Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
柱塞泵/隔膜泵/往复泵/计量泵/加药泵 (Reciprocating Positive Displacement Pump)柱塞泵/隔膜泵/往复泵/计量泵/加药泵 (Reciprocating Positive Displacement Pump)
⚠ ⚠ Top risk: 吸入/排出阀片失效 · RPN 120 (High) — watch this one first at the equipment
Risk Board (all 15 · by RPN · top 6 highlighted urgent)
Shield: Safety = people/environment　Production = production only
Technical mechanism/mitigation body in Chinese (red line: no fabricated MT; EN UI labels translated)
15Failure Modes
9High/Critical
10Standards
8Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (10 standards / 8 accidents)
Standards (10 de-duplicated)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Accident Lessons (8 de-duplicated)
2019-01-I-TXcsb2019 ↗
ITC Deer Park Tank-farm Circulation Pump Failure Fire
NUREG-LER-2005-012-01NUREG2005 ↗
Kewaunee 余热排出泵(RHR)不可用事件（LER 2005-012-01）
NUREG-LER-2021-001-00-GINNUREG2021 ↗
R.E. Ginna 辅助给水泵绕组失效（LER 2021-001-00）
2004-08-I-NMcsb2004 ↗
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
2020-01-I-TXcsb2019 ↗
Aghorn 注水泵站硫化氢泄漏（敖德萨）
NUREG-LER-2010-004-01NUREG2010 ↗
Browns Ferry 1 号机 余热排出泵(RHR)电机失效导致堆芯冷却瞬态（LER 2010-004-01）
2013-02-I-LAcsb2013 ↗
Williams Geismar Olefins Plant Reboiler Explosion
2016-03-I-LAcsb2016 ↗
ExxonMobil Baton Rouge Refinery Explosion
FM Traceability Cards (15)
Generated by Reliability AI
吸入/排出阀片失效RPN 120 · High
Failure Mechanism
阀片疲劳、冲蚀或异物卡阻致关闭不严/打不开
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 阀声/示功图分析
  • 监测排量波动
  • 定期解体检查阀组
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
NUREG-LER-2005-012-01NUREG2005Operational
Kewaunee 余热排出泵(RHR)不可用事件（LER 2005-012-01）
Root cause: RHR 泵相关设备退化/失效
Official source ↗
NUREG-LER-2021-001-00-GINNUREG2021Operational
R.E. Ginna 辅助给水泵绕组失效（LER 2021-001-00）
Root cause: 辅助给水泵电机绕组失效
Official source ↗
排量不足/打量下降RPN 80 · Medium
Failure Mechanism
阀组/填料内漏或柱塞磨损致有效排量下降
How to Detect
Online monitoring · Detection rate 70% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 监测排量与进出口压差
  • 性能曲线对比
  • 检查阀组与填料
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
柱塞填料泄漏RPN 72 · High
Failure Mechanism
填料磨损或冲洗不足致沿柱塞泄漏
How to Detect
Inspection/offline · Detection rate 60% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 目视检漏
  • 检查填料函温度
  • 定期压紧/更换填料
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
曲轴/连杆磨损RPN 72 · High
Failure Mechanism
润滑不良或载荷过大致曲轴/连杆轴承磨损
How to Detect
Online monitoring · Detection rate 75% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 振动与异响分析
  • 油质分析
  • 检查曲轴箱
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
NUREG-LER-2010-004-01NUREG2010Operational
Browns Ferry 1 号机 余热排出泵(RHR)电机失效导致堆芯冷却瞬态（LER 2010-004-01）
Root cause: 电机绝缘/轴承老化退化导致失效
Official source ↗
液力端裂纹RPN 64 · Critical
Failure Mechanism
腐蚀疲劳或超压致缸体/阀座裂纹
How to Detect
Inspection/offline · Detection rate 50% ；Interval by RBI
Mitigation (What to Do)
  • 磁粉/超声波检测缸体
  • 监测压力波动
  • 检查腐蚀减薄
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
柱塞磨损/划伤RPN 60 · Medium
Failure Mechanism
介质含磨粒或冲洗不足致柱塞表面划伤
How to Detect
Inspection/offline · Detection rate 60% ；Interval by RBI
Mitigation (What to Do)
  • 检查柱塞表面
  • 油液颗粒度分析
  • 监测填料泄漏趋势
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
十字头磨损/敲缸RPN 60 · Medium
Failure Mechanism
滑履磨损或间隙过大致敲击与导向失稳
How to Detect
Online monitoring · Detection rate 70% ；Interval by RBI
Mitigation (What to Do)
  • 异响/振动分析
  • 检查十字头间隙
  • 监测导向磨损
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
脉动/振动大RPN 60 · Medium
Failure Mechanism
阻尼器失效或气囊漏气致脉动与管路振动大
How to Detect
Online monitoring · Detection rate 70% ；Interval by RBI
Mitigation (What to Do)
  • 振动与压力脉动分析
  • 检查阻尼器气囊
  • 检查管架与固有频率
