Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Reactorreactor
⚠ ⚠ Top risk: Blade Detachment · RPN 400 (Low) — watch this one first at the equipment
Risk Board (all 45 · 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)
45Failure Modes
30High/Critical
33Standards
11Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (33 standards / 11 accidents)
Standards (33 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
  • GB/T 11348
  • GB/T 6075
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • ISO 13374 — Condition monitoring and diagnostics of machines — Data processing, communication and presentation
  • ISO 17359 — Condition monitoring and diagnostics of machines — General guidelines
  • GB/T 27921-2023
  • IEC 60300-3-10 — Dependability management — Part 3-10: Application guide — Maintainability
  • ISO 55001 — Asset management — Management systems — Requirements
  • API 581-2025
  • GB/T 44692
Accident Lessons (11 de-duplicated)
2008-08-I-WVcsb2008 ↗
Bayer CropScience 废料储罐失控反应爆炸（Institute）
2023-03-I-LAcsb2023 ↗
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
2021-04-I-OHcsb2021 ↗
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
2020-07-I-NCcsb2020 ↗
Evergreen 纸浆漂白塔热工作业火灾（Canton）
2014-08-I-TXcsb2014 ↗
DuPont La Porte Phosgene Release
2011-02-I-NCcsb2011 ↗
Synthron Reactor Runaway Explosion
2008-06-I-WVcsb2008 ↗
Bayer CropScience MIC Release
1998-06-I-NJcsb1998 ↗
Morton International 染料反应釜失控反应爆炸
2004-10-I-ILcsb2004 ↗
Formosa Plastics Illiopolis PVC 反应器误排爆炸
2004-04-I-ILcsb2004 ↗
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
NUREG-LER-2011-003-BRUNSWICKNRC2011 ↗
R.E. Ginna Nuclear Plant: Turbine Lube-oil Piping Fatigue Rupture Causing Reactor Trip
FM Traceability Cards (45)
Generated by Reliability AI
Blade DetachmentRPN 400 · Low
Failure Mechanism
Bolt loosening or fatigue fracture; poor weld quality or lack of penetration; overspeed or overload
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically replace connecting bolts
  • Check weld quality
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Fatigue FractureRPN 288 · Critical
Failure Mechanism
Long-term cyclic bending or torsional stress; machining defect or stress concentration on shaft surface; insufficient fatigue strength or improper heat treatment
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically replace agitator shaft
  • Perform NDT
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Stress Corrosion Cracking (SCC)RPN 270 · Critical
Failure Mechanism
Residual or weld stress; chloride or H2S in medium; sensitized material (stainless steel)
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodic NDT (e.g., PT, MT)
  • Monitor stress level
  • Control medium composition
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Half-pipe Weld LeakRPN 270 · Critical
Failure Mechanism
焊接质量不合格（气孔、未熔合）；热循环应力导致疲劳裂纹；焊缝处介质腐蚀
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 定期进行焊缝无损检测（PT/MT）
  • 检查焊缝外观
  • 监测泄漏迹象
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Weld CrackRPN 240 · Critical
Failure Mechanism
焊接工艺参数不当（预热/后热不足）；焊材与母材不匹配；焊缝存在未熔合或夹渣
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 定期进行无损检测（如RT、UT）
  • 监控焊缝区域
  • 检查焊接工艺参数
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Bearing FailureRPN 224 · High
Failure Mechanism
Poor lubrication or contaminated lubricant; overload or impact load; poor installation alignment
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically replace bearing
  • Monitor bearing vibration and temperature
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 (28)
  • API 580 — Risk-Based Inspection
  • GB/T 11348
  • GB/T 6075
  • GB/T 7826-2012
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • ISO 13374 — Condition monitoring and diagnostics of machines — Data processing, communication and presentation
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • ISO 17359 — Condition monitoring and diagnostics of machines — General guidelines
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Dry-running BurnRPN 216 · Critical
Failure Mechanism
冲洗液中断或压力不足；操作失误导致干运转；密封腔排气不充分
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Install dry-run protection
  • 确保密封腔有冲洗液时才能启动
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Premature Fatigue RuptureRPN 189 · Critical
Failure Mechanism
Frequent pressure fluctuation; material corrosion; improper installation torque
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically replace rupture disk
  • Check installation stress
  • Record operating-pressure fluctuations
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 (26)
  • API 580 — Risk-Based Inspection
  • GB/T 27921-2023
  • GB/T 7826-2012
  • IEC 60300-3-10 — Dependability management — Part 3-10: Application guide — Maintainability
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • ISO 55001 — Asset management — Management systems — Requirements
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Relief Line BlockageRPN 180 · Low
Failure Mechanism
Medium prone to polymerization or crystallization; insufficient line slope in design; lack of regular cleaning
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically clean relief line
  • Check for deposits
  • Use anti-clog design
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Set Point DriftRPN 168 · High
Failure Mechanism
Relief valve set-pressure drift: long-term spring stress creep/fatigue, loose setting nut, or seat fouling make actual opening pressure deviate from set point. Consequence: (1) too high -> valve fails to lift when needed, equipment overpressure (safety/integrity risk); (2) too low -> spurious lift in normal operation (production loss, media release). Progressive degradation; managed by periodic set-pressure verification (API 510 / GB-T 44692 class).
