Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
MVR Unit (Mechanical Vapor Recompression)mvr_unit
⚠ ⚠ Top risk: Tube-sheet Expansion Joint Leak · RPN 192 (Critical) — watch this one first at the equipment
Risk Board (all 43 · 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)
43Failure Modes
33High/Critical
18Standards
1Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (18 standards / 1 accidents)
Standards (18 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Accident Lessons (1 de-duplicated)
CN-MEM-2026-03-28CN-MEM2026 ↗
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
FM Traceability Cards (43)
Generated by Reliability AI
Tube-sheet Expansion Joint LeakRPN 192 · Critical
Failure Mechanism
Temperature fluctuation causing thermal fatigue; improper expansion joint; vibration or impact load
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Annual pressure test, hold 30 min with no leak
  • Helium leak test every 2 years to detect micro-leaks
  • Visual inspect expansion joints at each shutdown; record leak traces
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Gear-tooth FractureRPN 144 · Critical
Failure Mechanism
严重过载或卡阻；齿根疲劳裂纹扩展；材料缺陷或热处理不当
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每季度进行振动监测，设置突发大幅值报警阈值
  • 每半年进行油液分析，检测大颗粒金属碎片
  • 每年进行磁粉无损检测，检查齿根裂纹
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Fatigue CrackRPN 135 · Critical
Failure Mechanism
Frequent start/stop or load swing causing cyclic stress; impeller manufacturing defect (porosity, inclusions); resonance or operating at critical speed
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Continuously monitor HF vibration acceleration; if envelope rises, shut down to inspect
  • Impeller MT or UT every half-year; replace if cracks found
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Tube-bundle LeakRPN 128 · Critical
Failure Mechanism
冷却水腐蚀性；管束振动疲劳；制造缺陷或安装应力
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每运行8000小时进行壳程压力试验，保压30分钟无压降
  • 每年进行氦检漏，检测泄漏率不超过1×10^-6 Pa·m³/s
  • 每季度进行超声波测厚，当壁厚减薄超过20%时更换管束
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Gasket Aging Leak (Plate Type)RPN 120 · Medium
Failure Mechanism
Gasket material not resistant to medium; improper compression; temperature swing causing gasket aging
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Replace all gaskets every 2 years
  • Check gasket compression after each disassembly
  • Use torque wrench and tighten per spec during installation
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Insufficient Seal-steam Pressure -> Air In-leakageRPN 112 · High
Failure Mechanism
密封蒸汽供应压力波动；密封蒸汽管路堵塞；密封蒸汽调节阀故障
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 连续监测密封蒸汽压力，低于0.1MPa报警
  • 每日检查真空度，异常时排查密封蒸汽系统
  • 每月使用气体检漏仪检测轴封处
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Mechanical Seal LeakRPN 112 · High
Failure Mechanism
密封面润滑不足；安装不当或对中偏差；介质含颗粒物
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每日目视检查泄漏滴漏
  • 连续监测密封冲洗液压力
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Steam Droplet Entrainment -> Impeller ErosionRPN 108 · Critical
Failure Mechanism
蒸汽带水严重；入口分离器失效；压缩机启停频繁
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 连续监测蒸汽湿度，若超过5%则报警并检查入口分离器
  • 每季度进行叶轮无损检测（渗透或超声），若发现冲蚀坑则修复或更换
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
CorrosionRPN 108 · High
Failure Mechanism
Corrosive species in steam (chloride, acid gas); volute material insufficiently resistant; local high velocity or erosion-corrosion
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Visual inspect coating and insulation every 6 months
  • Perform UT thickness measurement every 12 months
  • Re-apply anti-corrosion coating every 24 months
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Wire-mesh (Demister) Damage -> Droplet EntrainmentRPN 108 · Critical
Failure Mechanism
丝网材料腐蚀；安装不当造成机械损伤；长期运行疲劳断裂
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每月目视检查丝网，发现破洞立即更换
  • 每周监测压缩机入口液滴，超过5ppm报警
  • 每日检查压差，异常下降时排查
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
IGBT Module FailureRPN 108 · Critical
Failure Mechanism
散热不良；负载突变；驱动电路故障
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 实时监测模块温度，超过85℃报警
  • 每3个月进行电流波形分析
  • 每6个月进行热成像检查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Capacitor AgingRPN 108 · High
Failure Mechanism
高温运行；纹波电流过大；寿命到期
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每2年更换电解电容
  • 每6个月测量电容容量和纹波电压
