机电工程技术2025，Vol.54Issue(11)：144-148,5.DOI:10.3969/j.issn.1009-9492.2025.11.027
基于FMEA的原油外输软管绞车可靠性分析与设计
Reliability Analysis and Design of Crude Oil Offloading Hose Reel Based on FMEA
摘要
Abstract
To address the reliability design challenges of crude oil offloading hose reels for floating production storage and offloading(FPSO)units under complex operating conditions such as dynamic loads and marine corrosion,a systematic solution based on failure mode and effects analysis(FMEA)is proposed to eliminate critical failures that may lead to mission failure during the entire lifecycle.A reliability analysis model encompassing seven major functional modules,including the drum assembly,drive system,and hose spooling device,is established.Through hydraulic drive performance experiments,material corrosion testing,and dynamic load simulations,23 core failure modes are identified,such as abnormal vibration of rotary supports and aging failure of sealing rings,with insufficient lubrication(37.6%),structural strength deficiencies(21.4%),and welding process deviations(15.8%)identified as primary failure mechanisms.Based on fault tree analysis results,a multi-dimensional control strategy is developed:implementing a dual-pump redundant hydraulic system to enhance drive reliability,adopting a 40%torque margin derating design for reducers,establishing an online monitoring system for welding parameters,formulating a proactive lubrication protocol with a 500 h maintenance cycle,integrating real-time vibration acceleration monitoring,and creating an emergency spare parts inventory for critical components.Industrial validation conducted on an FPSO platform in the south China sea over 93 offloading operations demonstrates the elimination of CategoryⅠ/Ⅱcritical failures and achievement of the 25 a lifespan design target for the drum assembly.The research outcomes break through traditional empirical design approaches,establishing a quantifiable and verifiable reliability engineering methodology that provides a systematic technical pathway for failure prevention and control in high-risk marine equipment.关键词
FPSO/原油外输系统/软管绞车/可靠性分析/FMEA/设计优化Key words
FPSO/crude oil offloading system/hose reel/reliability analysis/FMEA/design optimization分类
石油、天然气工程引用本文复制引用
马霖,赵雷刚,张宁,曹祺梵..基于FMEA的原油外输软管绞车可靠性分析与设计[J].机电工程技术,2025,54(11):144-148,5.基金项目
国家重点研发计划(2024ZD1403306) （2024ZD1403306）
