How to Avoid Errors in Pressure Vessel Operation?

I. Eliminate Violations of Regulations: Control Risks from the Source of Human Factors

1. Strictly Enforce Certification Requirements and Eliminate Unlicensed Operations
All operators must obtain a "Special Equipment Operator Certificate" (e.g., R1 class) and participate in regular recertification training to ensure they possess the ability to identify risks and handle emergencies.

2. Strictly Prohibit Pressurized Operations and Unauthorized Hot Work

Before any maintenance, tightening, or disassembly work, the pressure must be completely released, the medium isolated, and a "Do Not Operate" warning sign posted. Before hot work, gas analysis must be performed, blind flanges installed, and a hot work permit obtained. Acting based on experience is strictly prohibited.

3. Prohibit Overpressure and Overtemperature Operations
It is strictly forbidden to disable safety interlocks or operate beyond limits in pursuit of production output. If pressure or temperature is found to be approaching the upper limit, the pressure and temperature should be immediately reduced, and the cause investigated.

4. Standardize Valve Operation to Prevent Misoperation

Implement a "double-person confirmation system," requiring two people to verify the operation of critical valves; Set clear signs to avoid incorrect opening or closing, and prevent backflow or pressure buildup.

II. Strengthen Safety Accessory Management: Ensure the Reliability and Effectiveness of the "Last Line of Defense"

1. Implement a Regular Calibration System

Safety Valves: Calibrate at least once a year to ensure automatic pressure relief at the set pressure;

Pressure Gauges: Calibrate every six months; the dial should be marked with a red line to indicate the maximum allowable working pressure.

2. Prevent Accessory Failure or Arbitrary Removal

It is strictly forbidden to use pressure gauges to replace sealing elements, or to disassemble or block safety valves without authorization; If safety accessories are damaged or have exceeded their inspection period, the equipment must be immediately shut down until repaired and calibrated successfully.

3. Establish Records and Dynamic Monitoring
Establish a safety accessory file for each container, recording the installation date, calibration cycle, and replacement records to achieve full lifecycle management.

III. Standardize Operating Procedures: Achieve Standardized Control Throughout the Process

1. Develop and Implement Dedicated Operating Procedures
Different types of containers (e.g., reactors, autoclaves) should have independent operating procedures, clearly defining start-up and shutdown steps, parameter ranges, and abnormal handling procedures, eliminating "operation based on intuition."

2. Promote the Principle of "Smooth Operation"

Pressure increase, depressurization, temperature increase, and temperature decrease should be carried out slowly to avoid thermal stress shock;
Control the feed rate to prevent runaway reactions leading to sudden pressure increases.

3. Strengthen Inspection and Record Management

Operators should conduct inspections hourly, focusing on leaks, abnormal noises, deformation, and instrument readings;
Complete and accurate operation records should be filled out as a basis for accident tracing and management improvement.

4. Establish an Emergency Response Mechanism
In the event of any of the following situations, an immediate emergency shutdown and report must be made:

Pressure/temperature exceeds limits and cannot be controlled;
Main pressure-bearing components develop cracks, bulges, or leaks;
Safety accessories fail or a fire threatens equipment safety.