Ensuring the reliability of high-pressure process plants requires a systematic safety management approach that bridges design, operation, and risk assessment. This study proposes an integrated framework combining Failure Mode and Effects Analysis (FMEA), Finite Element (FE) stress analysis, and real-time condition monitoring to evaluate the safety of a pilot-scale heat-exchanger network. First, a comprehensive FMEA identified critical failure modes such as tube rupture and flange leakage. Next, FE simulations quantified stress concentrations under transient thermal-hydraulic loads, validating the design against ASME VIII-1 standards. Finally, a wireless sensor array was deployed to monitor temperature, pressure, and vibration, with data fed into a predictive maintenance algorithm that flags deviations exceeding two standard deviations from baseline conditions. Over six months of operation, the proposed framework reduced unplanned downtime by 38% and lowered the overall risk rating from high to medium on the facility risk matrix. The results confirm that a mechanicsdriven safety management system can significantly enhance both operational safety and productivity, providing a scalable template for industrial plants handling hazardous fluids.