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Guangdong Petrochemical: \"Corrosion Protection Records\" to effectively address salt spray challenges

2025-12-14View Original

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  Located on the coast of the South China Sea, Guangdong Petrochemical faces a harsh corrosive environment characterized by high salinity and humidity, frequent typhoons, and intense sunlight, putting the safety of its facilities under constant strain. To this end, a systematic \"anti-corrosion campaign\" covering the entire plant was launched – the \"anti-corrosion records\" were used to effectively address the challenges posed by salt spray. On December 3, Guangdong Petrochemical conducted a special inspection of the quality of anti-corrosion coatings on the catalytic cracking, aromatic compounds production, and sulfur recovery units. Led by Wei Xiaoke, the head of the Mobile Equipment Department, the team focused on checking the quality of rust removal before painting in areas prone to erosion, as well as the thickness and appearance of the coating, and inspected for issues such as missed painting or sagging of the coating. This inspection covered 21 pumps and motors, 240 meters of critical pipelines, as well as over 400 welds and flange connections, to ensure the long-term stable operation of the installation in a coastal environment with high salt levels.   Located on the coast of the South China Sea, Guangdong Petrochemical faces a harsh corrosive environment characterized by high salinity and humidity, frequent typhoons, and intense sunlight, putting the safety of its facilities under constant strain. Through nearly a year of systematic management, the company has achieved phased results in salt spray corrosion prevention, providing strong support for the long-term safe operation of coastal petrochemical facilities.   Top-level drive and systematic planning as a unified approach: “For a large-scale integrated manufacturing enterprise 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 Motor 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 paints, to adhering to the standard practice of applying thin layers multiple times – all to ensure that the coating is even and free of any defects.   In the quality acceptance phase, the thickness gauge serves as the “final arbiter”. The coating thickness at each inspection point must meet the specified standards, ensuring that the anti-corrosion layer remains intact and dense, thereby preventing salt spray corrosion. 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 implementation of these measures for tackling this challenge, Guangdong Petrochemical has included key indicators related to corrosion prevention in the KPI assessments of various departments, using strict managerial constraints to lay a solid foundation for the long-term stable operation of coastal equipment.   Targeted efforts to combat corruption: practical measures being taken on the frontlines. At the corporate level, strong leadership is provided; the key lies in implementation at the grassroots level. Faced with the severe salt spray challenges, various production departments responded swiftly, coming up with effective measures to put anti-corrosion solutions into practice.   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 adopted a thorough inspection approach, implementing a closed-loop management system that involves addressing each issue, verifying its resolution, 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 guarantee corrosion resistance at each stage.   Initial results are evident: a solid \"ballast\" for stable operation has been established. After nearly a year of sustained, systematic efforts, the results achieved in addressing salt spray corrosion at Guangdong Petrochemical have become apparent, showing 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, equipment, 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 caused by chloride ions has been effectively eliminated, thereby greatly reducing the overall corrosion rate of the critical equipment.   At the safety level, a range of major safety hazards have been eliminated at their root by preventing pipeline leaks and equipment structural failures caused by corrosion. According to preliminary assessments, this approach is expected to save up to 30% to 60% on daily maintenance costs, enabling a strategic shift from reactive repairs to proactive protection.

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