Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Filter Separatorfilter_separator
⚠ ⚠ Top risk: Quick-opening Blind Flange Seal Failure · RPN 112 (High) — watch this one first at the equipment
Risk Board (all 8 · 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)
8Failure Modes
5High/Critical
21Standards
2Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (21 standards / 2 accidents)
Standards (21 de-duplicated)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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
Accident Lessons (2 de-duplicated)
2019-02-I-TXcsb2019 ↗
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
1998-002-I-LAcsb1998 ↗
Sonat 油气分离设施容器灾难性超压破裂
FM Traceability Cards (8)
Generated by Reliability AI
Quick-opening Blind Flange Seal FailureRPN 112 · High
Failure Mechanism
Seal material aging; improper preload at installation; frequent operation causing fatigue
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Visual check seal face for leakage every 3 months
  • Annual pressure test to verify sealing
  • Replace seal ring every 2 years
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗
Filter Element Rupture -> Filtration FailureRPN 96 · Critical
Failure Mechanism
Excessive differential pressure causing mechanical rupture; medium corrodes filter element; installation damage
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Monthly downstream particle-size analysis
  • Inspect immediately when differential pressure drops suddenly
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 (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗
Valve Blockage / Internal LeakRPN 96 · High
Failure Mechanism
Impurities or scaling in medium; valve long uncleaned; valve-seat sealing surface worn
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Check valve open/close smooth weekly
  • Daily monitor differential pressure or flow anomalies
  • Monthly blowdown inspection
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 (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗
Internal CorrosionRPN 90 · High
Failure Mechanism
Corrosive species in medium; coating damage; poor grounding causing galvanic corrosion
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • UT thickness measurement every half-year
  • Annual endoscopy
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 (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗
Demister Failure -> Droplet PenetrationRPN 84 · High
Failure Mechanism
Demister fouled by solids; chemical degradation or excessive temperature; velocity above design
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Monthly downstream liquid-content analysis
  • Sample and check demister condition quarterly
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 (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗
Impulse Line BlockageRPN 60 · Medium
Failure Mechanism
介质含易结晶或高粘度物质；环境温度过低；引压管未保温或伴热
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每日对比差压变送器与现场压力表读数
  • 每周检查引压管温度
  • 每月吹扫引压管
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 (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗
Sensor DriftRPN 60 · Medium
Failure Mechanism
Sensor aging from long-term use; large ambient temperature variation; zero not calibrated
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 (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗
Filter-element Blockage -> Pressure-drop IncreaseRPN 48 · Medium
Failure Mechanism
上游介质含杂质过多；滤芯寿命到期；旁路阀未关闭导致短路
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 连续监测进出口压差
  • 压差达设定值时更换滤芯
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 (21)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 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 (2)
2019-02-I-TXcsb2019Fatalities 1 · Injuries 30 · Safety
KMCO Crosby Filter Separator (y-strainer) Brittle Fracture Explosion
Root cause: Gray-iron y-strainer brittle fracture (casting / material defect + corrosion thinning) + inadequate isolation / pressure relief + no remote emergency shutoff valve.
Official source ↗
1998-002-I-LAcsb1998Fatalities 4 · Safety
Sonat 油气分离设施容器灾难性超压破裂
Root cause: 分离容器缺乏有效超压保护且启动程序缺陷，液体过充超压致容器灾难性破裂，4 名近旁作业工人当场死亡
Official source ↗