Tap any failure mode → flip to its on-site guidance (pure-CSS, no JS needed on mobile)
Storage Tankstorage_tank
⚠ ⚠ Top risk: Corrosion Under Insulation (CUI) · RPN 196 (High) — watch this one first at the equipment
Risk Board (all 24 · 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)
24Failure Modes
21High/Critical
28Standards
16Real Accidents
Tap any failure mode to flip to its on-site guidance
Device-level standard/accident index (28 standards / 16 accidents)
Standards (28 de-duplicated)
  • 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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • API 754 — Process Safety Performance Indicators
  • API 576 — Inspection of Pressure-Relieving Devices
  • API 689 — Collection and Exchange of Reliability and Maintenance Data
  • API 755 — Human Factors
  • ISO 20815:2018 — Petroleum, petrochemical and natural gas industries — Production assurance and reliability
  • IEC 61511:2016 — Functional safety — Safety instrumented systems for the process industry sector
  • ISO 31000:2018 — Risk management — Guidelines
  • GB/T 20438
  • GB/T 21109
  • IEC 61511 — Functional safety — Safety instrumented systems for the process industry sector
Accident Lessons (16 de-duplicated)
2006-03-I-FLcsb2006 ↗
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
2017-06-I-WVcsb2017 ↗
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
2006-08-I-ILcsb2006 ↗
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
2005-02-I-TXcsb2004 ↗
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
2011-01-I-NYcsb2010 ↗
DuPont Buffalo 常压储罐动火爆炸（布法罗）
2005-04-I-TXcsb2005 ↗
BP Texas City Refinery Explosion and Fire
2014-01-I-WVcsb2014 ↗
Freedom Industries Storage Tank Release (MCHM)
2013-03-I-TXcsb2013 ↗
West Fertilizer Ammonium Nitrate Explosion
2008-06-I-WVcsb2008 ↗
Bayer CropScience MIC Release
2010-04-I-ILcsb2009 ↗
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
2006-07-I-MScsb2006 ↗
Partridge-Raleigh 油田储罐动火爆炸
2009-01-I-PAcsb2008 ↗
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
2008-02-I-IAcsb2007 ↗
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
2017-08-I-TXcsb2017 ↗
Arkema Crosby 洪水失冷有机过氧化物分解起火
2017-03-I-LAcsb2017 ↗
PCA DeRidder 臭凝液罐动火作业爆炸
2019-03-I-TXcsb2019 ↗
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
FM Traceability Cards (24)
Generated by Reliability AI
Corrosion Under Insulation (CUI)RPN 196 · High
Failure Mechanism
Insulation jacket seal failure; insulation absorbs water; lack of vapor barrier
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically inspect insulation jacket sealing
  • Apply CUI-specific coating
  • Perform thickness measurement under insulation
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Bottom Weld CrackRPN 180 · Critical
Failure Mechanism
焊接质量缺陷（如未熔合、气孔）；底板变形引起的附加应力；介质应力腐蚀环境
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 定期进行焊缝无损检测（如MT、UT）
  • 优化焊接工艺，降低残余应力
  • 控制液位变化速率，减少循环载荷
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Weld CrackRPN 160 · Critical
Failure Mechanism
焊接工艺不当；介质应力腐蚀；循环载荷疲劳
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • 对焊缝进行100%无损检测（MT、UT）
  • 控制焊接质量，消除缺陷
  • 评估应力腐蚀环境，必要时进行热处理
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Seal Leak -> VOC EmissionRPN 160 · Medium
Failure Mechanism
Seal material aging; floating-roof tilt causing seal gap; improper installation
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically replace seals
  • Inspect seal-face wear
  • Perform VOC leak detection
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Differential SettlementRPN 160 · Critical
Failure Mechanism
Non-uniform foundation soil; groundwater level change; improper foundation design
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every6months
Mitigation (What to Do)
  • Periodically monitor foundation settlement
  • Inspect ring-foundation cracks
  • Evaluate foundation stability
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Bottom Plate PerforationRPN 144 · Critical
Failure Mechanism
Bottom-plate coating damage or cathodic protection failure; tank-bottom water not drained; sulfur/chloride etc. in medium
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodically inspect bottom-plate corrosion
  • Perform bottom-plate thickness measurement
  • Replace corroded-perforated bottom plate
