⚠ ⚠ Top risk: Relief Valve Set-pressure Drift · RPN 252 (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)
Relief Valve Set-pressure Drift
252 S9·O7·D4
Online monitoring · Detection rate 80%Re-inspect ≤every6months
Safety
Steam Drum Internal Corrosion
120 S8·O5·D3
Inspection/offline · Detection rate 55%Re-inspect ≤every12months
Safety
Furnace Tube Rupture
120 S10·O4·D3
Online monitoring · Detection rate 80%Re-inspect ≤every12months
Safety
High-temperature Oxidation / Creep
120 S8·O5·D3
Inspection/offline · Detection rate 55%Re-inspect ≤every12months
Safety
Superheater Tube Rupture
108 S9·O4·D3
Online monitoring · Detection rate 80%Re-inspect ≤every24months
Safety
Internal Fouling -> Overheating
96 S8·O4·D3
Online monitoring · Detection rate 80%Re-inspect ≤every24months
Safety
Ignition Failure / Flameout
96 S8·O4·D3
Inspection/offline · Detection rate 55%Re-inspect ≤every24months
Safety
Insufficient Deaeration -> Oxygen Corrosion
96 S8·O4·D3
Online monitoring · Detection rate 80%Re-inspect ≤every24months
Safety
Steam Separator Failure -> Wet-steam Carryover
84 S7·O4·D3
Inspection/offline · Detection rate 55%Re-inspect ≤every24months
Safety
Valve Seat Leak
84 S7·O4·D3
Inspection/offline · Detection rate 55%Re-inspect ≤every24months
Safety
Dew-point Corrosion Perforation
84 S7·O4·D3
Online monitoring · Detection rate 80%Re-inspect ≤every24months
Safety
Burner-tip Coking / Blockage
84 S7·O4·D3
Inspection/offline · Detection rate 55%Re-inspect ≤every24months
Safety
Mechanical Seal Leak
80 S5·O4·D4
Online monitoring · Detection rate 80%Re-inspect ≤every24months
Safety
Cavitation
72 S6·O4·D3
Online monitoring · Detection rate 80%Re-inspect ≤every24months
Safety
14 Failure Modes
12 High/Critical
20 Standards
2 Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (20 standards / 2 accidents)
Standards (20 de-duplicated)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesAccident Lessons (2 de-duplicated)
2017-04-I-MO csb 2017 ↗ Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture 2022-01-I-OH csb 2022 ↗ BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire FM Traceability Cards (14)
← Back to Risk Board Relief Valve Set-pressure Drift RPN 252 · Critical
Failure Mechanism
Relief valve set-pressure drift: long-term spring stress creep/fatigue, loose setting nut, or seat fouling make actual opening pressure deviate from set point. Consequence: (1) too high -> valve fails to lift when needed, equipment overpressure (safety/integrity risk); (2) too low -> spurious lift in normal operation (production loss, media release). Progressive degradation; managed by periodic set-pressure verification (API 510 / GB-T 44692 class).
