Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Centrifugal Compressorcentrifugal_compressor
⚠ ⚠ Top risk: Fatigue · RPN 162 (Critical) — watch this one first at the equipment
Risk Board (all 42 · 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)
42Failure Modes
35High/Critical
25Standards
1Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (25 standards / 1 accidents)
Standards (25 de-duplicated)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 581-2025
  • GB/T 44692
  • GB/T 11348
  • GB/T 6075
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • ISO 13374 — Condition monitoring and diagnostics of machines — Data processing, communication and presentation
  • ISO 17359 — Condition monitoring and diagnostics of machines — General guidelines
Accident Lessons (1 de-duplicated)
ARR-2023-01-KMScsb2023 ↗
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
FM Traceability Cards (42)
Generated by Reliability AI
FatigueRPN 162 · Critical
Failure Mechanism
Excessive torsional vibration or bending stress; material defect; stress concentration (e.g., keyway)
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Perform spindle MT or UT
  • Monitor vibration and torque
  • Inspect fatigue cracks
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 (17)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
O-ring AgingRPN 144 · High
Failure Mechanism
Temperature exceeds O-ring limit; chemical medium corrosion; O-ring installation damage or compression set
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Replace all O-rings every 2 years
  • Check O-ring hardness at each maintenance; replace if hardness change >10%
  • Record O-ring installation date and batch
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Impeller Fatigue CrackRPN 135 · Critical
Failure Mechanism
Alternating stress (e.g., surging); material defects; resonance
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Continuous vibration monitoring with alarm threshold
  • MT inspection every 6 months
  • Install anti-surge control system
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Bending / BowingRPN 128 · Critical
Failure Mechanism
叶轮不平衡；热膨胀不均；轴承损坏
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期测量主轴径向跳动
  • 监测主轴振动频谱
  • 检查热变形情况
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Keyway CrackRPN 128 · Critical
Failure Mechanism
键槽加工缺陷；过大的扭矩波动；材料疲劳
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每3个月进行振动监测
  • 每年进行无损检测（磁粉、着色）
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Tube-bundle LeakRPN 128 · Critical
Failure Mechanism
腐蚀减薄；机械振动疲劳；热应力循环
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每运行8000小时进行壳程压力试验，保压30分钟无压降
  • 每年进行氦检漏，检测泄漏率不超过1×10^-6 Pa·m³/s
  • 每季度进行超声波测厚，当壁厚减薄超过20%时更换管束
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Impeller Corrosion / Stress CorrosionRPN 120 · Critical
Failure Mechanism
Corrosive species in medium; improper material selection; residual tensile stress
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Visual inspection and dye penetrant test every 6 months
  • Analyze medium composition every 2 years
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Duplex Filter Changeover FailureRPN 120 · High
Failure Mechanism
切换阀长期未操作导致卡涩；润滑油中杂质沉积在阀芯；密封件老化或损坏
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每3个月进行一次切换阀操作测试，确保灵活转动
  • 每次切换时记录操作力矩，若超过基准值20%则拆检清洗
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
CorrosionRPN 108 · High
Failure Mechanism
Gas contains corrosive species (H2S, Cl-); moisture present; improper material selection
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Visual inspect coating and insulation every 6 months
  • Perform UT thickness measurement every 12 months
  • Re-apply anti-corrosion coating every 24 months
RCM Strategy
RTFDesign 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
CorrosionRPN 108 · High
Failure Mechanism
Gas contains corrosive species; moisture present; improper material selection
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Visual inspect coating and insulation every 6 months
  • Perform UT thickness measurement every 12 months
  • Re-apply anti-corrosion coating every 24 months
RCM Strategy
RTFDesign 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Blade ErosionRPN 105 · High
Failure Mechanism
气体含固体颗粒；气体含液滴；气流速度过高
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 检查叶片表面冲蚀深度
  • 测量叶片厚度