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 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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Concrete CrackRPN 144 · High
Failure Mechanism
Non-uniform foundation settlement; concrete shrinkage and thermal stress; corrosive medium penetration causing rebar rust expansion
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodically inspect concrete surface cracks
  • Measure crack width and depth
  • Patch cracks and apply waterproofing
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Pad FailureRPN 128 · Critical
Failure Mechanism
垫层材料老化或配比不当；基础排水不良导致积水；施工时压实度不足
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 检查沥青砂垫层完整性
  • 进行罐底电位检测
  • 修复或更换破损垫层
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Under-deposit CorrosionRPN 126 · High
Failure Mechanism
Solid-particle deposition in medium; insufficient tank-bottom slope causing poor drainage; excessively long cleaning interval
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • Periodically clean tank-bottom deposits
  • Use online corrosion probe to monitor corrosion rate
  • Perform bottom-plate UT thickness measurement
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Seat CorrosionRPN 120 · Medium
Failure Mechanism
介质含硫化氢等腐蚀性组分；密封面材料不耐腐蚀；长期未维护导致腐蚀积累
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期检查呼吸阀密封面
  • 更换腐蚀严重的密封件
  • 使用耐腐蚀材料
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 (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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Element PluggingRPN 120 · Critical
Failure Mechanism
介质含固体杂质或易聚合组分；阻火芯间隙设计过小；缺乏定期清洗
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期检查阻火芯压差
  • 清洁或更换堵塞的阻火芯
  • 安装过滤器预处理介质
RCM Strategy
CBMOn-Condition Maintenance
Interval: High risk 1-3 mo / Medium 6-12 mo / Low risk at turnaround (by API 581 RBI risk ranking)
Engineering-inferred (not measured history); confirm with equipment owner before execution
Standards (23)
  • API 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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Displacer PerforationRPN 120 · Critical
Failure Mechanism
介质腐蚀性强；浮子材质选择不当；介质含固体颗粒冲刷
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期检查浮子壁厚
  • 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 (24)
  • API 580 — Risk-Based Inspection
  • API 581-2025
  • GB/T 7826-2012
  • ISO 14224:2016 — Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
  • SAE JA1011_202411 — Evaluation Criteria for Reliability-Centered Maintenance Processes
  • GB/T 27921-2011
  • GB/T 36894-2018
  • GB/T 44958-2024
  • GB/T 37243-2019
  • GB/T 4888-2008
  • GB/T 29639-2020
  • AQ/T 3034-2022
  • API 581 — Risk-Based Inspection Methodology
  • API 510 — Pressure Vessel Inspection Code
  • API 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Freezing/StickingRPN 112 · High
Failure Mechanism
环境温度低于介质冰点；介质含湿量高或易结晶；阀盘密封面润滑不足
How to Detect
Online monitoring · Detection rate 80% ；Re-inspect ≤every12months
Mitigation (What to Do)
  • 定期检查呼吸阀阀盘灵活性
  • 清洁阀盘和阀座
  • 安装加热或防冻措施
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Contact CorrosionRPN 108 · High
Failure Mechanism
环境湿度过高或含腐蚀性气体；触点材料不耐腐蚀；密封不良导致介质侵入
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期清洁触点
  • 更换密封件
  • 涂防腐蚀涂层
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Floating Roof StickingRPN 105 · High
Failure Mechanism
导向轮磨损或腐蚀；浮盘变形；介质中杂质卡阻
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查浮盘导向机构灵活性
  • 清洁密封件和导轨
  • 润滑运动部件
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 (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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Wire StickingRPN 105 · High
Failure Mechanism
钢丝材质不耐腐蚀；导向轮磨损或偏斜；润滑不足或介质污染
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期润滑钢丝
  • 检查钢丝磨损
  • 更换钢丝
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Shell ThinningRPN 90 · High
Failure Mechanism
介质腐蚀性强；内壁涂层失效；外部环境腐蚀（如潮湿空气）
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期进行罐壁超声测厚
  • 检查防腐涂层完整性
  • 根据测厚结果制定维修计划
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Roof CorrosionRPN 90 · High
Failure Mechanism
罐顶内壁涂层失效；气相空间腐蚀；外部环境腐蚀
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查罐顶内表面腐蚀情况
  • 进行罐顶测厚
  • 修复防腐涂层
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 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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Element CorrosionRPN 90 · High