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
Annual online set-pressure verification Inspect spring appearance and dimensions every half-year Record actuation count after each action and analyze trend RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Steam Drum Internal Corrosion RPN 120 · Critical
Failure Mechanism
Improper water treatment, dissolved oxygen or pH exceeded; poor lay-up protection causing oxygen corrosion; accelerated corrosion at stress-concentration areas
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
Steam-drum inner-wall UT thickness every half-year Weekly water analysis monitoring dissolved oxygen and pH Endoscopy at each boiler shutdown RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Furnace Tube Rupture RPN 120 · Low
Failure Mechanism
Internal fouling or foreign-object blockage worsening heat transfer; flame skew or uneven heat load; tube material defect or weld-quality issue
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
Periodic inspection Vibration monitoring RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board High-temperature Oxidation / Creep RPN 120 · Critical
Failure Mechanism
Long-term operating temperature exceeds material allowable; frequent start/stop causing thermal stress cycles; initial material defect or poor selection
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
Metallographic check to assess oxide layer and creep damage every half-year Annual wall-thickness measurement and diameter bulge monitoring High-temperature section tube life assessment every 2 years RCM Strategy
RTF Design Modification / Inspection Task
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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Superheater Tube Rupture RPN 108 · Critical
Failure Mechanism
Abnormal steam temperature control causing over-temperature; internal fouling or blockage; material aging or weld defect
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
Daily monitor steam temperature and trend analysis Wall-thickness measurement and metallographic check every half-year Monthly review tube-wall temperature monitoring data RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Internal Fouling -> Overheating RPN 96 · Critical
Failure Mechanism
Water hardness or silica exceeded; improper feedwater treatment or insufficient blowdown; poor steam-water separation in operation
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
Daily monitor tube-wall temperature distribution Monthly water analysis monitoring hardness, silica, etc. Annual cut-pipe inspection for fouling RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Ignition Failure / Flameout RPN 96 · Critical
Failure Mechanism
点火电极老化或位置偏移；燃料供应中断或压力波动；风门调节不当，空气量过大
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
每日检查火焰探测器信号 每周监测点火变压器电流 每月检查点火电极和燃料阀 RCM Strategy
RTF Design Modification / Inspection Task
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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Insufficient Deaeration -> Oxygen Corrosion RPN 96 · Critical
Failure Mechanism
除氧器温度或压力未达到设计值；排气阀故障导致氧气无法排出；进水含氧量过高或流量波动
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
每日在线溶解氧分析仪监测出水含氧量 每周检查除氧器排气口蒸汽量是否正常 每月检测给水铁离子浓度 RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Steam Separator Failure -> Wet-steam Carryover RPN 84 · High
Failure Mechanism
分离器内部构件腐蚀或脱落；蒸汽负荷波动过大；安装或维修不当造成密封失效
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
每日监测蒸汽钠离子或电导率 每周检查汽包水位波动 每季度检查分离器内部状态 RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Valve Seat Leak RPN 84 · High
Failure Mechanism
密封面腐蚀或冲蚀；阀座与阀瓣间有异物；安装对中不良或预紧力不当
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
每日进行泄漏检测（听音、气泡或气体检测） 每季度进行密封性试验 每次检修检查密封面状态 RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Dew-point Corrosion Perforation RPN 84 · High
Failure Mechanism
燃料含硫量高，烟气露点温度高；给水温度过低导致管壁温度低于露点；运行中过量空气系数控制不当
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
每日监测排烟温度和给水温度 每月进行壁厚测量 每季度计算或在线监测烟气露点温度 RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Burner-tip Coking / Blockage RPN 84 · High
Failure Mechanism
燃料质量差，含焦油或杂质高；空气/燃料比例不当，燃烧不充分；烧嘴设计或安装不合理，局部温度过低
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
每日观察火焰形状和颜色异常 每周监测燃烧器压差升高 每月内窥镜检查烧嘴口 RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗ ← Back to Risk Board Mechanical Seal Leak RPN 80 · Medium
Failure Mechanism
密封面润滑不足或干磨；介质含颗粒物磨损密封面；安装时压缩量不当或轴跳动过大
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
RCM Strategy
CBM On-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 (20)
API 580 — Risk-Based InspectionGB/T 7826-2012ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipmentSAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance ProcessesGB/T 27921-2011GB/T 44958-2024GB/T 4888-2008GB/T 29639-2020AQ/T 3034-2022API 581 — Risk-Based Inspection MethodologyAPI 510 — Pressure Vessel Inspection CodeAPI 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 579-1/ASME FFS-1 — Fitness-For-ServiceAPI 754 — Process Safety Performance IndicatorsAPI 576 — Inspection of Pressure-Relieving DevicesAPI 689 — Collection and Exchange of Reliability and Maintenance DataAPI 755 — Human FactorsISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliabilityIEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sectorISO 31000:2018 — Risk management — GuidelinesLessons Learned (2)
2017-04-I-MO csb 2017 Fatalities 4 · Injuries 1 · Safety Loy-Lange Box Steam-system Pressure Vessel (boiler-like) Oxygen Pitting Rupture Root cause: Oxygen pitting + general corrosion thinning + poor 2012 repair (left damaged material) + missing inspection -> pressure vessel rupture. Official source ↗ 2022-01-I-OH csb 2022 Fatalities 2 · Safety BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM). Official source ↗