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The Evolution of Corrosion Management

“If the present growth trends in world population, industrialization, pollution, food production, and resource depletion continue unchanged, the limits to growth on this planet will be reached sometime within the next one hundred years. The most probable result will be a rather sudden and uncontrollable decline in both population and industrial capacity”, concluded in 1972 the report The Limits to Growth, published by the Club of Rome.

This global think tank was the first to use computer simulation analyzing exponential economic and population growth versus finite resource supplies. The original version presented a model based on five variables: world population, industrialization, pollution, food production and resources depletion. These variables are considered to grow exponentially, while the ability of technology to increase resources availability is only linear. So the 1970’s would know the environmental movement.

Since corrosion has a direct impact in pollution, it was about the same time that the first evaluation of the cost of corrosion was conducted. The Hoar Report revealed that 3% to 4% of the GDP of industrialized countries is lost annually to corrosion. All similar evaluations performed later by different organizations basically came to the same conclusion. But the Hoar Report already emphasized that 25% of the annual cost of corrosion could be saved just by applying existing knowledge on corrosion control.

R&D efforts

The World Corrosion Organization published a whitepaper in 2009 (Dissemination, Research, and Development in Materials Deterioration and Corrosion Control) that concludes:

“To satisfy the basic needs of the 6.3 billion people on this globe, including proper nutrition, clean water, good health, safe housing, dependable energy, effective communication, and mobility, many technological changes with global dimensions must be accomplished. While this concept is widely appreciated as such, there is often only a limited awareness of how critical it is to solve corrosion problems and what the real implications are to society”.

The intention of the study was to demonstrate with several examples that future technological challenges can only be met by “immense R&D efforts worldwide in the fields of materials, surface protection, corrosion control, and condition-based monitoring”.

“It appears that in literally all cases, key problems related to materials degradation and corrosion must be solved. This involves materials stability under new environmental conditions or functional adjustment of environments and materials surface properties by appropriate surface modification methods. This work must include efficient management of corrosion mitigation and service integrity. Condition-based monitoring will be one of the key factors to ensure service integrity. However, this can only be accomplished with innovative sensor devices that have yet to be developed. Global standards should be established to foster condition-based monitoring as a standard procedure”, stated the document.

Maintenance and corrosion management systems

Duperron Marangon office at the beginning of the 1990sDespite the Digital Revolution and its growing popularity from the 1970’s, it was only in the beginning of the 1990’s that computers starter to be used to maintenance and corrosion management. Until that time, all the information of critical facilities, like ships or offshore platforms, was kept in papers that used to be spread in lots of piles when any repair must have been done.

“Then we were forced to follow blindly the price of shipyards without any control”, remember Duperron Marangon, naval engineer and consultant for Brazilian mining company Vale at that time, for the maintenance of its ships (the picture shows his office at the beginning of the 1990’s). It was a huge and non-intelligent work, so, he decided to develop a finite element calculator associated to digital spreadsheets that showed up to be much more efficient.

Ships are the largest steel structures produced by man. They go through a continuous process of maintaining their structures and equipment and, every five years, on average, need to stop in shipyards for structural repairs. Due to the aging fleet and the increasing environmental concerns, it has become essential to exercise better control over the maintenance of ships. Thus, they were natural candidates for carrying out validation tests of a maintenance management software.

CMMS

Today, a software like this is known as Computerized Maintenance Management System (CMMS). It is supposed to streamline the maintenance management of great responsibility structures, where failure may cause major damage, pollution and deaths, such as ships, oil platforms, bridges, aircrafts, industrial parks, minimizing the risk of accidents. The most advanced ones reproduces the 3D structures to simulate degradation over time, which results in a 4D perspective.

A software capable of performing intelligent maintenance management needs to have a graphical interface, because structures do not have identification numbers, as do the equipments, with each piece being recognized by a unique code. Even if each part of a structure is numbered in the construction project, the repair will occur in order to produce new regions, which can be inserted into the original or extend for many of them. The lack of this part number also prevents the use of the internet for the execution of quotations, since the shape of the repair and the region where it is located has a direct influence on the cost of implementation. The location, especially in large structures, has implications for the number of scaffoldings needed to perform the work.

The capability of knowledge management should be emphasized as well, because gathering information in a single database allows faster access, data security and consequent increased productivity. If you are interested in integrating the results with your ERP or other existing system, it must is also be possible. Otherwise, you will remain at Stone Age and information will just be dispersed in a very large number of plans, sketches and paper reports. Humanity is still not sure about the limits to growth in a planetary scale, but at least for corrosion management, as the music says, “the future has arrived”.

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Warning: You’re Losing Money by Not Using Corrosion Prevention

World’s foremost authority on corrosion, Nace International has just published the study “International Measurements of Prevention, Application and Economics of corrosion Technology”, Impact. In it, the association estimated at $ 2.5 trillion per year the overall cost of corrosion today, equivalent to 3.4% of world GDP. Prepared for two years and presented in Canada, the study calculated that the implementation of better corrosion prevention practices could result in an overall saving of 15% to 35% of the cost of the damage, ie between $ 375 billion and $ 875 billion.