Failure Mechanism
介质含腐蚀性气体如硫化氢；阻火芯材质不耐腐蚀；环境湿度高加速腐蚀
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期检查阻火芯腐蚀情况
  • 更换腐蚀严重的阻火芯
  • 选用耐腐蚀材料
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 (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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Antenna FoulingRPN 90 · Medium
Failure Mechanism
介质粘稠或易结晶；罐内蒸汽冷凝在天线上；缺乏定期清洁
How to Detect
Inspection/offline · Detection rate 55% ；Re-inspect ≤every24months
Mitigation (What to Do)
  • 定期清洗天线
  • 检查天线涂层
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Float StickingRPN 63 · High
Failure Mechanism
介质易结垢或结晶；浮球导向机构变形；介质含大量固体杂质
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 检查浮球活动
  • 清洗浮球
  • 检查介质结垢倾向
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
N2 Supply LossRPN 54 · Critical
Failure Mechanism
氮气瓶或管网压力不足；管道破裂或接头泄漏；阀门误操作或故障
How to Detect
Online monitoring · Detection rate 80% ；Interval by RBI
Mitigation (What to Do)
  • 安装氮气压力低报警
  • 配置备用氮气源
  • 定期检查管道和阀门
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Control Valve FailureRPN 42 · High
Failure Mechanism
阀芯结垢或腐蚀；定位器零点漂移；控制信号线路故障
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 定期检查调节阀动作
  • 清洗阀芯
  • 校验定位器
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗
Electronics FailureRPN 42 · High
Failure Mechanism
电子元件自然老化；环境潮湿导致电路板腐蚀；雷击或电源浪涌
How to Detect
Inspection/offline · Detection rate 55% ；Interval by RBI
Mitigation (What to Do)
  • 监测电子单元温度
  • 检查电源稳定性
  • 定期自检
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 653 — Tank Inspection, Repair, Alteration, and Reconstruction
  • 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 (16)
2006-03-I-FLcsb2006Fatalities 2 · Injuries 1 · Safety/Environmental
Bethune Point 污水处理厂甲醇储罐爆炸（代托纳海滩）
Root cause: 甲醇储罐上方动火（切割）引燃呼吸阀排放蒸气，回火入罐爆炸；热作业管控与火焰阻断器维护缺失
Official source ↗
2017-06-I-WVcsb2017Fatalities 2 · Safety
Midland Resource Recovery 反应危害储罐爆炸（菲利普）
Root cause: 对反应危害管理缺失（硫化物+酸生成气体/放热），储罐超压爆炸，2 死
Official source ↗
2006-08-I-ILcsb2006Fatalities 1 · Injuries 5 · Safety
Universal Form Clamp 开口罐易燃蒸气云爆炸（Bellwood）
Root cause: 开口储罐混合加热易燃液体缺乏安全控制，蒸气云被引燃；1 死 5 伤
Official source ↗
2005-02-I-TXcsb2004Injuries 3 · Safety
Marcus Oil 聚乙烯蜡储罐超压爆炸（休斯顿）
Root cause: 储罐氮封系统设计与操作不当，违规改造/修理导致超压爆炸火灾
Official source ↗
2011-01-I-NYcsb2010Fatalities 1 · Injuries 1 · Safety
DuPont Buffalo 常压储罐动火爆炸（布法罗）
Root cause: 储罐动火前未隔离、未监测可燃气体，焊接引燃；1 死 1 伤
Official source ↗
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 ↗
2014-01-I-WVcsb2014Environmental
Freedom Industries Storage Tank Release (MCHM)
Root cause: Tank bottom-plate corrosion perforation + no secondary containment + lack of monitoring.
Official source ↗
2013-03-I-TXcsb2013Fatalities 15 · Injuries 200 · Safety/Environmental
West Fertilizer Ammonium Nitrate Explosion
Root cause: Inadequate fire separation distance for warehouse + missing fire protection + large ammonium nitrate storage.
Official source ↗
2008-06-I-WVcsb2008Injuries 1 · Safety/Environmental
Bayer CropScience MIC Release
Root cause: Waste-kettle overpressure + blocked relief system + inadequate isolation.
Official source ↗
2010-04-I-ILcsb2009Fatalities 1 · Safety
NDK Crystal 高压晶体容器应力腐蚀开裂破裂（场外致死）
Root cause: 高压晶体生产容器内壁应力腐蚀开裂未被检测（碱性介质+高应力），灾难性破裂；100 磅钢梁飞出 650 英尺击毙场外卡车司机
Official source ↗
2006-07-I-MScsb2006Fatalities 3 · Injuries 1 · Safety
Partridge-Raleigh 油田储罐动火爆炸
Root cause: 在未清洗、未隔离、未做可燃气检测的原油储罐上方动火焊接，烃蒸气爆炸；站在罐顶的 3 名承包商工人死亡、1 人重伤
Official source ↗
2009-01-I-PAcsb2008Environmental/Safety
INDSPEC 发烟硫酸储罐转料失控泄漏（三镇疏散）
Root cause: 储罐液位报警器停用数月且无定期测试制度，转料时发烟硫酸失控释放形成酸雾云，约 2500 名居民疏散/就地避难
Official source ↗
2008-02-I-IAcsb2007Injuries 2 · Safety
Barton Solvents Des Moines 灌装静电引燃爆炸火灾
Root cause: 灌装组件金属部件未做跨接接地，静电火花引燃低电导率易燃溶剂蒸气，爆炸火灾致桶体飞射、周边企业疏散；1 员工轻伤 1 消防员就医
Official source ↗
2017-08-I-TXcsb2017Injuries 21 · Safety/Environmental
Arkema Crosby 洪水失冷有机过氧化物分解起火
Root cause: 设施位于百年洪泛区但设备设计标高不足，Harvey 洪水致电力与制冷系统全部失效，有机过氧化物失冷自燃；21 人因暴露烟气就医
Official source ↗
2017-03-I-LAcsb2017Fatalities 3 · Injuries 7 · Safety
PCA DeRidder 臭凝液罐动火作业爆炸
Root cause: 停车检修期间在未惰化/未隔离的臭凝液罐附近动火，罐内松节油类可燃蒸气爆炸，100 英尺罐体飞越管廊；3 死 7 伤
Official source ↗
2019-03-I-TXcsb2019Safety/Environmental/Fire
Intercontinental Terminals Company (ITC) Deer Park 罐区循环泵失效火灾
Root cause: 泵未纳入机械完整性/检验计划；无泄漏监测报警；无远程紧急隔离阀；罐区布置/围堰设计缺陷；PSM/RMP 监管覆盖空隙
Official source ↗