Chemical & Specialty
Chemical plants operate across a spectrum from continuous petrochemical processes to batch specialty operations, each presenting distinct integrity challenges. Process Safety Management requirements add a governance layer that demands rigorous change control — every metallurgy substitution, process condition change, or operating envelope modification must be captured, assessed, and approved before execution.
Applicable Standards
Critical focus areas
- Batch exposure and flow-accelerated corrosion (FAC) management
- Lined equipment integrity and inspection
- Hazardous material containment assurance
- Management of change (MOC) governance that supports PSM programmes
- Campaign-based degradation tracking
Key Challenges
- Aggressive corrosive environments with multiple simultaneous mechanisms
- Complex damage mechanism cross-talk in multi-product facilities
- Governed workflows across engineering and operations functions
- Batch vs. continuous operation creating non-uniform inspection cycles
Active damage mechanisms
Reliatic ships with a pre-loaded damage mechanism library for Chemical & Specialty. Each mechanism is linked to its relevant inspection techniques, examination intervals, and regulatory acceptance criteria.
Chloride Stress Corrosion Cracking (Cl-SCC)
Transgranular cracking in austenitic stainless steels exposed to chloride-containing environments above 60°C, often initiating at crevices and under deposits.
Corrosion Under Insulation (CUI)
External corrosion of carbon and low-alloy steel beneath insulation, particularly problematic in chemical plants with frequent wash-down and outdoor piping.
Flow-Accelerated Corrosion (FAC)
Dissolution of the protective oxide layer on carbon steel in single-phase and two-phase flow systems, creating localized wall thinning at elbows and tees.
Erosion-Corrosion
Combined mechanical and electrochemical material removal in slurry lines, catalyst transfer systems, and high-velocity process streams carrying suspended solids.
Amine Cracking
Alkaline stress corrosion cracking in carbon steel equipment handling amine solutions for acid gas removal, concentrated at welds not post-weld heat treated.
Platform Configuration for Chemical & Specialty
Outcome
Support PSM mechanical-integrity programmes with governed MOC workflows while optimizing inspection scope across batch and continuous operations with different degradation profiles.