Take a look at this 8 minute video.

“As the chief executive of Nace stated at the time, the study reinforces the need for a change in how the corrosion decisions are taken. Whether we are talking about oil rigs, ships, pipelines, airplanes or bridges, control and prevention are essential to avoid the disasters that are repeated from time to time”, says Duperron Marangon, CEO of PhDsoft and a specialist in maintenance management.

The only conclusion is: you’re loosing money by not using corrosion prevention on your company.

Impact includes a case study of corrosion management in the automobile industry that saved $ 9.6 billion in 1999, compared with 1975, to demonstrate the importance of adopting corrosion management systems throughout the life cycle of large structures such as those mentioned by Marangon. It states that the best practices in this area include: corrosion management systems that are integrated with the general policy of the organization; corrosion management information available to everyone in the organization, as well as linked to its overall objectives; and organizational leadership actively involved with the corrosion management decisions.

The problem is so critical, that NASA has a Corrosion Technology Laboratory that provides technical innovations and engineering services in all areas of corrosion.

As a university professor and CEO of PhDsoft, Duperron Marangon has been developing, in the last 20 years, softwares capable of increasing the efficiency of the process of maintaining large structures, while reducing costs. If you want to know more on corrosion or about projects in which the specialist is working nowadays, contact PhDsoft at +1 (713) 340-9958 or by the e-mail phdsoft@phdsoft.com.

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PhDsoft wins its 10th award since 2000

“The epic quest for oil, money and Power”, announces the subtitle of the classic book written by Daniel Yergin: “The prize”. At PhDsoft someone could add “for awards”. The company was founded in 2000 already being awarded by Finep at the I Venture Forum Brasil. Since then, it has never passed many time without recognition.

The last award was granted at the Rio ITech event, at Veiga de Almeida University. Before that, at 2015, PhDsoft had won the Louisiana Gulf Coast Oil Exposition (LAGCOE) New Technology Showcase, as Spotlight innovation technology.

Another highlight was in 2011, when PhDsoft won the Latin American and Caribbean Regional Partner Award in the Sustainability category at the Microsoft Worldwide Partner Conference. The Sustainability Partner of the Year Award recognizes exceptional partners who have delivered software and technology innovations built on the Microsoft platform that help people and organizations around the world reduce their impact on the environment.

“PhDC4D allows the customer to reduce maintenance costs by automating the engineering process of inspection and repair, and reducing unnecessary steel renewals due to subjective data interpretation. It also mitigates risks of catastrophic failures that could lead to environmental disasters by providing an accurate and comprehensive awareness of the structure integrity and risk levels. PhDC4D also provides regulatory compliance with Classification Societies Rules. Ultimately PhDC4D avoids accidents that can harm the environment as much as the BP accident in the Gulf of Mexico. Despite of deep water exploration in Brazilian, no incidents like that happened and this is partially due to PhDC4D contribution”, stated the company at the time.

In 2011, PhDsoft also won the Assespro Rio de Janeiro Award. In 2010 and 2008, PhDsoft won the Best Solution in Oil and Gas at the Rio Info Conference. It is really a great track record for such a recent story that reveals the potential of a glorious future.

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PhDsoft presents recent developments of PhDC4D to one of its clients

PhDsoft’s founder and CEO, Duperron Marangon spent last April 7th in a workshop with one of the company’s clients to explain the most recent developments of PhDC4D®, like piping integrity management. He also announced rapid piping modeling – reading data from Navisworks – as one of the ongoing developments.

PhDC4D® is a comprehensive system resulting from the synergistic integration of a 4D-space-time visualization software with a predictive corrosion algorithm, a regulatory code compliance engine and automation of engineering activities and best practices that consolidates a safer and cost-effective maintenance process for structures, piping and static equipment.

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PhDsoft wins another award

PhDsoft is proud to announce that is winning yet another award in recognition of its technology, this time in the United States along with a select group of only 6 companies.

World Oil: PhDsoft offers leading technology

Painel_C4D

LAFAYETTE — PhDsoft Technology’s C4D is an asset integrity management software that accurately predicts the degradation and corrosion of complex assets over time.

Leading technology to manage and monitor structures, static equipment and piping

Since 2000, PhDsoft has been providing world-leading technology to manage and monitor structural integrity, degradation protection and the safety of structures and static equipment. Our primary solution PhDC4D, or just C4D (“see in 4 dimension”) is an asset integrity management software that accurately predicts the degradation and corrosion of complex assets over time. It is a robust, proven solution that has been used by more than 110 assets.

