Firstly,based on data collection and operation fluid compatibility analysis,the damage modes of pressure vessels beyond their design life have been analyzed in response to the current issues for continued operation faced by the industry.Secondly,the corresponding damage characterization parameters and damage evolution laws for different damage modes determined.Finally,the analysis methods have been used to evaluate the failure modes caused by different damage modes in order to determine the safety status and residual life of the vessels.Following the above-mentioned criteria,a case study has been conducted for the fitness-for-service assessment of pressure vessels over the design life.The results have been showed that a small number of vessels with a short remaining life is recommended to be replaced.This practice can be referred to improve the safety operation and maintenance level of pressure vessels with over design life.