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 定期校验安全阀整定压力
  • 检查弹簧状态
  • 清洁阀座
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Jacket CorrosionRPN 144 · Critical
Failure Mechanism
加热/冷却介质腐蚀性强；夹套内存在氧浓差电池；材质耐腐蚀性不足
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期测厚检查夹套内壁
  • 监测腐蚀速率
  • 根据壁厚减薄趋势安排维修
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (24)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Thermowell CorrosionRPN 144 · Critical
Failure Mechanism
介质腐蚀性强；流速过高导致冲刷腐蚀；材料选型不当
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期测厚检查套管
  • 检查腐蚀情况
  • 根据腐蚀速率更换
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 (24)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Gear Wear/PittingRPN 140 · High
Failure Mechanism
润滑不良或油品污染；过载或冲击载荷；齿轮材料或热处理不当
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 检查齿轮齿面
  • 测量齿厚
  • 监测齿轮箱振动
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Spring FailureRPN 140 · High
Failure Mechanism
弹簧材料疲劳强度不足；安装时弹簧压缩量过大或过小；介质腐蚀导致弹簧截面减小
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每运行25000小时更换弹簧
  • 检查弹簧疲劳情况
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Glass-lining FailureRPN 135 · Critical
Failure Mechanism
温差过大导致热应力；搅拌器碰撞或异物冲击；介质渗透至搪层与金属界面
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期目视检查搪玻璃层
  • 进行电火花检测
  • 监控温度变化速率
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 (23)
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Backside CorrosionRPN 126 · High
Failure Mechanism
背压侧密封不严；环境湿度高；腐蚀性气体侵入
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 检查背压侧腐蚀情况
  • 保持背压侧干燥
  • 使用耐腐蚀材料
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 (25)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 44692
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Keyway WearRPN 120 · High
Failure Mechanism
键与键槽配合间隙过大；频繁启停或负载突变；润滑不良导致微动磨损
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 检查键槽尺寸
  • 着色探伤检查裂纹
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Blade CrackRPN 120 · Critical
Failure Mechanism
交变应力集中；腐蚀介质与应力协同作用；焊接缺陷或热处理不当
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 着色探伤检查桨叶表面
  • 超声波检测焊缝
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Internal Corrosion ThinningRPN 120 · Critical
Failure Mechanism
介质腐蚀性强且选材不当；工艺温度/浓度超出设计范围；内壁防护层失效
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodic thickness measurement
  • Check corrosion rate
  • 根据腐蚀速率预测剩余寿命
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 (24)
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Face WearRPN 120 · High
Failure Mechanism
介质含固体颗粒；端面比压过大或润滑不足；安装平行度偏差
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每运行25000小时更换机械密封
  • 检查密封端面磨损情况
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Secondary Seal LeakRPN 120 · High
Failure Mechanism
密封圈材料与介质不兼容；安装时密封圈扭曲或划伤；温度波动导致密封圈硬化或软化
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每运行25000小时更换辅助密封圈
  • 检查安装质量
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 (25)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 44692
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Coil PerforationRPN 120 · Critical
Failure Mechanism
介质腐蚀性强；材料选型不当；流速过高导致冲刷腐蚀
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期测厚检查盘管
  • Monitor medium corrosivity
  • 根据腐蚀速率预测寿命
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 (24)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Quench System FailureRPN 120 · Low
Failure Mechanism
淬灭剂泵故障；淬灭剂变质；阀门误关闭
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期测试淬灭系统功能
  • 检查淬灭剂存量
  • 检查供应系统
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 (23)
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
BendingRPN 112 · High
Failure Mechanism
搅拌桨叶不平衡产生过大径向力；操作温度过高导致材料屈服强度下降；安装对中不良或基础沉降
