Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Distillation Columndistillation_column
⚠ ⚠ Top risk: Stress Corrosion Cracking (SCC) · RPN 300 (Low) — watch this one first at the equipment
Risk Board (all 23 · 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)
23Failure Modes
15High/Critical
28Standards
2Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (28 standards / 2 accidents)
Standards (28 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
  • API 581-2025
  • GB/T 44692
  • GB/T 20438
  • GB/T 21109
  • IEC 61511 — Functional safety — Safety instrumented systems for the process industry sector
Accident Lessons (2 de-duplicated)
2005-04-I-TXcsb2005 ↗
BP Texas City Refinery Explosion and Fire
2018-03-I-WIcsb2018 ↗
Husky Superior Refinery Explosion
FM Traceability Cards (23)
Generated by Reliability AI
Stress Corrosion Cracking (SCC)RPN 300 · Low
Failure Mechanism
Medium contains chloride or H2S; high residual stress; material susceptible to SCC
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodic nondestructive testing
  • Control stress level
  • Monitor environmental corrosivity
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Fireproofing LossRPN 294 · High
Failure Mechanism
Poor bond between fireproofing and substrate; long-term high temperature or thermal cycling causing aging; mechanical impact or vibration
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically inspect fireproofing
  • Repair detached areas
  • Prevent mechanical damage
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Weld CrackRPN 270 · Critical
Failure Mechanism
Poor weld quality; improper heat treatment; stress concentration
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodic weld inspection
  • Control weld quality
  • Relieve stress
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Hydrogen-Induced Cracking / Blistering (HIC/HB)RPN 240 · Critical
Failure Mechanism
Sulfide inclusions or laminar defects in material; wet H2S environment (H2S+H2O); weld residual or high stress
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodic UT inspection
  • Control H2S concentration
  • Use hydrogen-resistant steel
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Nozzle Weld CrackRPN 210 · High
Failure Mechanism
焊接缺陷（未熔合、气孔等）；热循环或机械振动疲劳；应力腐蚀开裂（如氯离子）
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodic weld inspection
  • 控制热应力
  • 改善焊接工艺
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Internal Corrosion ThinningRPN 135 · Critical
Failure Mechanism
Highly corrosive medium; anti-corrosion layer failure; operating temperature / concentration exceeded
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodic thickness measurement
  • Check corrosion rate
  • Analyze medium corrosivity
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Tube LeakRPN 135 · Critical
Failure Mechanism
Corrosive species in column-bottom liquid (acid, chloride); high velocity causes erosion-corrosion; poor material selection or weld defect
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodic tube-bundle thickness measurement
  • Check corrosive medium
  • Replace leaking tube bundle
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 (27)
  • API 571 — Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 20438
  • GB/T 21109
  • GB/T 7826-2012
  • IEC 61511 — Functional safety — Safety instrumented systems for the process industry sector
  • 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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Tube PerforationRPN 120 · Critical
Failure Mechanism
冷却水中含腐蚀性离子（如氯离子）；管束材质不耐腐蚀；操作温度波动引起热应力
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期进行管束涡流检测
  • Check corrosive medium
  • 更换穿孔管束
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Tray CorrosionRPN 108 · High
Failure Mechanism
介质中含有腐蚀性组分（酸、碱、氯离子等）；操作温度或浓度超出设计范围；材料选型不当
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查塔盘厚度
  • 更换腐蚀严重塔盘
  • 优化操作条件
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Packing DegradationRPN 108 · High
Failure Mechanism
介质腐蚀性超出填料材质耐受范围；高温导致塑料填料软化变形；安装不当或超负荷导致填料破碎
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查填料状态
  • 更换腐蚀或变形的填料
  • 优化操作温度
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Tube FoulingRPN 108 · High
Failure Mechanism
塔底液中含有易结垢组分（如盐类、聚合物）；操作温度过高加速结垢；循环流速不足导致沉积
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查再沸器管束结垢
  • 化学清洗或机械清洗
  • 优化水质处理
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Packing FoulingRPN 105 · High
Failure Mechanism
进料中含固体杂质或悬浮物；操作温度或pH变化导致盐类结晶析出；液体分布不均造成局部干区加速结垢
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查填料结垢情况
  • 化学清洗或更换填料
  • 过滤进料固体颗粒
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
FloodingRPN 96 · Critical
Failure Mechanism
气相负荷超过设计上限；降液管堵塞或面积不足；塔盘安装水平度差
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查塔盘压降
  • 调整操作气速
  • 优化操作参数
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
CorrosionRPN 90 · High
Failure Mechanism
保温层破损或防水不良导致积水；裙座底部通风不良；涂层或防腐层失效
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查裙座底部
  • 防腐涂层维护
  • 改善排水
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Distributor PluggingRPN 90 · High
Failure Mechanism
进料中固体杂质未过滤；液体中聚合物或胶体沉积；分布器材质腐蚀产生碎屑
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查液体分布器孔口
  • 清理堵塞物
  • 更换损坏的分布器
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 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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Tube FoulingRPN 90 · Medium
Failure Mechanism
冷却水中硬度盐类沉积；工艺侧含易聚合或结晶组分；操作温度不当加速结垢
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查冷凝器管束结垢
  • 化学清洗或机械清洗
  • 优化冷却水处理
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Trim ErosionRPN 90 · Medium
Failure Mechanism
流体中含固体颗粒或腐蚀性介质；压差过大导致流速过高；阀芯材质硬度不足
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查阀芯冲蚀情况
  • 更换冲蚀阀芯
  • 优化流体速度或材质
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 (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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Downcomer PluggingRPN 84 · High
Failure Mechanism
介质中含有固体颗粒或聚合物；塔盘腐蚀产物脱落堆积；操作条件不当导致结垢
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查降液管入口和出口
  • 清理沉积物
  • 使用在线清洗或化学清洗
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Valve StickingRPN 75 · Medium
Failure Mechanism
介质结垢或聚合物沉积；腐蚀导致阀腿或阀孔尺寸变化；操作波动导致阀片撞击变形
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查浮阀活动性
  • 清洗浮阀及塔盘
  • 更换卡死或脱落的浮阀
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Sensor DriftRPN 60 · Medium
Failure Mechanism
长期使用导致电子元件老化；环境温度变化超出补偿范围；安装振动或过压损坏
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期校准差压变送器
  • 检查传感器老化
  • 更换漂移传感器
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Flange LeakRPN 45 · Medium
Failure Mechanism
螺栓预紧力不均匀或不足；垫片老化或选型不当；法兰面腐蚀或划伤
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期检查法兰密封
  • 紧固螺栓
  • 更换垫片
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Positioner FailureRPN 40 · Medium
Failure Mechanism
定位器内部电路故障；气源含油水或杂质；反馈杆松动或磨损
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期检查定位器
  • 清洁气源和电气连接
  • 更换故障定位器
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗
Impulse Line BlockageRPN 36 · Medium
Failure Mechanism
工艺流体中含固体颗粒或易结晶物质；引压管保温不足导致冷凝液积聚；安装位置不当造成气泡滞留
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期检查引压管
  • 吹扫或清洗引压管
  • 安装隔离罐或吹气装置
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 (2)
2005-04-I-TXcsb2005Fatalities 15 · Injuries 180 · Safety/Environmental
BP Texas City Refinery Explosion and Fire
Root cause: Level gauge failure + inadequate overflow protection + missing management-of-change.
Official source ↗
2018-03-I-WIcsb2018Injuries 11 · Safety
Husky Superior Refinery Explosion
Root cause: Atmospheric-column feed-line corrosion thinning + excessively long inspection interval.
Official source ↗