The failure rates of equipment are influenced by various factors, encompassing not only the engineering standards of entire industries but also the societal culture and the quality of the population. In similar scenarios, pressure vessels exhibit higher failure rates compared to other equipment. Typically designed to withstand static and steady loads, pressure vessels do not succumb to breakdowns from overuse like rotating machinery or cease operation due to fatigue like high-speed engines.
Research and practical observations highlight several reasons for the elevated failure rates of pressure vessels:
1. Stringent Working Conditions: Pressure vessels operate under demanding conditions, enduring various pressures, including pulsatile pressure. Additionally, they may be subjected to extreme environments such as cryogenic conditions or high temperatures with corrosive working media.
2. Susceptibility to Overloading: Pressure vessels are prone to overloading, as internal pressure can rise due to misoperation or abnormal reactions. These vessels may fail before abnormal conditions are detected.
3. Complex Local Stress: The presence of local stress, especially around openings and other discontinuous structures, can lead to fatigue fractures. Continual loading and unloading exacerbate this issue.
4. Hidden Defects: Welded or forged containers can develop serious defects, like fine cracks, during manufacturing. These defects may worsen during operation, leading to failures under specific conditions.
6. Neglect of Safety Operations: Some enterprises operate pressure vessels without proper knowledge and regulations. Lack of safety regulations, technical documentation, periodic inspections, and qualified personnel contribute to the unsafe use and management of pressure vessels.
7. Wrongful Operation and Overuse: Managers may neglect safety protocols, leading to the wrongful operation and overuse of pressure vessels. In some cases, broken vessels are repurposed, aggravating the potential for serious problems.
8. Ineffective Supervision: The local supervision department, administrative bodies, and law enforcement authorities often fall short in adapting to the changing market economy. The proliferation of small private enterprises exacerbates issues such as wrong operation, illegal equipment control, and lax supervision.
In summary, pressure vessels, designed to resist overuse and fatigue, face elevated failure rates due to factors like stringent conditions, overloading susceptibility, local stress, hidden defects, inadequate management, safety neglect, wrongful operation, and ineffective supervision. Addressing these issues is crucial for improving pressure vessel safety and overall equipment integrity in industrial settings.
