Why are ASME pressure vessels considered "high-risk, high-value" core equipment in industrial systems?
Publish Time: 2025-08-20
Although not often known to the public, ASME pressure vessels are widely used in key sectors such as petrochemicals, energy and power, aerospace, pharmaceuticals, and the nuclear industry, serving as the "backstage workhorses" that underpin industrial operations. They store high-pressure gases, carry out high-temperature reactions, and transport hazardous media, fulfilling irreplaceable functions. Precisely because of their extreme operating environments and potentially destructive potential, ASME pressure vessels are recognized as quintessential "high-risk, high-value" core equipment in industrial systems, and their design, manufacturing, operation, and oversight are subject to strict controls.1. High Value: The "Energy Hub" that Supports Industrial OperationsThe "high value" of ASME pressure vessels is reflected in their irreplaceable functional role and enormous economic impact. In oil refineries, ASME pressure vessels, such as reactors, separators, and storage tanks, form the core of process flows and are directly involved in key chemical reactions such as crude oil cracking and catalytic reforming. In thermal and nuclear power plants, steam generators, pressurizers, and primary vessels carry high-temperature, high-pressure working fluids, acting as hubs for energy conversion. In natural gas transmission systems, ASME pressure vessels in storage tanks and pipelines ensure a stable energy supply. A shutdown or failure of these devices can paralyze the entire production line, resulting in significant economic losses. Furthermore, the manufacturing cost of a large ASME pressure vessel can easily reach hundreds of thousands or even hundreds of millions of yuan, involving high-end materials, precision welding, and rigorous testing, making it a high-value-added industrial product.2. High Risk: Potentially Catastrophic Consequences of Energy ConcentrationHigh value is accompanied by high risk. ASME pressure vessels typically operate above atmospheric pressure, accumulating significant amounts of pressure potential energy within them. If ruptured due to material fatigue, corrosion, welding defects, or overpressure, the stored energy is released instantly and violently, potentially causing explosions, shock waves, flying debris, and media leaks. If the vessel contains flammable and explosive gases (such as hydrogen or liquefied petroleum gas), it could cause a secondary explosion or fire. If it contains toxic media (such as ammonia or chlorine), it could cause widespread environmental pollution and poisoning. Many major industrial accidents in history, such as the Flixborough cyclohexane leak explosion in the United States and the Bhopal gas leak in India, were closely linked to the failure of ASME pressure vessels, resulting in heavy casualties and ecological disasters.3. Complex Failure Mechanisms, Safety Supervision Throughout the LifecycleThe high risk of ASME pressure vessels stems from their complex failure modes. Over long-term operation, equipment can suffer from a variety of failure mechanisms, including fatigue damage (repeated pressurization and depressurization), stress corrosion cracking (the combined effects of specific media and stress), creep (slow deformation of the material at high temperatures), and hydrogen embrittlement (the embrittlement of the material caused by hydrogen atomic penetration). These damages are often hidden and difficult to detect through routine inspections. Once accumulated to a critical point, they can lead to sudden failure. Therefore, countries around the world have established strict ASME pressure vessel safety regulations, such as China's "Stationary ASME Pressure Vessel Safety Technical Supervision Regulation" (TSG), the US's ASME Boiler and Pressure Vessel Code, and the EU's PED Directive. These regulations cover the entire lifecycle of pressure vessels, including design, materials, manufacturing, inspection, use registration, periodic inspection, and disposal.4. High Technical Barriers, Safety Relies on System EngineeringEnsuring the safe operation of ASME pressure vessels is a systematic project. From the design stage, engineers must perform strength calculations, stress analysis, and failure mode assessments. During manufacturing, high-quality steel or specialty alloys must be used, and weld quality must be ensured through non-destructive testing methods such as X-rays, ultrasound, and magnetic particle inspections. After commissioning, pressure vessels must be equipped with monitoring devices such as safety valves, pressure gauges, and temperature sensors, and regular downtime inspections and lifecycle assessments must be conducted. In recent years, the application of intelligent monitoring technologies (such as acoustic emission and fiber optic sensing) has enabled ASME pressure vessel safety management to move towards predictive and predictive intelligent safety management.ASME pressure vessels are considered "high-risk, high-value" equipment precisely because they combine energy, technology, safety, and economics. They are both the driving force behind the efficient operation of industrial systems and the source of potential accidents. Therefore, their safety must never be compromised. Only through scientific design, rigorous manufacturing, standardized use, and intelligent supervision can we truly manage this "high risk," unleash its "high value," and safeguard the sustainable development of modern industry.
