What are the major maintenance challenges in petrochemical operations?

Petrochemical facilities operate under some of the most extreme industrial conditions. With constant exposure to corrosive chemicals, high temperatures, mechanical stress, and pressure, equipment deterioration is a persistent and costly issue.

Common Problems in Petrochemical Plants:

  • Corrosion in pipelines, tanks, vessels, and steel structures
  • Chemical attack from acids, alkalis, hydrocarbons, and solvents
  • Erosion and wear in pumps, agitators, impellers, and mixing equipment
  • Leaks in pressurised pipe systems, joints, and valves
  • Concrete degradation in chemical bunds, sumps, loading zones, and drainage areas

If not addressed effectively, these challenges lead to equipment failure, safety risks, environmental hazards, and production losses.

Roof and Repair Protection

How do protective coatings improve durability in petrochemical environments?

At UNIQUE POLYMER SYSTEMS (UPS), we supply advanced chemical-resistant protective coatings tailored to withstand the extreme demands of petrochemical processing and refining operations.

Our Protective Coating Solutions Include:

  • Chemical-resistant linings – for storage tanks, bunds, dosing systems, and separators
  • Corrosion barrier coatings – for pipelines, structural steel, pipe racks, and flare stack frames
  • High-temperature coatings – for heat exchangers, chimneys, vessels, and exhausts
  • Abrasion-resistant coatings – for pumps, mixers, valves, and rotating components
  • Concrete coatings and resurfacing systems – for chemical bunds, floors, drainage areas, and trench linings

All coatings are solvent-free, fast-curing, and high-performance, designed to create a reliable barrier against chemical, thermal, and mechanical degradation — while supporting compliance with environmental and safety standards.

Roof and Repair Protection

What composite repair systems are available for petrochemical plant maintenance?

When damage or degradation occurs, UPS composite repair systems provide rapid, in-situ solutions — ideal for high-risk, time-critical, or hazardous zone applications where hot work or equipment removal isn’t viable.

Composite Repair Applications Include:

  • Metal repair compounds – rebuild worn pump casings, heat exchanger plates, flanges, housings
  • Pipe wrap and reinforcement systems – seal and reinforce corroded or leaking pipelines, even under pressure
  • Leak sealing kits – fast-acting emergency solutions for process leaks and hazardous fluid containment
  • Structural reinforcement materials – restore load-bearing strength in platforms, tank skirts, supports, and frames
  • Concrete repair systems – rebuild and seal damaged bunds, plinths, trench linings, and chemical flooring

These systems offer exceptional chemical resistance, durability, and fast curing, making them a vital tool for maintenance teams in critical environments.

Roof and Repair Protection

Where are UPS coatings and repairs used in the petrochemical sector?

UPS solutions are trusted across upstream, midstream, and downstream operations, including:

  • Refineries and processing plants – tank linings, bund coatings, pipeline and structural steel protection
  • Chemical storage and dosing facilities – coatings for tanks, containment systems, and transfer lines
  • Pump and valve repair zones – composite rebuilds for mechanical components and flow equipment
  • Utilities and infrastructure areas – coatings for floors, drains, trenches, walls, and sumps
  • Hazardous maintenance zones – pipe wrapping, sealing kits, structural reinforcement in restricted access areas

Roof and Repair Protection

What benefits do UPS solutions bring to petrochemical operations?

  • Extended asset life in chemically aggressive environments
  • Reduced downtime through fast, in-situ repair options
  • Lower maintenance costs and improved equipment reliability
  • Enhanced safety and environmental compliance
  • Minimised risk of system failure and unplanned production stoppages
Roof and Repair Protection

Why choose UNIQUE POLYMER SYSTEMS as your petrochemical maintenance partner?

We understand the technical, regulatory, and safety-critical demands of petrochemical operations. That’s why our systems are backed by expert guidance, real-world performance data, and robust product engineering to support high-risk environments.

Our Services Include:

  • Product selection tailored to specific chemical and thermal exposures
  • Chemical resistance charts and system specification guidance
  • Training and support for maintenance teams and contractors
  • On-site consultancy and full QA/QC documentation for compliance audits
Roof and Repair Protection