Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Shell-and-Tube Heat Exchangershell_tube_heat_exchanger
⚠ ⚠ Top risk: Cladding Disbonding · RPN 280 (Critical) — watch this one first at the equipment
Risk Board (all 28 · 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)
28Failure Modes
19High/Critical
29Standards
8Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (29 standards / 8 accidents)
Standards (29 de-duplicated)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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
  • 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
  • API 581-2025
  • GB/T 44692
Accident Lessons (8 de-duplicated)
2008-06-I-TXcsb2008 ↗
Goodyear 换热器破裂与氨泄漏（休斯顿）
2016-02-I-MScsb2016 ↗
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
2012-03-I-CAcsb2012 ↗
Chevron Richmond Refinery Piping Leak and Fire
2010-05-I-WAcsb2010 ↗
Tesoro Anacortes Refinery Heat Exchanger Rupture
2013-02-I-LAcsb2013 ↗
Williams Geismar Olefins Plant Reboiler Explosion
2016-03-I-LAcsb2016 ↗
ExxonMobil Baton Rouge Refinery Explosion
2006-1-I-TXcsb2005 ↗
Formosa Plastics Olefins Unit Release
2010-08-I-WAcsb2010 ↗
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
FM Traceability Cards (28)
Generated by Reliability AI
Cladding DisbondingRPN 280 · Critical
Failure Mechanism
Improper welding procedure; hydrogen embrittlement; thermal cycling stress
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Perform cladding UT inspection
  • Check bonding interface for disbondment
  • Control thermal-cycle rate
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Stress Corrosion Cracking (SCC)RPN 270 · Critical
Failure Mechanism
Residual or operating stress; corrosive medium (Cl-, H2S); susceptible material (austenitic stainless steel)
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodic NDT (e.g., PT, UT)
  • Monitor corrosion-environment parameters (e.g., chloride concentration, pH)
  • Check stress-relief status
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Relief Valve Set-pressure DriftRPN 224 · Critical
Failure Mechanism
Relief valve set-pressure drift: long-term spring stress creep/fatigue, loose setting nut, or seat fouling make actual opening pressure deviate from set point. Consequence: (1) too high -> valve fails to lift when needed, equipment overpressure (safety/integrity risk); (2) too low -> spurious lift in normal operation (production loss, media release). Progressive degradation; managed by periodic set-pressure verification (API 510 / GB-T 44692 class).
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Annual online set-pressure verification
  • Inspect spring appearance and dimensions every half-year
  • Record actuation count after each action and analyze trend
RCM Strategy
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Shell CrackRPN 216 · Critical
Failure Mechanism
焊接缺陷或热处理不当产生残余应力；频繁的温度波动引起热疲劳；应力腐蚀开裂（如氯化物应力腐蚀）
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 每12个月进行渗透检测和超声波检测，重点检查焊缝和应力区
  • 安装声发射监测系统，实时检测裂纹扩展
  • 发现裂纹立即停机评估并修复
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Fatigue CrackingRPN 192 · Critical
Failure Mechanism
频繁的启停或温度波动；膨胀节设计不当（如波数不足）；安装偏差导致附加应力
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 监测膨胀节位移和应力
  • 进行疲劳寿命分析
  • 检查裂纹
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Flow-induced Vibration Fatigue (Tube)RPN 160 · Critical
Failure Mechanism
Excessive velocity; excessive support span; tube natural frequency coupled with excitation frequency
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Monitor tube-bundle vibration acceleration
  • Inspect support-plate wear
  • Adjust flow velocity or add anti-vibration rods
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 (27)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Bolt RelaxationRPN 160 · Medium
Failure Mechanism
Operating temperature above bolt creep temperature; initial preload too low/high; low bolt creep strength
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Check bolt preload
  • Replace aged bolts
  • Re-tighten and lock
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Corrosion ThinningRPN 126 · High
Failure Mechanism
介质腐蚀性强；流速过高加速腐蚀；材料耐蚀性不足
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每年进行壁厚测量（超声测厚）
  • 若壁厚减薄超过10%则计划更换
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 (23)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Expanded Joint LeakRPN 126 · High
Failure Mechanism
Improper expansion; large temperature swing; corrosive medium attacking expansion face
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodic expansion-joint leak test
  • Check expansion residual stress
  • Replace gasket
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Corrosion ThinningRPN 126 · High
Failure Mechanism
壳程或管程流体含腐蚀性介质；膨胀节材料耐蚀性不足；防腐涂层失效或未涂覆
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 超声波测厚检查壁厚
  • 监测腐蚀速率
  • 涂覆防腐涂层
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 (23)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Tube Hole EnlargementRPN 108 · High
Failure Mechanism
介质腐蚀；多次胀接；管孔加工精度不足
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 超声波测厚检查管孔壁厚
  • 检查胀接处密封性
  • 必要时重新胀接或堵管
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 (23)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Baffle Corrosion / Wear -> Loss of Tube SupportRPN 108 · High
Failure Mechanism
壳程流体含固体颗粒或腐蚀性介质；流体流速过高或流向不均；折流板材料耐蚀性不足
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每12个月抽芯检查折流板厚度和完整性
  • 当折流板减薄超过50%时，更换折流板