  • 外观检查电容有无漏液或鼓包
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Fouling -> ImbalanceRPN 105 · High
Failure Mechanism
蒸汽水质未达标，硬度或碱度过高；蒸汽流速过低或温度波动导致过饱和析出；未定期进行化学清洗或在线除垢
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 连续监测振动频谱，若1倍频振幅超过报警值则安排清洗
  • 每半年进行叶轮表面结垢厚度检查，若超过1mm则化学清洗
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Internal CorrosionRPN 105 · High
Failure Mechanism
蒸汽中含氧或酸性气体；管材耐腐蚀性不足；冷凝液pH值过低
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每半年进行涡流检测，记录管壁厚度
  • 每月检查冷凝液pH值，低于6.5报警
  • 每周监测冷凝液含氧量，超过10ppb报警
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Bearing FailureRPN 96 · Critical
Failure Mechanism
润滑不足或油品变质；安装不对中或预紧不当；异物进入或腐蚀
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日监测轴承温度，超过85℃报警
  • 每月进行振动频谱分析，识别轴承特征频率
  • 每6个月更换润滑脂
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Condensate BackflowRPN 96 · High
Failure Mechanism
冷凝水排放不畅；密封蒸汽温度过低；疏水阀故障
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日检查冷凝水排放管路是否畅通
  • 连续监测密封蒸汽温度，低于120℃报警
  • 每周检查疏水阀工作状态
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
CavitationRPN 96 · Critical
Failure Mechanism
入口过滤网堵塞；液位过低导致吸入口露出液面；泵转速过高或入口管路阻力大
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日监测泵入口压力是否低于汽蚀余量
  • 每周听泵体是否有异常噪音和振动
  • 每半年检查叶轮表面是否有麻点或蜂窝状腐蚀
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Mechanical Seal LeakRPN 96 · High
Failure Mechanism
密封面干磨（缺液）；介质含颗粒物磨损密封面；安装不当或密封件老化
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日目视检查泄漏滴漏
  • 连续监测密封冲洗液压力
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
CPU/Power Redundancy Switchover FailureRPN 90 · Critical
Failure Mechanism
Power module aging; switchover circuit design defect; firmware error
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Quarterly redundancy switchover test
  • Replace power module annually (based on MTBF)
  • Check and update firmware version at each shutdown
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Sensor DriftRPN 90 · Medium
Failure Mechanism
长期使用漂移；环境腐蚀；校准不当
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Zero and span calibration every 6 months
  • Compare redundant-sensor readings every 3 months
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Insufficient LubricationRPN 84 · High
Failure Mechanism
油位过低或泄漏；油泵故障或管路堵塞；油品老化或污染
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日检查油位计，确保油位在正常范围
  • 连续监测油压，低于0.1MPa报警
  • 每周检查齿轮箱温度，超过85℃报警
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Pump CavitationRPN 84 · High
Failure Mechanism
凝水罐液位过低；入口管路堵塞；泵安装高度过高
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • Continuously monitor pump discharge and suction pressure
  • Daily auscultate pump for abnormal noise
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Carbon-ring WearRPN 80 · Medium
Failure Mechanism
轴表面粗糙或对中不良；碳环材料硬度不足或润滑不良；蒸汽含颗粒杂质
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日监测密封泄漏量，超过5g/h报警
  • 每月测量轴振动，超过0.05mm报警
  • 每半年检查碳环厚度，低于初始值80%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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Shell CorrosionRPN 80 · Critical
Failure Mechanism
Corrosive species in process liquid; improper shell material selection; anti-corrosion coating failure
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • UT thickness measurement every 6 months
  • Visual check of coating integrity every 12 months
RCM Strategy
RTFDesign Modification / Inspection Task
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Cooling Fan FailureRPN 80 · Medium
Failure Mechanism
灰尘堵塞；轴承润滑失效；电机过载
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 实时监测风扇转速，低于额定值80%报警
  • 每3个月清洁风扇及散热器
  • 每6个月检查轴承润滑
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Corrosion / Stress CorrosionRPN 72 · Critical
Failure Mechanism
蒸汽中含氯离子或酸性物质（如CO2、H2S）；材料选型不当（如未使用双相不锈钢）；残余应力或装配应力过大
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每月分析蒸汽氯离子浓度，若超过10ppm则调整工艺
  • 每半年进行叶轮渗透检测，若发现裂纹则评估更换
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Gear-tooth PittingRPN 72 · High
Failure Mechanism
润滑不良或油品污染；过载或冲击负荷；齿面硬度不足或接触精度差
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每月进行油液铁谱分析，监测颗粒浓度和尺寸
  • 每季度进行振动边频带分析，评估齿面状态
  • 每半年开盖目视检查齿面，记录点蚀面积
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
External (Shell-side) Fouling -> Reduced Heat-transfer CoefficientRPN 72 · High
Failure Mechanism
料液硬度高或含易结垢物质；流速过低；温度过高导致过饱和
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日监测传热系数，下降超过10%报警