C4D is a comprehensive system resulting from the synergistic integration of a 4D-space-time visualization software with a predictive corrosion algorithm, a standards code compliance engine and automation of engineering activities and best practices. It consolidates a safer, cost-effective maintenance process for structures, piping and static equipment.

Using cutting-edge 4D technology, C4D provides automation to accurately predict the cost of repair and maintenance. It enables cost savings for companies by eliminating unnecessary repairs, increasing inspection intervals for low-risk assets and preventing failures in structures, and avoiding financial loss due to disasters and accidents.

C4D integrates the management of complex systems, including fixed and floating platforms, subsea equipment, tankers and oil refineries. In fact, it is the only software solution capable of managing an entire Floating Production Storage and Offloading (FPSO) or offshore platform, including the structure, topside equipment, piping and risers.  C4D can also be used to evaluate assets in many different industries including aviation, industrial plants, and infrastructure.

One of the unique features of C4D is its 4D software interface analysis. It enables the users to create inspection sketches, calculate repair areas, determine steel and paint areas and volumes, redesign and position anode protection, assess the ‘as built’ and ‘as is’ structural condition at any time, identify a problem’s location in the actual structure, easily reference an area in the structure through the use of a photo key, and use a single file paradigm such as Word, Excel, etc. More than just software, C4D implements a process, where data is naturally fed into a database, facilitating the maintenance and integrity management cycle for all parts involved.

Another important attribute is the ability to quickly generate inspection reports. With C4D, spreadsheets are automatically completed, with the relevant isometric drawings and tables that can be exported. As a result, inspection companies only have to provide the thickness readings that are then imported back into the model, where the original thicknesses are compared to the corroded ones.

C4D gives users the ability to modify the date to predict the corrosion condition at specific times in the future and easily visualize all the parts that will have excessive corrosion. It then generates a list according to the condition and the remaining life. The information allows the user to schedule repairs and maintenance, prioritizing replacement and ranking parts to be replaced according to the risk of failure for different elements such as paint, coating condition, corrosion, cracks, pitting, etc.

Many types of documents containing relevant data can be accommodated by C4D, including text, spreadsheets, photographs, original drawings, schedules, and reports. This information is organized in a database that is used to prepare tools for analysis such as statistical curves, probabilities of corrosion rates, evaluations of repair volumes, detections and prioritizations of critical areas that exist in the present and over time. The C4D database can store petabytes of hybrid information.

Some of the benefits of C4D include substantial cost reduction, accurate prediction of future degradation, automated planning and operating process, reduction of engineering work, accurate estimation of cost and timing of repair, reduction of repair costs and downtime, accurate calculation of areas for shot-blasting and paint volumes, maintenance of accurate record of asset condition, creation of Best Practices for future use and enabling of operators to maintain control of the entire process.

In summary, C4D is the all-in-one integrity management solution—organizing data, allowing maintenance to be planned and executed more effectively and facilitating actions in the present to ensure proper structure maintenance and avoiding failures, accidents and extension of the life of their assets. PhDsoft is constantly developing new specialized features tailored to our clients’ needs. We focus on developing a long-term and unique business relationship with each of our clients by offering superior services. We have been recognized for our outstanding software solution, C4D, and have been the recipient of several awards.

Font: World Oil

Software made in Brazil

“Módulo Security Solutions is a Brazilian firm that has internationalized. Receiving this type of critical recognition from a major magazine in the IT segment was satisfying for us because we are doing the work right and we are showcasing Brazil among exporters of technology solutions,” recounts Sergio Thompson Flores, CEO of Módulo. With over 400 employees and its own offices in the United States, Canada, India and England, Módulo posted sales of more than R$85 million in 2013, up 20% over the previous year. “The outlook for 2014 is to continue our growth strategy by developing more solutions and functionalities in the Risk Manager software. We must continue to invest as well in stepping up our international work, primarily by setting up partnerships and winning new markets for the software,” stresses Rodrigo Palo, manager of the company based in Rio de Janeiro.

Another company from Rio is PhDsoft, which is on the verge of reentering the global market of suppliers of applications and technologies for the oil sector. The main product of the firm, founded 14 years ago by former UFRJ professor Duperron Marangon, is the C4D software, a simulation program that predicts structural failures on ships, oil platforms, bridges and other large constructions. The purpose of the technology is to prevent accidents and lower costs. C4D anticipates future conditions of critical structures. This avoids accidents and it also extends service life, resulting in significantly lower inspection and maintenance costs.

Large companies in the oil sector that operate in Brazil, such as Petrobras, Shell, Transpetro and Subsea7, are already clients of PhDsoft, which plans to open an office in Houston, Texas, by September of this year. “This will be our base for operations in the US market,” Marangon says. In addition, PhDsoft is negotiating with a government agency of the province of Nova Scotia in Canada to begin selling its products to that country. “We have always pursued the goal of internationalization. Expanding our sales outside Brazil will mean a change in the level of our business,” Marangon notes.

Read the complete report of Pesquisa Fapesp magazine here.