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 测量搅拌轴直线度
  • 监测弯曲振动
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Glass-lining DamageRPN 108 · Critical
Failure Mechanism
操作温度急剧变化；搅拌桨叶碰撞釜壁；搪玻璃层存在制造缺陷
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 检查搪玻璃层表面
  • 电火花检测
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 (23)
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Flange Face CorrosionRPN 105 · High
Failure Mechanism
介质腐蚀性强；法兰面保护层破损；安装时垫片错位或硬物划伤
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查法兰密封面腐蚀情况
  • 测量垫片压缩回弹性能
  • 根据腐蚀速率预测更换周期
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
O-ring AgingRPN 100 · Medium
Failure Mechanism
介质与O圈材料不相容；温度超过O圈耐温极限；压缩率过大或安装扭曲
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每运行25000小时更换O型圈
  • 检查O型圈状态
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 (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Valve Seat LeakageRPN 100 · Medium
Failure Mechanism
密封面损伤；杂质卡阻；弹簧力不足
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期进行密封性试验
  • 检查阀座密封面
  • 清洁杂质
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Vibration FatigueRPN 96 · High
Failure Mechanism
搅拌器不平衡或转速过高；盘管支撑不足；流体共振
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 监测振动水平
  • 检查盘管支撑状态
  • 分析振动频谱
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 (28)
  • API 580 — Risk-Based Inspection
  • GB/T 11348
  • GB/T 6075
  • GB/T 7826-2012
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • ISO 13374 — Condition monitoring and diagnostics of machines — Data processing, communication and presentation
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • ISO 17359 — Condition monitoring and diagnostics of machines — General guidelines
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (11)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
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 ↗
Support LooseningRPN 96 · Medium
Failure Mechanism
初始安装紧固不足；热循环导致螺栓松弛；振动磨损
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查并紧固支撑件
  • 检查螺栓扭矩
  • 检查支架磨损
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Gasket AgingRPN 90 · High
Failure Mechanism
垫片材料选择不当；长期超温或超压运行；安装时预紧力不足或不均
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每运行40000小时更换垫片
  • 检查法兰面状态
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (25)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 44692
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Electrode FoulingRPN 90 · High
Failure Mechanism
介质污染电极；电极使用超期；清洗不当
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期清洗电极
  • 更换老化电极
  • 校准仪表
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Corrosion/ErosionRPN 84 · High
Failure Mechanism
介质腐蚀性强或含磨蚀性颗粒；选材不当或涂层失效；流速过高或局部湍流
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 测量桨叶厚度
  • 检查表面腐蚀坑
  • 监测介质成分
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 (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Diaphragm FailureRPN 84 · High
Failure Mechanism
压力波动过大；介质结晶或颗粒堵塞；隔膜材料老化
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查隔膜外观
  • 监测压力波动
  • 安装过滤器防止堵塞
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Oil Seal LeakRPN 80 · Medium
Failure Mechanism
油封材料与介质不兼容；轴表面粗糙或划伤；安装时唇口翻边或损伤
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每运行40000小时更换油封
  • 检查轴表面磨损情况
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
CorrosionRPN 75 · Medium
Failure Mechanism
防腐涂层失效；积水或潮湿环境；接触腐蚀性介质（如酸雾）
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每5年重新防腐涂装
  • 检查支座腐蚀情况
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Jacket FoulingRPN 72 · Medium
Failure Mechanism
介质硬度高或含悬浮物；流速过低导致沉积；未定期进行化学清洗
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期清洗夹套
  • 使用在线除垢装置
  • 优化水质或介质过滤
