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⚠ ⚠ Top risk: Mechanical Seal Leak · RPN 144 (Critical) — watch this one first at the equipment
Risk Board (all 14 · by RPN · top 6 highlighted urgent)
Shield: Safety = people/environment　Production = production only
Technical mechanism/mitigation body in Chinese (red line: no fabricated MT; EN UI labels translated)
14Failure Modes
14High/Critical
9Standards
1Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (9 standards / 1 accidents)
Standards (9 de-duplicated)
  • API 682
  • API 677
  • ISO 21940
  • ISO 10441
  • API 614
  • ISO 10816
  • API 541
  • IEC 61800-5-1
  • IEC 61800-3
Accident Lessons (1 de-duplicated)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024 ↗
Givaudan Sense Colour 粉尘爆炸
FM Traceability Cards (14)
Generated by Reliability AI
Mechanical Seal LeakRPN 144 · Critical
Failure Mechanism
密封面磨损/弹簧失效致工艺介质外泄
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 密封冲洗检查
  • 泄漏监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • API 682
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
齿轮齿面磨损/点蚀RPN 126 · High
Failure Mechanism
齿面接触疲劳/润滑污染致点蚀或断齿
How to Detect
Online monitoring · Detection rate 70% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 齿面检查
  • 油样分析
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • API 677
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
齿轮箱轴承失效RPN 120 · Critical
Failure Mechanism
齿轮箱轴承疲劳/润滑不良致卡滞或碎裂
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 齿轮箱油样分析
  • Vibration monitoring
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (2)
  • API 677
  • ISO 21940
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
叶轮不平衡/磨损RPN 120 · High
Failure Mechanism
叶轮结垢/磨损/腐蚀致不平衡与振动升高
How to Detect
Online monitoring · Detection rate 75% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 动平衡校验
  • 叶轮检查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • ISO 21940
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
密封冲洗失效RPN 120 · Critical
Failure Mechanism
冲洗液中断/堵塞致密封面干磨失效
How to Detect
Online monitoring · Detection rate 75% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 冲洗管线检查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • API 682
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
联轴器失效RPN 105 · High
Failure Mechanism
联轴器弹性元件老化/螺栓松动致传递失效或振动
How to Detect
Online monitoring · Detection rate 75% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 联轴器对中检查
  • 螺栓紧固
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • ISO 10441
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
热变形/热应力开裂RPN 98 · High
Failure Mechanism
温度剧烈波动致轴/壳体热应力变形或开裂
How to Detect
Online monitoring · Detection rate 60% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 温度梯度监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • ISO 21940
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
润滑失效/油污染RPN 90 · High
Failure Mechanism
润滑油劣化/污染/液位低致齿轮箱润滑失效
How to Detect
Online monitoring · Detection rate 70% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 油样分析
  • 滤油
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • API 614
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
振动高（底座松动/不对中）RPN 90 · High
Failure Mechanism
地脚螺栓松动/不对中致整机振动超标
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Vibration monitoring
  • 紧固检查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • ISO 10816
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
电机-齿轮箱-轴不对中RPN 90 · High
Failure Mechanism
安装对中漂移致附加弯矩与轴承早期失效
How to Detect
Online monitoring · Detection rate 75% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 激光对中
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • ISO 10441
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
轴弯曲/偏转RPN 84 · High
Failure Mechanism
悬臂轴受力过大/热变形致轴弯曲偏转
How to Detect
Online monitoring · Detection rate 70% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 轴跳动检查
  • 对中
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • ISO 21940
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
驱动电机过载/堵转RPN 84 · High
Failure Mechanism
高粘度/结晶物料致负载骤增电机过载或堵转
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Current monitoring
  • 负载检查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • API 541
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
调速/变频控制失效RPN 84 · High
Failure Mechanism
变频器/调速器故障致转速失控或停转
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 控制回路校验
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (2)
  • IEC 61800-5-1
  • IEC 61800-3
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗
叶轮紧固件松动RPN 72 · High
Failure Mechanism
叶轮锁紧螺母松动致叶轮轴向窜动
How to Detect
Online monitoring · Detection rate 70% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 紧固检查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (1)
  • ISO 21940
Lessons Learned (1)
CSB-GIVAUDAN-LOUISVILLE-2024csb2024Fatalities 2 · Safety
Givaudan Sense Colour 粉尘爆炸
Root cause: 可燃粉尘防爆（NFPA 652/654）执行缺陷；设备清洗/维护作业粉尘管控与点火源隔离不足
Official source ↗