Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
余热锅炉/废热锅炉/HRSG (Waste Heat Boiler)余热锅炉/废热锅炉/HRSG (Waste Heat Boiler)
⚠ ⚠ Top risk: 热疲劳 · RPN 72 (Critical) — watch this one first at the equipment
Risk Board (all 15 · 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)
15Failure Modes
14High/Critical
9Standards
4Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (9 standards / 4 accidents)
Standards (9 de-duplicated)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Accident Lessons (4 de-duplicated)
2011-05-I-KYcsb2011 ↗
Carbide Industries 电石电弧炉爆炸（Louisville）
2022-01-I-OHcsb2022 ↗
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
2024-01-I-CAcsb2023 ↗
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
CSB-HORSEHEAD-2015CSB2015 ↗
Horsehead Holding 致命爆炸火灾
FM Traceability Cards (15)
Generated by Reliability AI
热疲劳RPN 72 · Critical
Failure Mechanism
热疲劳 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 70% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 磁粉/超声波检测
  • 应力分析复核
  • Periodic nondestructive testing
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 (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
湿硫化氢损伤RPN 72 · Critical
Failure Mechanism
湿硫化氢损伤 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
高温硫化氢/氢腐蚀RPN 72 · Critical
Failure Mechanism
高温硫化氢/氢腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
CSB-HORSEHEAD-2015CSB2015Fatalities 2 · Explosion/Fire
Horsehead Holding 致命爆炸火灾
Root cause: 高温熔炼设备完整性与点火源管控不足（跨行业映射至加热炉）
Official source ↗
保温层下腐蚀RPN 54 · High
Failure Mechanism
保温层下腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 60% ；Interval by RBI
Mitigation (What to Do)
  • 拆除保温检查
  • UT 壁厚测量
  • 保温修复与防水
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 (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
蠕变与应力破裂RPN 54 · High
Failure Mechanism
蠕变与应力破裂 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • Periodic inspection
  • 状态监测
  • 性能评估
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 (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
酸性水腐蚀RPN 54 · High
Failure Mechanism
酸性水腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • Periodic inspection
  • 状态监测
  • 性能评估
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 (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
锅炉水/凝结水腐蚀RPN 54 · High
Failure Mechanism
锅炉水/凝结水腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • Periodic inspection
  • 状态监测
  • 性能评估
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 (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
高温氧化RPN 54 · High
Failure Mechanism
高温氧化 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • Periodic inspection
  • 状态监测
  • 性能评估
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 (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
CSB-HORSEHEAD-2015CSB2015Fatalities 2 · Explosion/Fire
Horsehead Holding 致命爆炸火灾
Root cause: 高温熔炼设备完整性与点火源管控不足（跨行业映射至加热炉）
Official source ↗
硫化腐蚀RPN 54 · High
Failure Mechanism
硫化腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
冲蚀/冲刷腐蚀RPN 54 · High
Failure Mechanism
冲蚀/冲刷腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
硫氢化铵腐蚀RPN 54 · High
Failure Mechanism
硫氢化铵腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
均匀/局部减薄（通用减薄）RPN 54 · High
Failure Mechanism
均匀/局部减薄（通用减薄） 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
烟气露点腐蚀RPN 54 · High
Failure Mechanism
烟气露点腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • Periodic inspection
  • 状态监测
  • 性能评估
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 (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
大气腐蚀RPN 54 · High
Failure Mechanism
大气腐蚀 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 壁厚测量(UT)
  • 目视/内窥镜检查
  • 腐蚀速率监测
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗
结垢/堵塞RPN 45 · Medium
Failure Mechanism
结垢/堵塞 驱动材料退化/功能失效
How to Detect
Online monitoring · Detection rate 60% ；Interval by RBI
Mitigation (What to Do)
  • 监测压差/流量
  • 定期清洗/化学清洗
  • 检查堵塞物
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (9)
  • API 530
  • API 534
  • ASME BPVC Sec I
  • API 572
  • API 570 — Piping Inspection Code
  • API 580 — Risk-Based Inspection
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • GB/T 16507
  • API RP 571
Lessons Learned (3)
2011-05-I-KYcsb2011Fatalities 2 · Injuries 2 · Safety
Carbide Industries 电石电弧炉爆炸（Louisville）
Root cause: 电弧炉炉盖冷却水泄漏长期带病运行（多年反复维修而不更换），水入炉与电石反应压力骤升爆炸，热气与飞屑击穿控制室窗致 2 死 2 伤
Official source ↗
2022-01-I-OHcsb2022Fatalities 2 · Safety
BP-Husky Toledo Fuel-gas Mix Drum Overflow -> Boiler/Heater Fire
Root cause: Missing Fuel Gas Mix Drum high-level / overflow safeguards + alarm flooding + inadequate abnormal-situation management (ASM).
Official source ↗
2024-01-I-CAcsb2023Injuries 1 · Safety
Marathon Martinez Renewable Diesel Unit Heater Tube Rupture Fire
Root cause: Valve misalignment caused low-flow maldistribution + burner air-duct blockage reignition -> furnace tube over-temperature rupture.
Official source ↗