대하여집중적인검사기법을제공함은물론손상에따른메카니즘을제공하여효율적인검사와함께검사비용의절감을꾀할수있다. 4) 이는 RAM 기반의 LNG 플랜트모듈화를위한핵심사항의하나이며, 전체설비계통에대한정성적 정량적위험도지수를평가하고각설비에대한안전지수를산정하여저비용고효율의안전관리시스템을구축하는진단및관리기술로정의할수있다. 즉, LNG 플랜트에서존재하는상시위험성에대한정량적인시스템위험도평가및비파괴평가시스템을구축한후인공지능미들웨어를탑재하고 Enterprise resource planning(erp) 시스템과연동이가능하도록엔지니어링요소기술및핵심인자를제공함으로써, 대형사고예방및에너지자원의안정적공급을도모할수있는필수적기술이라할수있다. 3. LNG 플랜트의파손확률및피해영향평가모델 LNG플랜트에대한고정장치 ( 압력용기, 배관, 드럼, 열교환기, 타워등 ) 에대한위험성평가를위해서는우선장치의파손확률 (P f(t)) 을계산하여야한다. 이경우 API Code 에서제시하고있는일반파손빈도 (gff) 와손상인자 (D f(t)) 및경영평가인자 (F MS) 를곱하여파손확률을계산할수있다. 일반파손빈도는전세계석유화학업계에서축적된데이터를근거로하여 American Petroleum Institute(API) 에서수집한자료를바탕으로 Code 에반영하였으며, 손상인자는아래의 Table 1과같이총 21개로구성되어있다. Fig. 1에서제시된바와같이 API 581 RP Code에서기술하는위험도평가를위한플랜트내의파손확률은아래의식 (1) 로표현된다. 5) (1) P f(t) : Probability of failure gff : Generic failure frequency D f(t) : Damage factor : management system factor F MS 위험성기반진단기술에서파손확률을평가할경우개정된 API RP 581 Code 에서는기존의 API BRD 581 Code 에서제시된 Technical Module Subfactor 의 Furnace Tube 항목이삭제되어있다. 특히두께감육의경우에는국부부식과전면부식으로구분할수가있으며, 손상기구별부식의전체값은다음과같이나타낼수있다. Fig. 1. Definition of risk. 특히, LNG 플랜트의경우에는저온운전조건으로단열재 Table 1. Damage Factor for Evaluation of Probability of Failure Damage Factor Thinning SCC-PTA Cracking External CUI CLSCC -Austenitic Component Component Lining SCC-CLSCC HTHA(High Temp. Hydrogen Attack) SCC-Caustic Cracking SCC-HSC-HF Brittle Fracture SCC-Amine Cracking SCC-HIC/SOHIC-HF Temper Embrittlement SCC-Sulfide Stress Cracking External Corrosion-Ferritic Component 885 Embrittlement SCC-HIC/SOHIC-H 2S CUI-Ferritic Component Sigma Phase Embrittlement SCC-Carbonate Cracking External CLSCC-Austenitic Component Piping Mechanical Fatigue 180 CORROSION SCIENCE AND TECHNOLOGY Vol.11, No.5, 2012

