Haihao Group’s view on the cause of pressure vessel explosion

As a leader in pipeline systems and a trusted supplier of forging and pressure vessel components, Haihao Group has gained extensive expertise in the field of pressure vessels. Today, we’d like to share insights into the common causes of pressure vessel explosions, based on our experience in the industry.

pressure vessels

1.Overheating and Overpressure

Pressure vessels can experience overheating or overpressure due to the following reasons:

Operational Errors: Improper operation, immature processes, or lack of effective control over process conditions can lead to increased temperature and pressure, resulting in higher stress on the vessel or a reduction in material strength.

Blindly Increasing Operating Conditions: Operators may raise temperature and pressure to accelerate chemical reactions and improve productivity. However, this approach can significantly shorten the lifespan of the vessel or increase the risk of failure.

Localized overheating caused by issues such as insufficient water supply or scaling in heat recovery boilers can also lead to a reduction in mechanical properties and cause explosions.

2.Inherent Defects in the Vessel

Pressure vessel defects may arise due to:

Inadequate design or design errors

Poor structural design or improper material selection

Insufficient strength or low manufacturing quality

Poor welding or installation practices

3.Severe Corrosion

Corrosion of the vessel’s internal and external surfaces can thin the walls and significantly reduce its strength, increasing the likelihood of explosions.

4.Excessive Cracks

Cracks can develop over time due to:

Frequent start-stop cycles or improper operations

Rapid cooling and heating

Pressure or load fluctuations

These conditions lead to alternating stress on the steel, causing fatigue cracks. Additionally, grooves formed by fluid erosion can weaken the vessel’s strength.

pressure vessel

5.Faulty Safety Devices

Many pressure vessel accidents are caused by:

Missing or malfunctioning safety devices

Incorrectly installed safety valves that fail to relieve pressure

Lack of interlocking devices in quick-opening pressure vessels such as sterilizers, vulcanizers, and autoclaves

Interlocking devices ensure safety by preventing the vessel door from opening if pressure is not fully released and blocking pressure entry unless the door is locked securely.

6.Other Causes

Ductile Failure: Occurs when the wall stress exceeds the material’s strength limit, causing the vessel to rupture.

Brittle Failure: Happens without significant plastic deformation, often at stress levels below the material’s yield strength.

Fatigue Failure: Results from high-cycle fatigue, typically when the load exceeds the material’s elastic stress limit over cycles exceeding 100,000.

Plastic Deformation Failure: Long-term exposure to high temperatures causes slow plastic deformation, eventually leading to failure.

Corrosion Damage: Prolonged exposure to corrosive media thins the walls or alters material properties, weakening the vessel’s structural integrity.

Understanding the causes of pressure vessel explosions is crucial for ensuring their safe operation. At Haihao Group, we are committed to delivering high-quality products and sharing industry knowledge to help our partners mitigate risks. With decades of experience in manufacturing and supplying components for pressure vessel systems, we strive to be a reliable partner for our global clients.