  • 涂覆耐磨涂层
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 (20)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 44692
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Deposit / Fouling -> Efficiency LossRPN 105 · Medium
Failure Mechanism
气体含尘或液滴；入口过滤失效；操作工况偏离设计点
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 清洗扩压器流道
  • 检查沉积物成分
  • 优化过滤系统
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Cooler FoulingRPN 105 · Medium
Failure Mechanism
冷却水质差导致水侧结垢；气体中杂质沉积在管束；长期运行未清洗
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每年清洗冷却器管束
  • 每月监测冷却器出口温度，超过设定值报警
  • 每季度检查冷却水流量和温差
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
CorrosionRPN 105 · High
Failure Mechanism
气体中含酸性组分；冷却水pH值偏低；管束材料不耐腐蚀
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Visual inspect coating and insulation every 6 months
  • Perform UT thickness measurement every 12 months
  • Re-apply anti-corrosion coating every 24 months
RCM Strategy
RTFDesign 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
WearRPN 96 · High
Failure Mechanism
润滑不良或润滑油污染；轴向推力过大；推力盘表面硬度不足或加工精度差
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 检查推力盘表面磨损量
  • 测量推力盘厚度
  • 监测轴向位移
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 (17)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Thrust Bearing (Pad) WearRPN 96 · High
Failure Mechanism
润滑油污染或供油不足；轴向推力过大；推力瓦材料或加工缺陷
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每3个月测量推力瓦厚度，记录磨损量
  • 每日监测推力轴承温度，超过85℃报警
  • 每周检查轴向位移，超过0.3mm报警
RCM Strategy
PMScheduled (Proactive) 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Actuator FailureRPN 96 · Critical
Failure Mechanism
气源压力不足或泄漏；膜片破裂或弹簧疲劳；电磁阀故障
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
ErosionRPN 90 · Medium
Failure Mechanism
气体含固体颗粒；入口过滤失效；气流速度过高
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 超声波测厚检查蜗壳壁厚
  • 检查冲蚀坑深度
  • 涂覆耐磨层
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 (18)
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Impeller Fouling -> ImbalanceRPN 84 · High
Failure Mechanism
气体含尘或液滴；入口过滤失效；操作工况偏离设计点
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每3个月进行振动监测，分析频谱变化
  • 每6个月进行轴位移监测
  • 每年进行内窥镜检查叶轮表面
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
High Bearing (Pad) TemperatureRPN 84 · High
Failure Mechanism
润滑油流量不足或油温过高；轴承间隙过小；转子不对中或载荷过大
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 监测轴承瓦块温度
  • 检查润滑油流量
  • 分析油质
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Labyrinth-seal Wear -> Increased Inter-stage LeakageRPN 72 · High
Failure Mechanism
转子不平衡或振动过大；热膨胀导致碰磨；润滑不良
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每月监测级间压力
  • 每3个月进行性能监测
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Excessive Axial DisplacementRPN 72 · Critical
Failure Mechanism
压缩机工况突变（如喘振）；推力轴承磨损或失效；平衡盘密封失效
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 安装冗余轴向位移探头，实时监测并触发联锁停机
  • 每季度测试平衡盘密封和防喘振阀功能
  • 制定工况突变操作规程，防止喘振
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Seal-gas InterruptionRPN 72 · Critical
Failure Mechanism
上游气源压力波动或中断；密封气管道堵塞或泄漏；控制系统故障导致阀门误关
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 安装冗余密封气压力变送器，低压力联锁停机
  • 每周检查密封气过滤器压差，超过0.1MPa更换
  • 每季度测试密封气阀门动作
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Positioner FailureRPN 72 · High
Failure Mechanism
反馈杆松动或磨损；电路板故障；气路喷嘴堵塞
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每6个月进行定位器自诊断测试
  • 每季度清洁气源过滤器，检查反馈杆
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Lube-oil Pump FailureRPN 72 · Critical
Failure Mechanism
电机故障；泵体磨损或气蚀；联轴器损坏
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 安装冗余油泵，自动切换
  • 每日监测油压，低于0.15MPa联锁停机
  • 每月进行振动和温度监测，趋势分析
RCM Strategy
PMScheduled (Proactive) 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Oil-tank Water IngressRPN 72 · Critical
Failure Mechanism
油箱顶部密封垫老化；呼吸器干燥剂失效；冷却器泄漏
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日检查油箱底部排水，若发现积水则立即排查
  • 每周检查呼吸器干燥剂颜色，若变色超过50%则更换
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Loose Wiring / TerminalsRPN 72 · High
Failure Mechanism
机组振动导致端子松动；环境潮湿导致氧化；安装时未紧固
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每6个月检查并紧固所有接线端子
  • 使用扭矩扳手按规范力矩紧固
  • 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Babbitt Wear / FlakingRPN 70 · High
Failure Mechanism
润滑油温度过高或油膜不稳定；转子不平衡导致动载荷过大；巴氏合金浇铸质量缺陷
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 检查巴氏合金层厚度
  • 超声波检测结合强度
  • 监测轴承温度