  • 每周检查管束外观，记录结垢情况
  • 每月监测压差，上升超过20%清洗
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Blade WearRPN 72 · High
Failure Mechanism
介质含硬质颗粒；长期运行未维护；润滑不良
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每月监测真空度下降趋势
  • 每半年测量叶片厚度
  • 每年更换叶片（基于运行时间）
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Loose Wiring / TerminalsRPN 72 · High
Failure Mechanism
安装时未按规定扭矩紧固；长期振动导致螺母自松；温度变化引起热胀冷缩差异
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每6个月检查并紧固所有接线端子
  • 使用扭矩扳手按规范力矩紧固
  • 红外热成像检测异常温升
RCM Strategy
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
I/O Card FailureRPN 64 · Critical
Failure Mechanism
环境温度过高；电源波动；静电损坏
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每3个月执行一次自诊断测试并记录结果
  • 每6个月检查信号回路并紧固接线端子
  • 保持备件库存，故障时立即替换
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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Sample Line BlockageRPN 50 · Medium
Failure Mechanism
介质含固量高或易结晶；取样管径过小或弯头过多；未定期冲洗或吹扫
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每3个月反吹或冲洗取样管
  • 每6个月拆卸检查并清理
  • 监测取样流量，低于设计值80%报警
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Wire-mesh (Demister) Blockage -> Pressure-drop IncreaseRPN 48 · Medium
Failure Mechanism
蒸汽中夹带固体颗粒；料液起泡严重；清洗不及时
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测除沫器前后压差，超过0.5kPa报警
  • 每周检查蒸汽流量，下降超过10%排查
  • 每月目视检查丝网，记录堵塞面积
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Level Control FailureRPN 48 · High
Failure Mechanism
液位计堵塞或失灵；控制阀卡涩；控制器参数设置不当
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每月校准液位计，误差不超过±2%
  • 每季度检查控制阀动作，确保全行程时间不超过5秒
  • 设置高低液位报警，每班次确认报警功能正常
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
High Seal-water Temperature -> Reduced ExtractionRPN 48 · High
Failure Mechanism
密封水冷却器故障；密封水流量不足；环境温度高
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测密封水温度和真空度
  • 每周检查冷却水系统流量
  • 每月清洗密封水冷却器
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Piping Leak -> Insufficient VacuumRPN 48 · Critical
Failure Mechanism
腐蚀性介质；机械振动；安装缺陷
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测真空度趋势
  • 每月进行肥皂泡检漏
  • 每季度进行超声波检漏
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Fouling / ScalingRPN 42 · High
Failure Mechanism
料液硬度高或含易结垢成分；换热面温度过高；流速过低促进沉积
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测换热器进出口温差和压降
  • 每季度化学清洗或机械清洗
  • 根据水质分析调整阻垢剂添加量
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Cooling-water-side Fouling -> Vacuum LossRPN 42 · High
Failure Mechanism
冷却水硬度高未处理；冷却水流速低；冷却水温度过高
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测冷凝器真空度和冷却水温差
  • 每月检查冷却水水质，必要时加药处理
  • 每半年机械清洗或化学清洗
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Level Fluctuation -> Dry WallRPN 40 · Medium
Failure Mechanism
进料流量不稳定；液位控制系统故障；蒸发速率波动
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 连续监测液位，波动超过±10%报警
  • 每日检查加热管束表面温度分布，异常时调整
  • 每周计算传热系数，下降超过5%排查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Valve Internal LeakRPN 36 · High
Failure Mechanism
介质含杂质；密封面腐蚀；执行机构故障
How to Detect
Online monitoring · Detection rate 80% ；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 (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Fouling / ScalingRPN 30 · Medium
Failure Mechanism
蒸汽水质差，含高浓度溶解盐；蒸汽流速低或温度变化导致析出；未定期清洗
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测换热器进出口温差和压降
  • 每季度化学清洗或机械清洗
  • 根据水质分析调整阻垢剂添加量
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Fouling / ScalingRPN 30 · Medium
Failure Mechanism
料液含易结垢成分；蒸汽流速过高；清洗周期过长
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每日监测换热器进出口温差和压降
  • 每季度化学清洗或机械清洗
  • 根据水质分析调整阻垢剂添加量
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗
Impeller WearRPN 30 · Medium
Failure Mechanism
料液含硬质颗粒；流速过高导致冲刷；介质腐蚀性较强
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每月监测泵振动和流量变化
  • 每半年拆检测量叶轮厚度
  • 当振动或流量异常时立即停机检查
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • 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 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2026-03-28CN-MEM2026Fatalities 1 · Physical
Sichuan Yingda Lithium Battery Materials Co.: MVR System Secondary Separator Drain-port Scald Accident (Mar 28)
Root cause: No safe-operation management system or procedure for secondary-separator flush work (first-time task); inadequate training (wrong assessment of high-temperature / work-at-height risks); inadequate hazard investigation (residual hot water, unqualified work-at-height personnel, unstable scaffolding).
Official source ↗