Author: Ing. Mario Toyo, July 3, 2023.
Introduction
The energy and industrial sector constantly face the deterioration of structures and equipment failures due to the action of the environment in which they are used, which generates a fight between the elements mainly involved: corrosion vs asset management, demonstrating how the triumph of one implies the defeat of the other.
Imagine an oil rig enduring the ravages of corrosion, with damaged piping, corroded structures, and a high risk of failures and accidents. What has happened in this scenario? It is clear that asset management has been flawed, allowing corrosion to set in and wreak havoc on the infrastructure. The lack of an adequate strategy has led to a functional loss and a considerable economic burden for the company.
On the other hand, let us consider a situation where no corrosion is observed on the assets. Here, we can infer that asset management has been successful and effective. In this case, the company has managed to implement a solid strategy that prevents corrosion and protects its assets in the long term. This approach translates into greater functional efficiency and a competitive economic advantage.
Throughout this article, we will dive into the world of asset management and corrosion, using tangible examples to illustrate the importance of proper management in preventing corrosion. We will explore effective strategies that have proven their worth in various energy and industrial sectors, from oil and gas to renewable energy.
Professionals from the energy and industrial sectors, students, businessmen and companies in general, all have a common interest in efficiency and profitability. Understanding this relationship will not only give you a clearer picture of the challenges you face, but also the opportunities that come with implementing a strong management strategy.
Corrosion in assets: a challenge for the industry
Corrosion, in its various forms, is presented as a recurring challenge in the industry of the energy sector. This unwanted chemical reaction can compromise the integrity of assets, from pipelines and storage tanks to offshore platforms and refining equipment.
Its impact can be devastating, generating considerable costs for businesses and putting operational security at risk. Understanding the magnitude of these effects is crucial to appreciating the importance of proper asset management, for example:
- Degradation of structural integrity . Corrosion can weaken the structure of assets over time. For example, on an oil platform, corrosion can affect the structural foundations, supports, and pipes, compromising their strength and stability. This not only increases the risk of catastrophic failure, but can also result in loss of production and interruption of operations.
- Increased repair and replacement costs . When corrosion is not addressed in a timely and effective manner, the costs to repair or replace assets can increase significantly. Corrective maintenance tasks and urgent repairs are often more expensive than preventive actions. Also, in some cases, advanced corrosion may require complete replacement of the asset, which implies a significant investment.
- Impact on the useful life of the assets . Corrosion accelerates the deterioration of assets and can reduce their useful life. For example, in the case of corroded pipes, their fluid transport capacity is compromised, which limits the efficiency of the operation. Premature replacement of assets due to corrosion can create additional cost and affect a company’s long-term profitability.
- Reputation and loss of trust . The presence of corrosion on assets can have a negative impact on a company’s reputation. Customers, investors, and stakeholders may perceive corrosion as a sign of poor management and a neglect of safety. This can result in a loss of confidence in the company and affect its competitive position in the market.
In summary, the corrosion of assets has a direct impact on the integrity of the asset and the costs related to its repair or replacement. Effective asset management that includes corrosion prevention and control is essential to safeguard the useful life of assets, reduce operational risks and optimize a company’s financial resources. By investing in proper asset management, companies can prevent corrosion and ensure optimal performance of their facilities,
An emblematic example is the case of corrosion under insulation (CUI). This form of corrosion occurs when moisture accumulates under the thermal insulation, accelerating the corrosive process. According to studies, the CUI represents approximately 40% of pipe failures in industrial facilities, which demonstrates the importance of addressing this challenge efficiently.
Corrosion vs asset management
Asset management as the key to corrosion prevention plays a fundamental role in corrosion prevention and control. An effective and well-implemented strategy can significantly reduce associated risks and ensure long-term asset integrity. In the figure. 1 shows some strategies to implement in your business.
Effective strategies that companies can implement to ensure sound management of their assets and minimize the risks associated with corrosion.
- Regular inspections and advanced monitoring
- Preventive maintenance programs
- Use of protection technologies and coatings
- Staff training and awareness
- Data analysis and data-driven decision making
A notable case is that of the Norwegian company Equinor. Through their comprehensive approach to asset management, they have managed to minimize the effects of corrosion at their offshore facilities. The implementation of regular inspections, preventive maintenance programs and the use of advanced monitoring technologies have been key to its success. Thanks to these practices, they have managed to reduce maintenance costs related to corrosion by 15% and increase the operational availability of their assets by 10%.
