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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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PhDC4D offers investment opportunities for oil companies

This is a Remotely Operated Vehicles (ROV) integrated with PhDC4D. It was a project financed by a private company, like the oil ones obliged to invest part of its revenue in R&D, in Brazil. Last year, this obligation resulted in more than R$ 1 billion invested in projects like this. PhDsoft is looking for new partnerships.

There are no limits for what can be done with PhDC4D. The software operates in a Computerized Maintenance Management System (CMMS) category, which is like the known businesses managements ERP (Enterprise Resource Plannning), but focused on maintenance. In terms of business intelligence and knowledge management, PhDC4D is a CMMS. Its differential is that both CMMS end ERP can be resumed as an amount of tables.

In other hand, PhDC4D begins with the modeling of a structure in three dimensions, at a specific date. Somebody could think about defining it as a sophisticated CAD, but what about this fourth dimension that allows to simulate the evolution of structure along time? It results in a 4D software that can help to solve any kind of problem.

 

R&D obliged investments in Brazil

In order to expand technology to meet the integrated needs of customers, PhDsoft has traditionally built partnerships with big players of the oil sector, like Petrobras. These partnerships has resulted in a sort of new features such as the ROV integration.

This project used PhDC4D’s technology to manage the hulls and keep track of the maintenance of an offshore platform´s operation integrity by using the exact location of the data obtained by robots in real time.

The best news is that, although it has international headquarters in Houston, PhDsoft’s development teams continue to be coordinated by its unit In Brazil. This means PhDsoft is still a Brazilian company an so can be considered eligible to the demand for national content for the R&D investments oil companies are obliged to make in the country.

 

Internet of things

Last year, the Brazilian National Agency of Petroleum, Natural Gas and Biofuels (ANP) has changed the rules for these investments. From now on, 10% of the revenues must be invested in Brazilian companies other than the one that originated the revenue, like PhDsoft.

In the first three months of 2016, almost R$ 150 million were generated for obliged investments in R&D by oil companies operating in Brazil. In 2015, the amount reached more than R$ 1 billion. The deadline for the investments related to 2016 ends at June 30th 2017.

The next generation of projects PhDsoft is preparing intends to enroll everything related to maintenance in one only solution: static and submarine equipments, pipes, risers, structures and secondary structures, cranes, among others. One goal is to make it all ready to the internet of things. The objective is to integrate PhDC4D with sensors like the ones inserted in pipes to measure corrosion taxes or the ultrasonic thickness and strain gauges.

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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.

How to avoid unexpected expenditures on painting maintenance

During the preparation of the painting repair specification for the next dry dock of one container ship, an experienced engineer from a PhDsoft client realized the painting areas might had been underestimated. They were using figures from the design information booklet approved by the internal supervision team and classification society, and thus were supposed to be correct. The complex shapes of the tanks would make it unfeasible to recalculate manually.

The painting areas were recalculated in a few hours using the painting tools of PhDC4D®. Errors ranging from 20% to 260% were fixed. The fore tanks had the largest errors due to more developed forms.

As a result, an accurate painting repair specification was prepared and thus avoiding large unforeseen expenditures on repair execution; accurate amounts defined previously allowed a better base for price negotiation with shipyard; and the repair budget became accurate.

“We would never reach a conclusion without the help of C4D® since a lot man hours should be used for recalculating. It would be impracticable. It makes sense now why we always spent much more paint than initially planned. We thought it was due to inefficiency during the painting work. Why no one else detected this error previously during the plan approval process?”, stated the company.

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C4D software helped a client save US$ 400K

A container ship suffered bottom damage due to grounding. Two shipyards were contacted to evaluate the damage and provide repair estimates. But the estimates of the amount of steel required for repairs varied by 40%. An accurate assessment of the actual extent of damage extent and required repair material was urgently needed.

The case is real and happened to a PhDsoft client, a major company that operates ships in Brazil. In a few hours, using the repair tools of C4D Software®, the steel requirements were recalculated, showing that actual repair needs were 61 tons of steel, 60% less than the high estimate. It was clear that the shipyards significantly overestimated the amount of steel to be replaced.

Considering the cost of steel renewal in local shipyards of $11K/ton, the result was a saving of $400k. With the actual figure at hand, the client could safely and confidently select the shipyard with lower price and avoid the risk of the scope of materials increasing during repair execution.

“Without C4D Software we would have been forced to blindly follow the quotation of the shipyards with no control over the situation. Without C4D we never would have received the accurate numbers in time to make the right decision. The calculation of steel renewal done by C4D Software is more accurate than the shipyard because it takes into account all the original thicknesses”, stated the company.