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As the core pressure-bearing equipment in industrial production systems, the safe operation of pressure vessels is directly related to the safety of people’s lives and property. This article will systematically elaborate on the key control elements in various stages of pressure vessel design and selection, processing and manufacturing, operation monitoring, inspection and maintenance, as well as emergency response, providing comprehensive technical guidance for relevant professionals. **I. Technical specifications in the design and selection phase ** When determining the design parameters, it is necessary to take into account various factors such as the properties of the medium, process conditions, and environmental factors. It is recommended to use 3D modeling software for stress analysis in order to scientifically determine the pressure level, structural dimensions, and material selection. It is particularly important to note that: the pressure threshold should be set at less than 80% of the material’s yield strength, and the decrease in elastic modulus due to temperature fluctuations must also be taken into account. The volume design should allow for a 10–15% margin for expansion resulting from phase changes in the medium. It is advisable to use mature steel grades specifically designed for pressure vessels, such as ASME Standard SA-516 Gr.70. **II. Quality control system during the manufacturing process** **(I) Key points regarding material control** Strict procedures must be followed for re-inspecting raw materials upon arrival, with particular attention paid to the chemical composition and mechanical properties specified in the quality certificates. Plates with a thickness of ≥30 mm must undergo 100% ultrasonic testing to ensure the absence of internal defects such as delaminations and cracks. **(II) Welding process control: Conduct welding procedure qualification (WPS/PQR), and use automated welding equipment such as submerged arc welding. After welding, the following tests must be carried out: 100% visual inspection (VT), random inspection of 20% using radiographic testing (RT), hardness testing (HB≤220), and impact testing on the welded joints. **(III) Pressure testing specifications** The hydraulic testing pressure should be ≥1.25 times the design pressure, with a holding time of no less than 30 minutes. The temperature of the test medium must be at least 30°C above the material’s brittle transition temperature, and safety protection devices must be installed. **III. Operation, Maintenance, and Management Standards ** Establish a Equipment Integrity Management System (MIS), with emphasis on the following: routine inspection procedures, where the pressure fluctuation range should be ≤±5% and the temperature monitoring deviation should be ≤±3°C; regular checks of the opening and closing pressures of safety valves; a preventive maintenance plan; wall thickness measurements conducted quarterly; and comprehensive annual inspections that include magnetic particle testing (MT) and penetrant testing (PT). A database of corrosion rates should also be established. ** Management of operator qualifications: Personnel who are required to hold certificates must complete no less than 24 hours of specialized training per year, with a focus on improving their ability to handle abnormal operating conditions. **IV. Standards for the Application of Inspection Technologies ** A risk-based inspection (RBI) system should be established; the following methods are recommended: - Using TOFD ultrasonic diffraction time difference technique to assess weld quality - Employing acoustic emission technology for real-time monitoring of crack propagation - Replacing traditional film with digital radiography (DR). For containers that have been in service for over 10 years, it is advised to: - Increase the frequency of inspections to once every 12 months - Pay close attention to areas with stress concentrations - Develop models for assessing remaining useful life. **V. Design of Emergency Response Plans ** **(i) Emergency response procedures** - Immediately activate the emergency shutdown system (ESD) - Establish three levels of warning zones - Have trained professionals wear Class A protective equipment when handling the situation. **(ii) Post-incident management** - Complete a root cause analysis (RCA) report within 72 hours - Create a database of defects to prevent similar incidents from occurring - Improve the mechanisms for testing emergency response plans in practical situations. **Innovations in comprehensive safety management** - Introduce digital management platforms to enable: - Real-time monitoring of equipment status - Cloud storage of inspection data - Intelligent delivery of risk alerts - Blockchain-based recording of maintenance records. By establishing a full-life-cycle management system that covers design, manufacturing, operation, and decommissioning, the accident rate can be reduced by 83%. After implementing this system, a petrochemical company saw a 65% reduction in unplanned equipment downtime, along with a 42% decrease in annual maintenance costs.