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Inlet Line BlockageRPN 108 · Critical
Failure Mechanism
介质含固体杂质；介质易结垢；管道设计不合理导致死角
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每3个月检查入口管压差
  • 每6个月进行内窥镜检查
  • 安装压差报警装置
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Tube Sheet CorrosionRPN 105 · Medium
Failure Mechanism
介质腐蚀性强；管板材料耐蚀性差；缝隙腐蚀
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 检查管板表面腐蚀深度
  • 测量管孔直径变化
  • 涂覆防腐涂层
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 (24)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Channel Flange LeakRPN 105 · Medium
Failure Mechanism
垫片失效；螺栓预紧力不足；法兰面腐蚀
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 检查法兰密封面腐蚀
  • 更换垫片
  • 按扭矩紧固螺栓
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Shell Internal Corrosion / ErosionRPN 105 · High
Failure Mechanism
壳程流体含有腐蚀性成分（如H2S、CO2、Cl-）；流体流速过高或存在湍流、涡流；壳体材料选型不当或缺乏防腐涂层
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每6个月进行超声波测厚，重点检查入口和底部
  • 当壁厚减薄至设计最小值的85%时，安排修复或更换
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 (22)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Bolt CorrosionRPN 105 · High
Failure Mechanism
环境含腐蚀性介质（如湿H2S、氯化物）；螺栓材料耐蚀性不足；防腐涂层失效
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每6个月进行目视检查，记录腐蚀情况
  • 每2年进行超声波测厚，测量螺栓剩余直径
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Gasket Aging / Creep -> LeakRPN 100 · Medium
Failure Mechanism
垫片材料与介质不兼容；运行温度超过垫片额定温度；垫片长期受压蠕变
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每40000小时或5年更换垫片
  • 每次检修时检查垫片压缩回弹率
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Partition LeakRPN 96 · Medium
Failure Mechanism
密封垫片老化；隔板腐蚀；安装偏差
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 检查隔板密封面腐蚀情况
  • Replace gasket
  • 重新紧固螺栓
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
ErosionRPN 90 · High
Failure Mechanism
流速过高；流体含固体颗粒；管束入口处湍流
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每半年检查管壁冲蚀迹象（目视或超声）
  • 若发现局部减薄则分析原因并防护
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 (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Baffle Vibration FatigueRPN 84 · High
Failure Mechanism
壳程流体流速过高或脉动；折流板间距过大或厚度不足；管束与折流板间隙过大导致冲击
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，安装加速度传感器
  • 当振动幅值超过阈值时，调整流速或增加支撑
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Valve Seat LeakRPN 84 · High
Failure Mechanism
密封面腐蚀或磨损；密封面有异物；阀座材料不当
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日进行泄漏检测（听音、气泡或气体检测）
  • 每季度进行密封性试验
  • 每次检修检查密封面状态
RCM Strategy
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Improper Gasket InstallationRPN 72 · Medium
Failure Mechanism
安装人员操作不规范；法兰面有划痕或腐蚀；垫片型号或尺寸错误
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 安装后立即进行气密试验
  • 发现泄漏后重新安装并检查法兰面
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 (22)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
BlockageRPN 72 · Medium
Failure Mechanism
介质含固体杂质；介质易结垢或聚合；阀门长期未操作导致沉积
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 发现流量减小后立即清理阀门通道
  • 定期检查介质过滤情况
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 (22)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Sensor DriftRPN 60 · Medium
Failure Mechanism
敏感元件老化；传感器污染；环境温度变化
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • Zero and span calibration every 6 months
  • Compare redundant-sensor readings every 3 months
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 (22)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Fouling/PluggingRPN 54 · High
Failure Mechanism
水质硬度高或含悬浮物；流速过低导致沉积；介质易结焦或聚合
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每月监测换热器压差和出口温度
  • 若压差升高或传热效率下降则进行化学清洗或机械清理
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 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Valve Internal LeakRPN 54 · High
Failure Mechanism
密封面磨损或腐蚀；密封面有异物；阀杆操作不当导致密封面损伤
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每月监测阀门前后压差
  • 每季度进行内漏测试（如温度检测）
  • 每年检修阀门密封面
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 (22)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗
Loose Wiring / TerminalsRPN 48 · Medium
Failure Mechanism
振动导致松动；接线端子腐蚀；安装时未拧紧
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
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 (22)
  • 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 36894-2018
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • 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 (8)
2008-06-I-TXcsb2008Fatalities 1 · Injuries 6 · Safety/Environmental
Goodyear 换热器破裂与氨泄漏（休斯顿）
Root cause: 维护完成后的超压保护（泄压阀/安全系统）未有效复位或设定不足，换热器异常超压破裂，氨释放致 1 死 6 伤
Official source ↗
2016-02-I-MScsb2016Safety/Operational
Enterprise Pascagoula 气体厂换热器热疲劳破裂（帕斯卡古拉）
Root cause: BAHX 热疲劳开裂；服役寿命与热循环评估不足，PHA 未识别低温热疲劳失效
Official source ↗
2012-03-I-CAcsb2012Safety/Environmental
Chevron Richmond Refinery Piping Leak and Fire
Root cause: High-temperature sulfidation corrosion rate underestimated + insufficient wall-thickness monitoring.
Official source ↗
2010-05-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes Refinery Heat Exchanger Rupture
Root cause: Shell-side corrosion of heat exchanger not detected + design did not address shell-side integrity.
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
2006-1-I-TXcsb2005Injuries 2 · Safety
Formosa Plastics Olefins Unit Release
Root cause: Heat-exchanger nozzle weld defect + delayed leak detection.
Official source ↗
2010-08-I-WAcsb2010Fatalities 7 · Safety
Tesoro Anacortes 炼厂换热器高温氢腐蚀破裂爆炸
Root cause: 换热器碳钢壳体长期高温氢环境服役发生 HTHA 劣化，行业标准（API RP 941 Nelson 曲线）不足以预防；破裂爆炸致 7 名员工死亡
Official source ↗