Benefits of effective asset management
Effective asset management not only prevents corrosion, but also brings numerous functional and economic benefits to companies in the energy sector.
In terms of functional efficiency, proper asset management makes it possible to proactively identify and address factors that can trigger corrosion. This involves the implementation of periodic inspection, condition monitoring, and preventative maintenance programs, leading to increased operational reliability and a reduction in unplanned downtime.
From an economic perspective, companies that invest in strong asset management experience a significant return on investment. According to a report by the consulting firm Accenture, every dollar invested in asset management can save up to five dollars in operating and maintenance costs. In addition, the reduction in failures and the extension of the useful life of the assets contribute to maximizing the economic benefits in the long term.
Practical examples of asset management to prevent corrosion
1. Implementation of regular inspections and corrosion monitoring
An outstanding case is that of the ExxonMobil company. This company has established a comprehensive asset management program that includes regular inspections, risk assessment, and data analysis. They use advanced technologies, such as drone inspection and remote monitoring, to identify areas of potential corrosion and take preventative action in a timely manner. Thanks to these strategies, ExxonMobil has been able to minimize corrosion incidents and maintain the integrity of its assets.
2. Preventive and corrective maintenance programs based on asset management
Another example of successful management to prevent corrosion in assets is the case of the American company Chevron. They have implemented a data and analytics-driven approach to maintenance, using cutting-edge technologies such as real-time monitoring and the use of artificial intelligence. By collecting and analyzing data, Chevron can identify corrosion patterns and proactively plan preventive maintenance interventions. This has allowed them to extend the useful life of their assets, reduce maintenance costs and prevent catastrophic failures.
3. Use of protection technologies and coatings
Shell has implemented an asset management approach focused on integrity and reliability. They use predictive analytics and advanced models to assess corrosion risk at your facility. In addition, they have developed state-of-the-art anti-corrosion protection systems and special coatings to extend the useful life of your assets. These practices have enabled Shell to minimize repair costs and maintain high safety standards in its operations. In fig. 2, one of these products is observed.
4. Training and awareness of staff.
BP has implemented extensive training programs for its staff, both in operational areas and in maintenance and asset management. These programs focus on awareness of corrosion risks, the importance of proper asset management, and best practices to prevent and control corrosion.
The company offers specific courses and workshops on topics such as the identification of signs of corrosion, preventive maintenance techniques, the use of anti-corrosion coatings and materials, and the implementation of monitoring systems. These training programs are tailored to different levels of responsibility and knowledge, from field operators to engineers and managers.
5. Data analysis and data-driven decision making
Siemens Energy has taken an innovative approach to asset management in the energy industry. They use real-time monitoring technologies and data analysis to assess the condition of assets and predict potential corrosion problems. This allows them to proactively plan preventive maintenance activities and optimize resources. Thanks to these strategies, Siemens Energy has been able to reduce the costs associated with corrosion and maximize the availability of its assets.
Asset management as a competitive advantage in the energy and industrial sector.
Efficient asset management becomes a competitive advantage for companies in the energy sector. Those that prioritize corrosion prevention and the integrity of their assets are able to build a strong reputation, increase operational reliability, and ensure safety for both their people and the environment.
A notable example is the case of Mary Barra, CEO of General Motors (GM), who has led a transformation in the company’s asset management. By taking a proactive approach to corrosion prevention and asset maintenance, GM has been able to reduce failure and repair costs, improve the quality of its vehicles, and gain a competitive advantage in the automotive industry.
Conclusion
The relationship between corrosion in assets and their management is crucial in the energy and industrial sector. The presence of corrosion indicates inadequate asset management, while the absence of corrosion is an indicator of a successful and effective strategy. Proper asset management prevents corrosion and provides long-term functional and economic benefits.
By implementing strategies such as regular inspections, advanced monitoring, preventative maintenance, and data-driven approaches, companies can win the battle against corrosion, achieving greater efficiency and profitability in their operation.
Don’t wait any longer, start protecting your assets today!
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