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Petrochemical

Petrochemical Manufacturing Plant Asset Protection Services


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MISTRAS offers advanced asset protection solutions – including inspection, maintenance, engineering consulting, access, and data management – to keep your petrochemical assets safe and in compliance.

Petrochemical facilities must adhere to strict safety standards as they convert natural resources into products that we use every day, from cosmetics to plastics to medical supplies.

When dealing with potentially hazardous materials, it is essential for plant and personnel safety to ensure that assets are operating safely and that chemical processes are sound. Petrochemical asset failure can be extremely dangerous, can incur huge costs, and can potentially affect the production of the end products that society relies on.

MISTRAS’ asset protection solutions help keep your petrochemical assets and facility operating safely, efficiently, and in compliance. Our inspection, consulting, maintenance, access, and data management solutions optimize production for a wide variety of petrochemical assets, including:

  • Coker Drums
  • Heat Exchangers
  • Piping
  • Pressure Vessels
  • Pumps
  • Spheres
  • Stacks
  • Storage Tanks

Petrochemical Inspection & Maintenance Services 

MISTRAS has the capabilities to perform inspection, maintenance, and repair services for all of the assets in your petrochemical facility.

Our traditional and advanced non-destructive testing (NDT) technology enable us to perform inspections on your assets while they remain in services, limiting downtime for your plant. Our technicians work with MISTRAS’ engineering consultant experts and with plant operators to conduct inspections according to plant-wide mechanical integrity (MI) programs, and in accordance with risk based inspection (RBI) methodologies.

Our NDT inspection services include:

MISTRAS can also centralize all asset inspection and mechanical integrity data in our industry-leading inspection data management software, Plant Condition Management Software (PCMS®). Through PCMS, you can keep tracking of historical inspection data, future inspection dates, condition monitoring locations (CMLs), risk-based inspection (RBI) assessments, and much more.

Our advanced technicians are trained and certified to perform a variety of mechanical services for petrochemical assets in order to ensure that assets and equipment are free of damage and operationally sound, including:

We perform these inspection and maintenance services on the ground and in at-height locations through the use of trained and certified rope access technicians, and professional unmanned system (drone) pilots.

Process Safety Management (PSM) Consulting Services for Petrochemical Plants

Since petrochemical plants deal with potentially hazardous materials and processes, it is critical that facilities maintain the correct safety procedures to prevent accident and injury.

With extensive industry experience in petrochemical engineering, MISTRAS consultants are well-equipped to create Process Safety Management (PSM) programs tailored to the individual needs of your facility.

MISTRAS has expertise in all realms of planning, development, maintenance, and repair for Petrochemical facilities, so our plant consulting services are all–encompassing of any asset needs or potential flaws.

Our PSM program implementation and management services include:

  • Change Management
  • Compliance Audits
  • Extensive Workforce Training
  • Hazard and Operability (HAZOP) Reviews
  • Incident Investigation
  • Integrity Operating Window (IOW) Development
  • Non-Routine Work Authorizations
  • Pre-Startup Procedures
  • Process Hazard Analyses (PHA)
  • Safety Reviews
  • Written Plans and Procedures (including operating procedures and emergency planning)

Our certified engineers will ensure that your plant remains in regulatory compliance and is operating according to industry standards. With safety at the core of what we do, our services emphasize sound plant operation while positioning your facility to achieve optimal production capacity. When developing PSM programs, we take into account:

Special Emphasis Programs for Common Corrosion & Cracking Defects

MISTRAS offers NDT inspection and monitoring technology that is specially designed to combat the flaws and defects that plague your petrochemical assets. Some of the most hazardous damage to your facility is the damage that accumulates rapidly and without many visual clues.

MISTRAS has developed proceduralized inspection, maintenance, and engineering programs to combat some of the most common corrosion and cracking issues that plague your petrochemical assets.

Corrosion Under Insulation (CUI)

MISTRAS offers prevention, early detection, mitigation, and preventative maintenance strategies to ensure that CUI does not cause your facility costly and hazardous damage. Hidden from view, CUI can be extremely hard to detect, but MISTRAS provides NDT inspection at-height and in confined spaces, along with insulation removal and replacement

High Temperature Hydrogen Attack (HTHA)

HTHA attacks steel assets at high temperatures, degrading the material through the growth of micro-cracking on the metal surface. MISTRAS offers non-destructive evaluation (NDE) techniques, along with consulting and metallurgic analysis, to determine the presence and extent of HTHA damage.

Sulfidation Corrosion

Sulfidation corrosion is the result of chemical reactions in crude oil attacking carbon steel and other petrochemical equipment, including piping, heater tubes, pressure vessels, and other assets. MISTRAS can develop comprehensive programs to help your facility avoid the risks of sulfidation corrosion damage and degradation, including project scope, program design, inspection, and reporting services.


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