Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Reciprocating Compressorrecip_compressor
⚠ ⚠ Top risk: Piston Rod Fracture · RPN 320 (Low) — watch this one first at the equipment
Risk Board (all 16 · 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)
16Failure Modes
10High/Critical
18Standards
1Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (18 standards / 1 accidents)
Standards (18 de-duplicated)
  • API 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 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
  • API 581-2025
Accident Lessons (1 de-duplicated)
CN-MEM-2014-07-08CN-MEM2014 ↗
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
FM Traceability Cards (16)
Generated by Reliability AI
Piston Rod FractureRPN 320 · Low
Failure Mechanism
Stress concentration (e.g., thread root); material defect or improper heat treatment; overload or resonance
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically measure cylinder liner bore
  • Replace cylinder liner
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 (17)
  • 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 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Valve Plate FractureRPN 168 · Critical
Failure Mechanism
气阀弹簧力不当导致阀片撞击；介质含杂质或液击；阀片材料缺陷或热处理不当
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 定期泄漏测试
  • 检查密封面
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 (17)
  • 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 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Valve Seat LeakRPN 144 · High
Failure Mechanism
Solid-particle erosion in medium; valve-seat material not corrosion-resistant; misalignment causing uneven wear
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodically measure piston-ring clearance
  • Replace piston ring
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Fatigue FractureRPN 144 · Critical
Failure Mechanism
Insufficient material fatigue strength; manufacturing defect (surface scratch, improper heat treatment); overload or resonance
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • MT inspection of crankshaft surface and stress-concentration areas every 8000 operating hours
  • Install online vibration monitoring; analyze spectrum every 2 weeks, focus on 1x and harmonics
  • Quarterly lube-oil ferrography to monitor wear-particle concentration and morphology
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Spring FailureRPN 140 · High
Failure Mechanism
Insufficient spring fatigue strength; resonance causing high stress; corrosion or high temperature accelerating failure
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Disassemble and measure spring free height every 8000 hours
  • Replace spring every 15000 hours
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Babbitt Bearing Wear / FlakingRPN 128 · Critical
Failure Mechanism
Excessive lube-oil temperature or degradation; improper bearing clearance; frequent starts causing thermal fatigue
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Daily monitor bearing temperature; alarm and inspect when >75 C
  • Weekly vibration monitoring, analyze HF acceleration envelope; schedule maintenance when trend rises
  • Measure bearing clearance quarterly; replace when clearance exceeds 20% of 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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Connecting-rod Bolt FractureRPN 120 · Low
Failure Mechanism
Preload too high or low; bolt material or heat-treatment defect; stress concentration at thread root
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Use torque wrench to check bolt preload every 4000 operating hours; keep within ±5% of standard
  • UT flaw detection of bolt root and threaded area at each major overhaul
  • Maintain bolt-replacement log; force-replace bolts every 20000 operating hours
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Tube-bundle LeakRPN 112 · High
Failure Mechanism
腐蚀性介质；管束振动疲劳；焊接缺陷
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 每运行8000小时进行壳程压力试验，保压30分钟无压降
  • 每年进行氦检漏，检测泄漏率不超过1×10^-6 Pa·m³/s
  • 每季度进行超声波测厚，当壁厚减薄超过20%时更换管束
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Ring WearRPN 96 · High
Failure Mechanism
润滑不良或油品不当；介质含磨粒；活塞环材料或硬度不合适
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期磁粉探伤
  • 检查活塞杆表面
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Journal WearRPN 96 · High
Failure Mechanism
润滑油污染或供油不足；轴颈表面硬度不足；安装对中不良
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每月测量轴颈直径，记录磨损量，当磨损量超过0.05mm时安排修复
  • 每周进行油液分析，监测铁含量，当铁含量超过50ppm时更换润滑油并检查过滤器
  • 每季度进行振动监测，分析轴颈通过频率幅值变化趋势
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Lube-oil Pump Wear -> Low PressureRPN 96 · High
Failure Mechanism
润滑油含杂质；长期运行疲劳；油泵选型不当
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日监测油压，当压力低于设定值0.2MPa时报警并检查
  • 每月进行油液分析，监测铁含量，当铁含量超过100ppm时安排检修
  • 每运行10000小时解体检查油泵齿轮和轴承磨损情况
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Packing Wear LeakRPN 80 · Medium
Failure Mechanism
润滑不足；活塞杆表面粗糙或划伤；填料材料不耐磨或安装不当
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 每日监测填料函泄漏量
  • 每月检查活塞杆表面状态
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Level Control FailureRPN 64 · Critical
Failure Mechanism
液位计堵塞；控制阀卡涩；仪表校准漂移
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每月校准液位计，误差不超过±2%
  • 每季度检查控制阀动作，确保全行程时间不超过5秒
  • 设置高低液位报警，每班次确认报警功能正常
RCM Strategy
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Tube-bundle FoulingRPN 60 · Medium
Failure Mechanism
水质硬度高；冷却水温度过高；未定期清洗
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每运行4000小时进行化学清洗，清除管束表面水垢
  • 每周监测冷却水进出口温差，当温差下降超过10%时安排清洗
  • 每月进行水样分析，控制钙镁离子浓度在标准范围内
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Liner WearRPN 45 · Medium
Failure Mechanism
润滑不良；介质含腐蚀性成分或磨粒；活塞环与缸套硬度不匹配
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 定期壁厚测量
  • 检查水质
  • 红外热成像
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (18)
  • API 580 — Risk-Based Inspection
  • 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 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗
Filter BlockageRPN 30 · Medium
Failure Mechanism
油液污染严重；滤芯寿命到期；旁路阀失效
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 每运行2000小时更换滤芯，并记录压差初始值
  • 每日监测过滤器压差，当压差超过0.1MPa时立即更换
  • 每月进行油液清洁度检测，确保NAS 1638等级不超过8级
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 (17)
  • API 580 — Risk-Based Inspection
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 44958-2024
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 754 — Process Safety Performance Indicators
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
Lessons Learned (1)
CN-MEM-2014-07-08CN-MEM2014Injuries 1 · Toxic
Qingdao Qichao Cold-storage Plant Refrigeration Compressor Liquid-ammonia Leak Accident (Jul 8)
Root cause: Compressor components not maintained in time (gasket aging); operator error in refrigeration operation (intercooler overpressure, liquid ammonia slugs back to cylinder); non-compliant emergency response; deficient safety management and training, shutdown order not enforced.
Official source ↗