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Oil-film Oscillation (Oil Whip)RPN 64 · Critical
Failure Mechanism
轴承设计参数不当（如长径比）；润滑油黏度或温度异常；转子不平衡或对中不良
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 监测轴承振动频谱
  • 监测轴心轨迹
  • 检查油膜压力
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 (22)
  • API 580 — Risk-Based Inspection
  • GB/T 11348
  • GB/T 6075
  • GB/T 7826-2012
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • ISO 13374 — Condition monitoring and diagnostics of machines — Data processing, communication and presentation
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • ISO 17359 — Condition monitoring and diagnostics of machines — General guidelines
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Oil Cooler LeakRPN 64 · Critical
Failure Mechanism
冷却水水质腐蚀性强；管束材料不耐油侧温度；安装或运行中振动疲劳
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每周进行油品含水分析，若含水量超过0.1%则报警
  • 每月监测冷却水出口油含量，若超过10ppm则安排检修
RCM Strategy
RTFDesign 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Piping VibrationRPN 63 · High
Failure Mechanism
气流脉动与管线固有频率共振；支架松动或设计不当；介质两相流
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每月进行振动监测，速度超过10mm/s报警
  • 每季度检查管线支撑和支架紧固情况
  • 每年进行振动频谱分析，识别共振
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Honeycomb Seal BlockageRPN 60 · Medium
Failure Mechanism
气体含尘或液滴；入口过滤失效；密封结构设计不合理
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每月监测级间压力
  • 每6个月进行内窥镜检查
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Differential-pressure Transmitter FailureRPN 56 · Medium
Failure Mechanism
传感器老化或漂移；接线松动或接触不良；环境振动或温度影响
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每半年校准差压变送器
  • 发现读数异常时立即更换
  • 备件库存保持2个
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Reverse-rotation DamageRPN 54 · Critical
Failure Mechanism
停机时防反转装置失效；操作失误导致反转；止逆阀故障
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 安装反转检测传感器，触发联锁停机
  • 每月测试防反转装置功能
  • 每季度检查止逆阀密封性
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Seal-face Contamination -> LeakRPN 48 · Critical
Failure Mechanism
工艺气体含固体颗粒或液滴；密封气源不洁净；密封面结焦或腐蚀
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测密封气泄漏量，超过标准值报警
  • 每周检查密封气过滤器压差，超过0.1MPa更换
  • 每半年检查密封面状态，使用内窥镜
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Valve-plug StickingRPN 48 · Critical
Failure Mechanism
介质结垢或腐蚀；阀杆与衬套间隙不当；长期未动作导致粘连
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每周进行部分行程测试，记录动作时间
  • 每月检查阀位反馈与指令偏差，超过2%调整
  • 每季度检查阀杆灵活性，添加润滑脂
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
I/O Module (Card) FailureRPN 48 · Critical
Failure Mechanism
电源波动或浪涌；卡件散热不良；固件缺陷
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每季度进行冗余卡件切换测试，确保切换正常
  • 每月检查卡件自检报警记录，若出现报警则更换
RCM Strategy
PMScheduled (Proactive) 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Probe FailureRPN 42 · High
Failure Mechanism
探头长期高温运行；感应面油污或金属屑附着；电缆绝缘破损
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每月进行探头间隙电压测试，若偏离基准值10%则更换
  • 每日检查信号趋势，若出现异常跳变则排查
RCM Strategy
PMScheduled (Proactive) 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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
FrettingRPN 40 · Medium
Failure Mechanism
轴向载荷波动导致微动；配合间隙过小；表面粗糙度不达标
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 检查推力盘表面微动痕迹
  • 监测轴向振动
  • 分析润滑油中磨粒
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 (17)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Filter BlockageRPN 36 · High
Failure Mechanism
气体中杂质过多；过滤器未及时更换；上游管道腐蚀产生颗粒
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每运行2000小时更换滤芯，并记录压差初始值
  • 每日监测过滤器压差，当压差超过0.1MPa时立即更换
  • 每月进行油液清洁度检测，确保NAS 1638等级不超过8级
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Fouling / ScalingRPN 30 · Medium
Failure Mechanism
冷却水硬度高；冷却水温控制不当；缺乏定期化学清洗
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测换热器进出口温差和压降
  • 每季度化学清洗或机械清洗
  • 根据水质分析调整阻垢剂添加量
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗
Booster Pump FailureRPN 28 · High
Failure Mechanism
电机烧毁或过载；泵体磨损或气蚀；电气控制故障
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测泵出口压力，低于设定值报警
  • 每周检查泵运行电流，异常时分析
  • 每月进行振动监测，趋势分析
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 (17)
  • 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 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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)
ARR-2023-01-KMScsb2023Safety/Environmental
Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation)
Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario.
Official source ↗