Materials expertise for petrochemicals and refineries
For operators of petrochemical plants and refineries: Fitness-For-Service assessments, failure analyses, materials consulting and on-site inspections – standards-based per API, NACE and ASME, practice-oriented and independent.
CHALLENGE
Petrochemical plants operate under conditions that systematically attack materials – high temperature, aggressive media, pressure cycling, H₂S and hydrogen.
- A finding during the turnaround leaves no room for delay – continued operation or replacement must be decided quickly and safely.
- Corrosion, HTHA or stress corrosion cracking is progressing – critical mechanisms were detected too late.
- A damage event requires immediate root cause clarification – for insurers, authorities and a safe restart.
- A new process chemical or changed operating parameters require a new materials assessment for existing components.
Turnaround running, finding open or unplanned plant shutdown?
SERVICES
Our services for petrochemicals and refineries
Fitness-For-Service analyses
Objective assessment of the fitness for service of pressure vessels, piping, heat exchangers and other components for safe continued operation. Estimation of safe remaining service life based on standards-based assessment procedures.
- FFS assessment per API 579-1 / ASME FFS-1
- Corrosion, fatigue and buckling assessment
- Remaining service life estimation for critical systems
- Assessment of dents, wall thickness loss, cracks
- Basis for regulatory continued operation approvals
Forensic failure analysis
Systematic root cause investigation of damage events in petrochemical plants and refineries – leaks, fractures, corrosion damage, pressure vessel failure. Clear recommendations to prevent recurrence, standards-based documentation per VDI 3822.
- Root cause investigation per API 571 (damage mechanisms)
- Metallography, SEM/EDX, fractographic analysis
- Expert reports for insurers, authorities and courts
- Recommendations for a safe restart
On-site inspection & turnaround support
Destructive and non-destructive testing directly at the plant – on site, without laboratory delay. Practice-oriented assessment of the real plant condition, documentation of findings and recommendations directly from the turnaround.
Materials consulting & welding consulting
Consulting on material selection for process components under H₂S, hydrogen, high-temperature and pressure conditions. Welding consulting for repairs and new builds under process conditions.
Corrosion consulting & protection concepts
Identification of critical corrosion mechanisms in petrochemical process environments. Development of tailored protection and inspection concepts to safeguard plant availability and reduce unplanned shutdowns.
STANDARDS EXPERTISE
DAMAGE MECHANISMS – WHAT WE SEE EVERY DAY IN PETROCHEMICALS AND REFINING
API 571 lists over 60 damage mechanisms – we know the critical ones for your plant.
Hydrogen attack at elevated temperatures and partial pressures – assessment based on Nelson curves (API 941), in-situ analysis and protective measures.
Hydrogen-induced cracking and sulfide stress corrosion cracking per NACE MR0175 – material selection, testing and risk assessment.
High-temperature corrosion from naphthenic acids in crude oil – materials assessment, TAN monitoring and protection concepts for affected plant parts.
Long-term damage from temperature fluctuations and creep loading on piping, heat exchangers and reactors – in-situ assessment and remaining service life.
Stress corrosion cracking in amine scrubbers and caustic environments – root cause analysis, heat treatment recommendations and inspection.
Wall thickness loss from erosion and turbulent flow in pipes and valves – assessment, protective measures and FFS integration.
PROJECT REFERENCES (ANONYMIZED)
From practice – what we have delivered for refinery operators and petrochemical plants
FFS assessment per API 579 and Nelson curve analysis for a reactor pressure vessel following a finding of changed operating parameters. In-situ analysis for HTHA damage.
→ Safe continued operation confirmed for 4 years, inspection plan adjusted
Forensic analysis after a leak in a process pipeline. SSC identified as the primary mechanism, unsuitable material selection in the original design process demonstrated.
→ Expert report for insurance settlement, recourse claim enforced
Analysis of naphthenic acid corrosion in vacuum distillation. Material change to higher-alloyed steels, TAN-based monitoring concept developed and implemented.
→ Inspection intervals doubled, production losses reduced by 70%
COLLABORATION
How a collaboration works
Request
Brief description of the finding, the plant or the question. Urgency is taken into account immediately.
Initial consultation
Within 24 hours: initial technical assessment, clarification of the scope of investigation and scheduling.
On-site appointment
On-site inspection or laboratory analysis – or both. Complete documentation of all findings and sampling.
Report & recommendation
Standards-based final report with clear recommendations – for continued operation, repair or replacement.
Acute damage case or ongoing turnaround?
WHY TECHNICAL CENTER
What refinery operators and petrochemical plants expect from us – and get
API 579, API 571, API 510, API 570, API 941 – we apply these codes every day, not just in the manual.
We come to your plant – on-site inspections and in-situ analyses are not a special case for us, but standard.
All reports per VDI 3822 – usable for insurers, authorities, continued operation approvals and court proceedings.
HTHA, SSC, HIC, naphthenic acid, amine cracking – we know the specific mechanisms of the petrochemical and refining industry.
TYPICAL OCCASIONS
When operators of petrochemical plants contact us
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During a turnaround with an open finding – continued operation or replacement must be decided quickly
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After a leak, a failure or an unplanned shutdown requiring clarification
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With changed operating parameters or new process chemicals – material suitability must be reassessed
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When HTHA is suspected and a Nelson curve assessment or in-situ analysis is needed
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With H₂S exposure and suspected SSC or HIC – materials testing and NACE-compliant assessment required
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For insurance or warranty proceedings following a damage event
FREQUENTLY ASKED QUESTIONS
What operators want to know before the first request
Yes. Materials assessment and selection per NACE MR0175 / ISO 15156, testing for SSC and HIC resistance, as well as consulting on the implementation of NACE requirements, are an integral part of our service portfolio for the petrochemical sector. We know the requirements from practice and translate them into concrete material and inspection decisions.
In cases of acute need for action – unplanned shutdown, leak or damage event – we are usually on site within 24–48 hours, nationwide. Please briefly describe the situation and urgency in your request so that we can prioritize immediately. For acute cases, direct contact by phone is fastest.
