Safety Measures in Pressure Vessel Manufacturing

Safety has always been an imperative aspect when it comes to pressure vessels. Simple pressure differentials have led to many fatal accidents. For this reason, pressure vessel manufacturers adhere to strict manufacturing standards and guidelines during their construction process.

Codes and Standards

To ensure the proper construction of vessels and maintain the safety of employees, manufacturers adhere to various codes and standards. A few important ones are:

• ASME Boiler and Pressure Vessel Code
• OSHA 1915 Subpart K for vessels, drums, and containers
• API 510 Vessel Code for maintenance, alteration, and repair
• API 572 for inspection

OSHA Guidelines

The Occupational Safety and Health Administration (OSHA) has also laid down many guidelines to ensure safe manufacture of vessels. Some of them have been noted here.

• Maximum Allowable Working Pressure: The maximum pressure for standard pressure vessels is determined by the ASME and API Code under which the vessels are constructed.
• Protection from Over Pressure: A pressure relieving device is provided along with every pressure vessel to ensure over pressure protection. Also, the pressure relief devices have to be certified by ASME-NB, indicating that they are safe to use.
• Inspection: These vessel owners adhere to the following procedures to ensure proper inspection:
• The vessel is thoroughly washed
• As required by the inspector, all hand or manhole plates, inspection plugs and water connections are removed
• Brickwork insulation is removed for the inspector to examine the furnace, headers, supports, etc.
• Pressure gauges are removed for testing
• To prevent any kind of leakage into the boiler, the connecting valve is disconnected using the most appropriate means
• For inspection of the steam generating unit, feed valves, non-return and stem top valves are closed, tagged, and padlocked. Along with these, the drain valves and cocks are opened.
• After boiler drainage, the blow-off valves are closed, tagged, and padlocked
• Drains and vent lines have to be opened.

Safety Measures Undertaken By Organizations

Pressure vessel manufacturers also create regulations within the company to ensure that the health and safety of any employee is never compromised. Some common safety practices are mentioned below.

• Safety Equipment: Only the right certified materials are chosen before design and manufacture of the pressure vessels take place. Operational safety is ensured by leaving no gaps in the vessel structure or pipe-work. When repairing a damaged system, a detailed examination must be done. This ensures that every component is in good working condition before the pressure vessel is sent back for field work. Also, new employees undergo a rigorous training process to understand all the safety requirements.
• Operation Conditions: When working with liquids and gases, the correct working pressures and temperatures can be set only when one understands whether the liquids or gases are flammable or toxic. It has been made mandatory that every product should have an accessible set of instructions, providing detailed information for operations and emergencies.
• Protective Devices and Maintenance: Protective devices such as safety valves are provided to each pressure vessel. Engineers have to make sure that the appropriate protective device is used for the right vessel. Protective devices have to be set at the appropriate settings and maintained regularly. Revealing sings of overpressure, corroded, or worn off devices are attended to immediately. Regular maintenance cycles are observed to create better working conditions.

Safety measures mentioned above ensure how to reduce pressure vessel failures, as well as maintain the safety of employees and products.