Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Cooling TowerCooling Tower
⚠ ⚠ Top risk: Fan Motor Failure · RPN 96 (High) — watch this one first at the equipment
Risk Board (all 14 · by RPN · top 6 highlighted urgent)
Shield: Safety = people/environment　Production = production only
Technical mechanism/mitigation body in Chinese (red line: no fabricated MT; EN UI labels translated)
14Failure Modes
12High/Critical
7Standards
1Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (7 standards / 1 accidents)
Standards (7 de-duplicated)
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 7190.2-2018
  • GB 50102
  • API RP 571
  • GB/T 50050
Accident Lessons (1 de-duplicated)
CCPS-BEACON-2025-10CCPS2013 ↗
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
FM Traceability Cards (14)
Generated by Reliability AI
Fan Motor FailureRPN 96 · High
Failure Mechanism
Bearing wear / motor overload / insulation aging
How to Detect
Online monitoring · Detection rate 82% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Motor vibration
  • Current monitoring
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (4)
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 7190.2-2018
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
轴承失效（磨损/剥落）RPN 54 · High
Failure Mechanism
轴承失效（磨损/剥落） 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 振动趋势监测
  • 油液分析
  • 对中/平衡复核
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
微生物腐蚀RPN 54 · High
Failure Mechanism
微生物腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
润滑失效RPN 54 · High
Failure Mechanism
润滑失效 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 振动趋势监测
  • 油液分析
  • 对中/平衡复核
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
冷却水腐蚀RPN 54 · High
Failure Mechanism
冷却水腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
不对中RPN 54 · High
Failure Mechanism
不对中 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 振动趋势监测
  • 油液分析
  • 对中/平衡复核
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
转子不平衡RPN 54 · High
Failure Mechanism
转子不平衡 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 振动趋势监测
  • 油液分析
  • 对中/平衡复核
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
冲蚀/冲刷腐蚀RPN 54 · High
Failure Mechanism
冲蚀/冲刷腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
齿轮磨损/点蚀RPN 54 · High
Failure Mechanism
齿轮磨损/点蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 振动趋势监测
  • 油液分析
  • 对中/平衡复核
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
均匀/局部减薄（通用减薄）RPN 54 · High
Failure Mechanism
均匀/局部减薄（通用减薄） 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
大气腐蚀RPN 54 · High
Failure Mechanism
大气腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
联轴器失效RPN 54 · High
Failure Mechanism
联轴器失效 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 振动趋势监测
  • 油液分析
  • 对中/平衡复核
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
Structural Corrosion / Wood Grid DecayRPN 45 · Medium
Failure Mechanism
Concrete carbonation / rebar corrosion / packing aging
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • Periodic structural inspection
  • Packing replacement
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 (4)
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 7190.2-2018
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗
结垢/堵塞RPN 45 · Medium
Failure Mechanism
结垢/堵塞 驱动材料退化/功能失效
How to Detect
Inspection/offline · Detection rate 60% ；Interval by RBI
Mitigation (What to Do)
  • 监测压差/流量
  • 定期清洗/化学清洗
  • 检查堵塞物
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 (6)
  • GB/T 7190.2-2018
  • GB 50102
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API RP 571
  • GB/T 50050
Lessons Learned (1)
CCPS-BEACON-2025-10CCPS2013Fatalities 29 · Injuries 30 · Fire/Explosion
Refinery Cooling Tower Explosion and Fire (CCPS Process Safety Beacon; 2013 India refinery case)
Root cause: Heat-exchanger tube-bundle corrosion leak allowed hydrocarbons into cooling water; no vent/gas detection at cooling-tower high point; isolation and shutdown-work rules not followed during commissioning; contractor unfamiliar with petrochemical hazards.
Official source ↗