Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Fan / Blowerfan_blower
⚠ ⚠ Top risk: Blade Fatigue Crack · RPN 144 (Critical) — watch this one first at the equipment
Risk Board (all 11 · 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)
11Failure Modes
7High/Critical
16Standards
1Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (16 standards / 1 accidents)
Standards (16 de-duplicated)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Accident Lessons (1 de-duplicated)
2018-02-I-WIcsb2018 ↗
Husky Superior Refinery FCC Main-air-blower Trip Explosion
FM Traceability Cards (11)
Generated by Reliability AI
Blade Fatigue CrackRPN 144 · Critical
Failure Mechanism
Blade design/manufacturing defect causing stress concentration; prolonged overspeed or surge; insufficient blade fatigue strength
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Visual inspect blade surface every 3 months
  • MT or PT inspection every 6 months
  • Continuous 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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Coupling Elastomer AgingRPN 140 · Medium
Failure Mechanism
Elastomer aging; operating temperature beyond allowable; misalignment causing extra stress
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Inspect elastomer condition every 12 months
  • Replace elastomer every 24 months
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Fatigue SpallingRPN 128 · Critical
Failure Mechanism
Prolonged bearing overload; improper installation causing abnormal clearance; poor or contaminated lubrication
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Weekly vibration acceleration envelope analysis; when envelope exceeds 10g, schedule bearing replacement
  • Monthly oil analysis monitoring iron content; when Fe >200 ppm check bearing
  • Measure bearing clearance every 10000 operating hours; replace when clearance exceeds 30% of original
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Bending DeformationRPN 128 · Critical
Failure Mechanism
Impeller imbalance or misalignment; bearing damage causing support failure; accidental impact or overload
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Measure spindle runout quarterly; when >0.05 mm, schedule straightening or replacement
  • Monitor vibration weekly; when 1x amplitude exceeds 7.1 mm/s, check alignment and balance
  • Inspect bearing at each shutdown; repair immediately if damaged and check spindle
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Grease Dry-out -> OverheatingRPN 120 · High
Failure Mechanism
Grease replenishment interval too long; bearing operating temperature too high; grease grade unsuitable
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Replenish grease every 2000 operating hours; each dose = 1/3 of bearing-housing volume
  • Daily monitor bearing temperature; when >70 C check grease condition
  • Check grease color and consistency quarterly; replace if discolored or hardened
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Belt Slippage / BreakageRPN 100 · Medium
Failure Mechanism
皮带张力调整不当；皮带磨损或老化；带轮表面油污或磨损
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每2000小时检查皮带张紧度并调整
  • 每4000小时更换皮带
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Shell CorrosionRPN 90 · High
Failure Mechanism
Highly corrosive medium; shell coating or lining failure; prolonged humid environment
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • UT thickness measurement every 6 months
  • Visual check of coating integrity every 12 months
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Corrosion / ErosionRPN 84 · High
Failure Mechanism
介质中含有腐蚀性气体或液体；气流中夹带固体颗粒；叶轮表面防护层失效
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每季度进行超声波测厚，当壁厚减薄超过15%时更换叶轮
  • 每月目视检查叶轮表面，发现腐蚀坑深度超过1mm时安排修复
  • 每周监测振动，当1倍频幅值增大超过20%时检查叶轮
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Dust Accumulation / Fouling -> ImbalanceRPN 75 · Medium
Failure Mechanism
进气过滤不足；介质含尘；运行环境潮湿
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每运行3000小时停机清理叶轮表面积灰和结垢
  • 每周监测振动速度有效值，当超过4.5mm/s时安排动平衡校正
  • 每月检查进气过滤器，确保过滤效率不低于99%
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Damper StickingRPN 60 · Medium
Failure Mechanism
介质中粉尘或杂质沉积；挡板轴或轴承腐蚀；润滑不足
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每3个月手动操作检查灵活性
  • 每6个月清洁并润滑转轴
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗
Actuator FailureRPN 36 · High
Failure Mechanism
电源或信号故障；气源压力不足或泄漏；机械部件磨损或卡涩
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每月检查执行机构动作灵活性并记录
  • 每季度监测电机电流或力矩变化
  • 每半年进行红外热成像检测异常温升
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 (16)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
2018-02-I-WIcsb2018Injuries 36 · Safety
Husky Superior Refinery FCC Main-air-blower Trip Explosion
Root cause: Inadequate main-air-blower trip emergency procedure + missing transient-operation safeguards + insufficient monitoring of key parameters.
Official source ↗