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
NUREG-LER-2005-012-01NUREG2005Operational
Kewaunee 余热排出泵(RHR)不可用事件（LER 2005-012-01）
Root cause: RHR 泵相关设备退化/失效
Official source ↗
NUREG-LER-2021-001-00-GINNUREG2021Operational
R.E. Ginna 辅助给水泵绕组失效（LER 2021-001-00）
Root cause: 辅助给水泵电机绕组失效
Official source ↗
润滑油污染变质RPN 60 · Medium
Failure Mechanism
油液污染或氧化致润滑性能下降
How to Detect
Online monitoring · Detection rate 65% ；Interval by RBI
Mitigation (What to Do)
  • 油质分析
  • 检查油位与油色
  • 定期换油
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
动力端RPN 54 · High
Failure Mechanism
润滑不良或疲劳致轴承剥落/烧损
How to Detect
Online monitoring · Detection rate 85% ；Interval by RBI
Mitigation (What to Do)
  • 振动分析
  • 监测轴承温度
  • 定期润滑与油质分析
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
NUREG-LER-2005-012-01NUREG2005Operational
Kewaunee 余热排出泵(RHR)不可用事件（LER 2005-012-01）
Root cause: RHR 泵相关设备退化/失效
Official source ↗
NUREG-LER-2021-001-00-GINNUREG2021Operational
R.E. Ginna 辅助给水泵绕组失效（LER 2021-001-00）
Root cause: 辅助给水泵电机绕组失效
Official source ↗
NPSH 不足RPN 48 · High
Failure Mechanism
有效 NPSH 低于必需 NPSH 致汽蚀
How to Detect
Online monitoring · Detection rate 70% ；Interval by RBI
Mitigation (What to Do)
  • 监测入口压力与温度
  • 噪声/振动特征分析
  • 检查阀座蚀坑
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
安全阀起跳/内漏RPN 48 · High
Failure Mechanism
阀座损伤或弹簧疲劳致安全阀内漏或误起跳
How to Detect
Inspection/offline · Detection rate 60% ；Interval by RBI
Mitigation (What to Do)
  • 检查安全阀回座与内漏
  • 校验整定压力
  • 监测排出压力波动
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
阀片断裂RPN 42 · High
Failure Mechanism
疲劳或材质缺陷致阀片断裂落入缸体
How to Detect
Online monitoring · Detection rate 75% ；Interval by RBI
Mitigation (What to Do)
  • 阀声/示功图分析
  • 磁粉检测阀片
  • 定期解体检查阀组
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗
隔膜泵RPN 42 · High
Failure Mechanism
疲劳或超压/进料不足致隔膜破裂
How to Detect
Online monitoring · Detection rate 75% ；Interval by RBI
Mitigation (What to Do)
  • 监测液压油污染
  • 检查隔膜行程/进料
  • 校验超压保护
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2013-02-I-LAcsb2013Fatalities 2 · Injuries 167 · Safety
Williams Geismar Olefins Plant Reboiler Explosion
Root cause: Reboiler level loss of control + inadequate overpressure protection + hot-gas bypass valve mistakenly opened.
Official source ↗
2016-03-I-LAcsb2016Injuries 4 · Safety
ExxonMobil Baton Rouge Refinery Explosion
Root cause: Heat-exchanger thermal fatigue + flange seal failure + insufficient pressure relief.
Official source ↗
联轴器对中不良RPN 30 · Medium
Failure Mechanism
安装对中不良致附加弯矩与振动
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 振动分析(1X/2X)
  • 激光对中复核
  • 检查联轴器部件
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 (10)
  • API 674
  • API 675
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • API 580 — Risk-Based Inspection
  • GB/T 9234
  • GB/T 7782
  • SH/T 3141
  • ISO 13372 — Condition monitoring and diagnostics of machines — Vocabulary
  • GB/T 6075
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
Lessons Learned (3)
2004-08-I-NMcsb2004Injuries 6 · Safety
Giant Ciniza Refinery Alkylation Reflux Pump Seal Failure Explosion
Root cause: Missing pump/compressor mechanical integrity + repeated seal failures not root-caused + inadequate isolation / pressure-relief procedure (missing MOC).
Official source ↗
2019-01-I-TXcsb2019Safety/Environmental
ITC Deer Park Tank-farm Circulation Pump Failure Fire
Root cause: Missing pump mechanical-integrity program + no condition monitoring (vibration / LEL) + no remote emergency isolation valve.
Official source ↗
2020-01-I-TXcsb2019Fatalities 2 · Safety/Environmental
Aghorn 注水泵站硫化氢泄漏（敖德萨）
Root cause: H2S 检测/报警失效、LOTO 未执行，泵房 H2S 积聚泄漏；2 死（1 工人+1 公众）
Official source ↗