【Learning from Others’ Experiences】Guangdong Petrochemical has established a \"protective barrier\" to ensure the long-term safe operation of petrochemical facilities by addressing salt spray corrosion issues in South China”
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“For a large-scale complex plant like Guangdong Petrochemical, the essence of corrosion protection is to prevent accidents and ensure safety. Corrosion and leakage in any pipeline or equipment can lead to unimaginable consequences. ”The words of Chang Guangdong, director of the Mobile Equipment Department, reflect the severe challenges faced by Guangdong Petrochemical, located on the shores of the South China Sea. Since the beginning of this year, the company has made salt spray corrosion prevention a priority for enhanced management. A systematic \"anti-corrosion campaign\" covering the entire factory was launched in full force. Led by the Mobile Equipment Department, dozens of detailed \"corrosion prevention profiles\" were customized for the installations and equipment in different areas, ensuring a tailored approach for each installation. On the construction site, supervisors carry standard cards and closely monitor each step of the process – from ensuring that rust is removed from the substrate so that the metal’s natural color is visible, to following the instructions precisely when mixing the paint, to using the proper technique of applying thin layers multiple times – all to ensure that the coating is even and free of any defects. During the quality inspection phase, the thickness gauge serves as the \"ultimate judge\" – the coating thickness at each testing point must meet the specified standards to ensure that the anti-corrosion layer is intact and dense, thereby preventing corrosion caused by salt spray. For complex components such as equipment flanges and valves, removable insulation sleeves are used, acting like a fitting \"protective armor\" that ensures sealing while also facilitating future maintenance. To ensure the success of this critical effort, Guangdong Petrochemical has incorporated key indicators related to corrosion prevention into the KPI assessments of various departments, using strict managerial constraints to lay a solid foundation for the long-term stable operation of equipment located along the coast.
Within the aromatic complex, equipment engineers carefully identified potential corrosion issues, conducting a thorough inspection of 523 pieces of equipment and 3,895 pipelines in key areas such as the continuous reforming unit and the aromatic complex. During construction, more than 10 construction standards are strictly followed, and centralized treatment is carried out using techniques such as high-pressure cleaning, professional rust removal, and proper painting. To address corrosion-prone areas such as the corners of equipment and pipeline connections, the Fourth Refining Department has innovatively adopted a \"comprehensive inspection\" approach, implementing a closed-loop management system that involves treating each area, verifying the completion of treatment, and then marking it as resolved. To strengthen the safety safeguards for equipment and pipelines in salt spray environments, the Second Refining Department conducted comprehensive inspections of five key units, including wax oil hydrogenation and catalytic cracking units, covering a total of 395 pieces of equipment and 3,997 pipelines. To ensure work quality and efficiency, during the construction process, the team applies strict standards to every step of the work. Professional rust-removal techniques are used to ensure that the base surface is properly prepared, and a three-layer protection system consisting of a rust inhibitor, a low-surface-tension primer, and a water-based polyurethane topcoat is employed to enhance the anti-corrosion properties step by step.
After nearly a year of sustained systematic efforts, the results of salt spray corrosion control measures implemented by Guangdong Petrochemical have become evident, demonstrating significant overall benefits. To date, the total painted area has exceeded 8,000 square meters. The effectiveness of governance is first reflected in the establishment of a standardized management system. The company has successfully established a standard framework covering the entire process from paint selection to application, inspection, and maintenance. It has also introduced an innovative \"four-party joint inspection\" mechanism, which effectively resolves the problem of lack of standards and chaotic construction that existed in the past. Furthermore, for the pipes, devices, and steel structures at the site that had a high level of corrosion, the condition of corrosion on their outer surfaces has been significantly improved. The risk of pitting corrosion caused by chloride ions has been effectively eliminated, thereby greatly reducing the overall corrosion rate of the critical equipment. At the safety level, by preventing pipeline leaks and equipment structural failures caused by corrosion, a range of serious safety hazards are eliminated at their root. According to preliminary assessments, this approach is expected to save up to 30% to 60% on daily maintenance costs in the long term, enabling a strategic shift from reactive repairs to proactive protection.
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