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 (2)
GB/T 7826-2012
API 660
Lessons Learned (5)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-MILLARD-2015CSB2015Toxic Millard Refrigerated 氨释放 Root cause: 氨制冷系统机械密封/容器完整性不足（跨行业映射至压缩机/压力容器） Official source ↗
除沫器堵塞→蒸汽带液RPN 140 · High
Failure Mechanism
雾沫夹带、结垢
How to Detect
Detection N/A ；Re-inspect ≤every12months
Mitigation (What to Do)
除沫器压差监测
定期拆洗
二次蒸汽雾沫夹带检测
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 ↗
湿蒸汽冲蚀/腐蚀RPN 140 · High
Failure Mechanism
二次蒸汽带液、颗粒
How to Detect
Detection N/A ；Re-inspect ≤every12months
Mitigation (What to Do)
叶轮/转子 VT 检查
二次蒸汽带液(雾沫)监测
叶片厚度 UT
材质/硬度评估
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 ↗
管内结垢/结疤传热恶化RPN 120 · Medium
Failure Mechanism
水质硬度、悬浮物
How to Detect
Detection N/A ；Re-inspect ≤every12months
Mitigation (What to Do)
换热端差(ΔT)与传热效率监测
定期化学清洗(CIP)
进水硬度/悬浮物预处理监控
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 (2)
GB/T 7826-2012
API 660
Lessons Learned (5)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-MILLARD-2015CSB2015Toxic Millard Refrigerated 氨释放 Root cause: 氨制冷系统机械密封/容器完整性不足（跨行业映射至压缩机/压力容器） Official source ↗
结垢转子不平衡RPN 120 · High
Failure Mechanism
介质沉积
How to Detect
Detection N/A ；Re-inspect ≤every12months
Mitigation (What to Do)
振动分析(ISO 10816)
Rotor dynamic balancing
结垢清理
进出口滤网检查
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 Fatigue CrackRPN 120 · Critical
Failure Mechanism
交变应力/共振
How to Detect
Detection N/A ；Re-inspect ≤every12months
Mitigation (What to Do)
叶片 PT/荧光检测
振动频谱分析(避开共振转速)
动平衡
应力/模态核算
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 (2)
GB/T 7826-2012
API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
Lessons Learned (5)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-MILLARD-2015CSB2015Toxic Millard Refrigerated 氨释放 Root cause: 氨制冷系统机械密封/容器完整性不足（跨行业映射至压缩机/压力容器） Official source ↗
轴承磨损/烧瓦RPN 112 · High
Failure Mechanism
油膜破坏、对中不良
How to Detect
Detection N/A ；Re-inspect ≤every12months
Mitigation (What to Do)
油膜/油质分析
轴承振动温度监测
对中校验
润滑油路检查
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 ↗
焊缝应力腐蚀/裂纹RPN 105 · High
Failure Mechanism
残余应力+腐蚀介质
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
焊缝 MT/PT 表面检测
定期 UT 体积检测
硬度/残余应力抽查
介质 Cl-/S 浓度监控
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 (2)
GB/T 7826-2012
API 660
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
分布孔堵塞RPN 100 · Medium
Failure Mechanism
悬浮物/结疤
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
分布器拆检/冲洗
进液过滤监控
分布器前后压差监测
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 (2)
GB/T 7826-2012
API 660
Lessons Learned (5)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 100 · Medium
Failure Mechanism
NPSH 不足
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
NPSH 余量核算
入口压力/汽蚀噪声监测
叶轮/口环检查
吸入管路阻力排查
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (5)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-MILLARD-2015CSB2015Toxic Millard Refrigerated 氨释放 Root cause: 氨制冷系统机械密封/容器完整性不足（跨行业映射至压缩机/压力容器） Official source ↗
Mechanical Seal LeakRPN 100 · Medium
Failure Mechanism
密封损伤
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
密封泄漏监测
密封冲洗系统检查
密封件定期更换
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (1)
2019-03-I-TXcsb2019Safety/Environmental/Fire Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾 Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙 Official source ↗
磨蚀/磨损RPN 100 · Medium
Failure Mechanism
高固含浆液
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
过流件厚度检查
浆液固含/粒径监控
耐磨衬里检查
间隙测量
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
测量漂移/导压管堵塞RPN 100 · Medium
Failure Mechanism
导压管堵、零点飘
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
变送器零点校准
导压管吹扫/疏通
与就地比对
定期校验
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 (2)
GB/T 7826-2012
GB/T 21109
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
电机过载/烧毁RPN 96 · High
Failure Mechanism
工况偏移、堵转
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
电机电流/温度在线监测
绝缘电阻/绕组检测
负载曲线核对
堵转保护校验
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 ↗
传感器失效RPN 96 · High
Failure Mechanism
元件老化
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
传感器定期标定
冗余比对
备件轮换
趋势监测
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 (2)
GB/T 7826-2012
GB/T 21109
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
润滑失效/断油RPN 84 · High
Failure Mechanism
油系统故障
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
油压/流量/油温在线监测
油滤压差
油箱液位
油质分析
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (1)
NUREG-LER-2011-003-BRUNSWICKNRC2011Operational R.E. Ginna Nuclear Plant: Turbine Lube-oil Piping Fatigue Rupture Causing Reactor Trip Root cause: High stress from original construction piping + substandard weld quality + cyclic fatigue; inadequate maintenance and inspection. Official source ↗
不凝气积聚→传热下降RPN 80 · Medium
Failure Mechanism
排气不畅
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
不凝气排放系统检查
冷凝侧真空/压力监控
排气阀功能测试
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 (2)
GB/T 7826-2012
API 660