3 DEVELOPMENT OF RISK-BASED INSPECTION(RBI) TECHNOLOGY FOR LNG PLANT BASED ON API RP581 CODE 가배관이나기계장치에적용되어지며, cyclic operation 및 idle상태에서도단열재에의한하부부식 (Corrosion under insulation, CUI) 이발생한다. 따라서파손확률평가에서도손상인자에 Table 1에서와같이외부손상인자중에서탄소강계통과같은 ferritic component 와 Austenite stainless 의 CUI에의한염소응력부식균열 (CLSCC) 이나타난다. 이러한 Damage Factor 를근거하여 LNG 플랜트의각핵심장치별손상기구를 VR시스템과연동하여 Fig. 2에각손상기구에대한평가결과를나타낼수있도록손상기구별 coloring 을도입하여 3차원플랜트설계도면에따른 Damage Factor Module 을설계하였다. 따라서, 이러한장치의손상정보를바탕으로향후검사계획및검사모니터링시스템과도연동하여안전관리를수행할수있을것이다. 또한, 피해영향평가모듈은아래의식 (2) 로표현된다. 이경우대표운전물질은 API Code에서대표값으로선택할수있으며, 누출속도는압력과함께누출 hole size(1/4", 1", 4", rupture) 에관계한다. 4. LNG 플랜트운전및관리시스템을탑재한 LNG- RBI 구조 Fig. 3은 LNG 플랜트시스템의위험도평가소프트웨어를위한기본개념설계를통한계층구조를나타낸것이다. User interface layer(uil) 는 Virtual Reality(VR) 와연계한 Graphic User Interface(GUI) 를제공하고있으며, Application layer는 Business logic로처리하고 Database layer는 data의저장및 ' 가져오기 ' 구조로이루어져있다. Fig. 4에는 LNG-RBI 소프트웨어의메인화면과내부평가모듈을나타내고있으며, 정성적및정량적평가로구성되어그결과값에근거하여검사계획을수립할수있도록하였다. Fig. 5의 (a) 는정성적위험도평가모듈과함께 VR 플랜 (2) CA : Consequence area a, b : reference fluid based on API RP 581 Part 3, Table X : Release rate Fig. 3. The three-tier architecture of LNG-RBI S/W. Fig. 2. Design of Damage Factor Modules. CORROSION SCIENCE AND TECHNOLOGY Vol.11, No.5,

4 SONG-CHUN CHOI, JAE-BOONG CHOI, AND IN-JU HAWANG Fig. 4. Development of algorithm for LNG-RBI S/W. (a) Fig. 5. Development of Operation & Management system LNG- RBI. (b) Fig. 6. System Configuration of Risk-Based Management for LNG Plant. 182 CORROSION SCIENCE AND TECHNOLOGY Vol.11, No.5, 2012

5 DEVELOPMENT OF RISK-BASED INSPECTION(RBI) TECHNOLOGY FOR LNG PLANT BASED ON API RP581 CODE 트의 Navigator 기능을탑재한평가모듈을보여주며, (b) 에는정량적평가모듈내핵심설비의설계도면을통한파손확률 / 피해범위및운전과장치정보를전체화면에보여주고있다. 정량적위험성평가기법은장치정보, 검사기록및유지관리정보뿐만아니라플랜트공정의기계적건전성과안전전반에다양한공정안전관리에영향을미친다. 6) Fig. 6에는본연구에서개발된 LNG-RBI 시스템을플랜트의메인서브와연결하여 ERP 시스템에적용이가능하도록 Module 을설계하였다. 즉, 통합정보관리시스템에 LNG- RBI Module 을탑재함에따라각장치별위험요소와함께핵심장치의부식및손상원인을평가하고그에따른피해확산범위를추정하여정량적인위험성평가를통한대형사고예방및안전관리를수행할예정이다. 5. 결론 API 581 RP code 에기반하여 LNG 플랜트의위험성평가를위한정성적 / 정량적평가모듈을개발하고그에따른진단 검사를위한정량적인지수및관리방안을제시하여, IT 기술접목에따른저비용고효율의안전관리시스템인 LNG-RBI 를구축하기위한소프트웨어기본설계를완성하였다. 특히, 위험도평가모듈과함께 VR플랜트의 Navigator 기능을탑재한손상기구별평가모듈을설계하였으며, 정량적 평가모듈내핵심설비의설계도면을통한파손확률 / 피해범위및운전과장치정보를제공하고자하였다. 특히, 현재건설중에있는 LNG 플랜트테스트베드에본연구결과물을적용하여신뢰성을확보하고이를통하여 LNG 플랜트건설, 증설및유지관리를위한첨단의안전시스템을구축함으로서 IT기반의위험성평가기술의해외수출에기여하고자한다. 후 본연구는국토해양부 LNG플랜트사업단의연구지원비에의해수행되었습니다. 기 참고문헌 1. Ministry of Knowledge Economy, Road Map of Technology for Plant Engineering (2005). 2. API, API BRD 581, American Petroleum Institute, Washington, D. C. (2000). 3. J. T. Reynolds, ASME PVP, 336, 125 (1996). 4. G. Alvarado, L. Kaley, and R. R. Valbuena, CORROSION 99, NACE International, No. 388 (1999). 5. API, API RP 581, American Petroleum Institute, Washington, D. C. (2008). 6. J. T. Reynolds, CORROSION 2000, NACE International, No (2000). CORROSION SCIENCE AND TECHNOLOGY Vol.11, No.5,

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