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Anchor Bolt LooseningRPN 64 · Medium
Failure Mechanism
初始预紧力不足；长期振动导致螺母自松；基础沉降或变形
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 定期检查地脚螺栓扭矩
  • 检查振动情况
  • 必要时重新紧固
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Flush LossRPN 64 · Critical
Failure Mechanism
冲洗泵故障或电源中断；管路堵塞或阀门误关；储液罐液位过低
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 安装流量开关和压力变送器
  • 实时监控冲洗液流量和压力
  • 报警并联锁停车
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Coating→False ReadingRPN 54 · High
Failure Mechanism
介质易结垢或粘附；清洗周期过长；测量元件表面粗糙
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期清洗测量元件
  • 检查介质结垢特性
  • 安装清洗装置
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Sensor DriftRPN 50 · Medium
Failure Mechanism
传感器老化；接线端子氧化；热套管结垢
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期校准温度传感器
  • 检查接线
  • 对比冗余传感器
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 (23)
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Calibration DriftRPN 40 · Medium
Failure Mechanism
温度变化；电极老化；标定间隔过长
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期标定仪表
  • 记录漂移趋势
  • 调整标定周期
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 (23)
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Filter CloggingRPN 30 · Medium
Failure Mechanism
冲洗液中含有颗粒杂质；过滤器选型不当（目数过细）；未定期清洗或更换滤芯
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 每3个月清洗或更换过滤器
  • 检查压差
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Impulse Line BlockageRPN 30 · Medium
Failure Mechanism
介质易结晶或聚合；伴热不足；引压管设计不合理
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期吹扫引压管
  • 检查介质结晶倾向
  • 安装伴热或冲洗系统
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗
Impulse Line BlockageRPN 30 · Medium
Failure Mechanism
介质易结晶或聚合；伴热不足；引压管设计不合理
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期吹扫引压管
  • 检查介质结晶倾向
  • 安装伴热或冲洗系统
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • 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 510 — Pressure Vessel Inspection Code
  • API 570 — Piping Inspection Code
  • API 579-1/ASME FFS-1 — Fitness-For-Service
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (10)
2008-08-I-WVcsb2008Fatalities 2 · Injuries 8 · Safety/Environmental
Bayer CropScience 废料储罐失控反应爆炸（Institute）
Root cause: 废料储罐内失控放热反应，超压爆炸；工艺安全信息/培训与 MOC 不足，2 死 8 伤
Official source ↗
2023-03-I-LAcsb2023Safety/Operational
Dow Louisiana 环氧乙烷装置容器爆炸（Plaquemine）
Root cause: 容器封闭与惰性化/泄压设计缺陷，环氧乙烷泄漏爆炸；无伤亡（官方确认 no injuries）
Official source ↗
2021-04-I-OHcsb2021Fatalities 1 · Safety
Yenkin-Majestic 树脂反应釜泄漏爆炸（哥伦布）
Root cause: 树脂反应釜泄漏，易燃蒸气积聚被引燃；1 死
Official source ↗
2020-07-I-NCcsb2020Fatalities 2 · Safety
Evergreen 纸浆漂白塔热工作业火灾（Canton）
Root cause: 容器热工作业前未清理可燃物、未做受限空间评估，引燃火灾；2 死
Official source ↗
2014-08-I-TXcsb2014Fatalities 4 · Injuries 1 · Safety/Environmental
DuPont La Porte Phosgene Release
Root cause: Wrong valve position + inadequate phosgene system isolation + missing training.
Official source ↗
2011-02-I-NCcsb2011Fatalities 1 · Injuries 1 · Safety
Synthron Reactor Runaway Explosion
Root cause: Cooling failure + runaway reaction + inadequate pressure relief.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
1998-06-I-NJcsb1998Injuries 9 · Safety/Environmental
Morton International 染料反应釜失控反应爆炸
Root cause: 放大生产未做充分反应危害评估，Yellow 96 反应放热失控（釜温超分解温度），超压喷发爆炸；9 名员工受伤、物料释放至社区
Official source ↗
2004-10-I-ILcsb2004Fatalities 5 · Injuries 3 · Safety/Environmental
Formosa Plastics Illiopolis PVC 反应器误排爆炸
Root cause: 操作员走错平台误开在运反应器底阀并使用旁路绕过安全联锁，氯乙烯单体大量释放被引燃爆炸；5 死 3 重伤，装置报废
Official source ↗
2004-04-I-ILcsb2004Fatalities 5 · Injuries 3 · Fire/Explosion/Toxic
Formosa Plastics Illiopolis PVC 装置反应器底阀安全联锁被旁路爆炸
Root cause: 未充分规划人因后果；安全联锁可被轻易旁路且无锁具；反应器分组相似无状态指示；培训与演练不足
Official source ↗