Lessons Learned (5)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 ↗
气封失效内漏RPN 80 · Medium
Failure Mechanism
迷宫密封磨损
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
级间泄漏(性能)监测
密封间隙检查
气封更换
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 80 · Medium
Failure Mechanism
水质/悬浮物
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
传热效率监测
定期清洗
进水水质监控
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 (2)
GB/T 7826-2012
API 660
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
固体堵塞RPN 80 · Medium
Failure Mechanism
结晶/大颗粒
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
进出口压差监测
进料过滤
冲洗/清堵程序
结晶倾向监控
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 (2)
GB/T 7826-2012
API 550
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
壳体均匀腐蚀减薄RPN 72 · High
Failure Mechanism
介质腐蚀、涂层失效
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
壳体壁厚超声测厚(UT)
涂层/衬里完整性目视
电火花检漏
介质腐蚀性监测(pH/Cl-)
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 (2)
GB/T 7826-2012
API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
管板泄漏RPN 72 · High
Failure Mechanism
胀接松弛、腐蚀
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
管板胀接区 PT/VT 检测
泄漏试验(水压/氦检)
缝隙腐蚀监控
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 (2)
GB/T 7826-2012
API 660
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 (3)
GB/T 7826-2012
API 617
GB/T 21109
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
变频器故障→压缩机跳闸RPN 72 · High
Failure Mechanism
过温/过流
How to Detect
Detection N/A ；Re-inspect ≤every24months
Mitigation (What to Do)
变频器温/流监测
散热/滤网检查
电容/IGBT 状态评估
参数备份
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
Impeller WearRPN 64 · Medium
Failure Mechanism
颗粒磨蚀
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
叶轮厚度/型线检查
介质颗粒度监控
口环间隙测量
材质评估
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (5)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-MILLARD-2015CSB2015Toxic Millard Refrigerated 氨释放 Root cause: 氨制冷系统机械密封/容器完整性不足（跨行业映射至压缩机/压力容器） Official source ↗
电机过载RPN 64 · Medium
Failure Mechanism
堵转/工况偏
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
电机电流/温度监测
绝缘/绕组检测
堵转保护校验
工况核对
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
CavitationRPN 64 · Medium
Failure Mechanism
NPSH 不足
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
NPSH 核算
汽蚀噪声监测
叶轮检查
吸入条件排查
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
密封泄漏RPN 64 · Medium
Failure Mechanism
密封损伤
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
密封泄漏监测
冲洗系统检查
密封件更换
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 (2)
GB/T 7826-2012
API 610
Lessons Learned (1)
2019-03-I-TXcsb2019Safety/Environmental/Fire Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾 Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙 Official source ↗
Shell CorrosionRPN 60 · Medium
Failure Mechanism
介质腐蚀
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
壳体外壁/内衬 VT
壁厚 UT
涂层完整性
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 (2)
GB/T 7826-2012
API 617
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
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 ↗
管束腐蚀RPN 60 · Medium
Failure Mechanism
腐蚀介质
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
管束 UT/ECT
内衬检查
介质腐蚀性监控
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 (2)
GB/T 7826-2012
API 660
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
通信中断RPN 60 · Medium
Failure Mechanism
网络故障
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
网络冗余/环网测试
通信诊断
接头/光纤检查
链路监控
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 (2)
GB/T 7826-2012
GB/T 21109
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
联锁误动→非计划停机RPN 60 · Medium
Failure Mechanism
误信号
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
信号回路抗扰/隔离检查
传感器冗余核对
误跳车根因分析
联锁表决逻辑复核
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 (2)
GB/T 7826-2012
GB/T 21109
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
控制逻辑失效/死机RPN 56 · High
Failure Mechanism
软件/硬件故障
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
PLC/DCS 冗余切换测试
程序版本/备份管理
看门狗/自诊断
定期维护
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 (2)
GB/T 7826-2012
GB/T 21109
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗
CSB-ENTERPRISE-PASCAGOULA-2019CSB2019Explosion/Fire Enterprise Pascagoula 气体处理厂爆炸火灾 Root cause: 换热器等静设备完整性不足导致烃泄漏爆炸 Official source ↗
联锁拒动RPN 48 · Critical
Failure Mechanism
SIS 未动作
How to Detect
Detection N/A ；Interval by RBI
Mitigation (What to Do)
SIS 周期性功能测试(Proof test)
联锁逻辑核验
诊断覆盖率确认
旁路管理
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 (2)
GB/T 7826-2012
GB/T 21109
Lessons Learned (3)
ARR-2023-01-KMScsb2023Safety/Environmental Kinder Morgan Snyder CO2 Compressor Station Closed-drain System Vessel Overpressure Rupture (CSB ARR compilation) Root cause: Wash-tower level dump valve stuck open (common in winter) + Joule-Thomson cooling froze/ hydrated off the relief path + closed-drain vessel design and overpressure protection inadequate + lack of pressure/temperature/level instrumentation; PHA did not identify the ice-plug scenario. Official source ↗