Background

In order to offer an engineering solution aimed at promoting the care and management of its clients' assets, Kot Engenharia developed CARE: Control of Assets for Structural Revitalization. As the name implies, the focus of this methodology is to take care of assets by promoting structured control over them and mitigating the risks associated with the use of equipment and structures.

The methodology is divided into six main stages, establishing a journey that enables better maintenance and Structural Integrity the asset. An overview of these stages can be seen in Figure 1:

Figure 1: CARE Methodology - SOURCE: Kot Collection.

Throughout its journey, CARE is based on risk management as recommended in ISO-31000 Risk Management, shown in Figure 2. It is important to note that risk cannot be eliminated from human activity. However, the use of engineering methodology to mitigate it can bring benefits in terms of reducing costs, catastrophic failures and saving lives.

Figure 2: Risk Management - SOURCE: ISO-31000.

Benefits of the Methodology

Based on the company's experience over the years, Kot has observed that incorrect engineering practices entail a very high risk to the Structural Integrity the asset and can cause serious accidents. With this in mind, the CARE methodology presented here goes through the main stages of asset management and control, offering a series of benefits to its clients. The following advantages can be obtained from its implementation:

• Security:

Proper design, a good state of repair of structures and their correct use are fundamental aspects of safety. Failure can lead to loss of production, injury or human loss, so the risk of structural failure is directly associated with the condition of the structures;

• Economic:

In addition to the safety aspect mentioned above, there is a major economic benefit in the CARE methodology, since the investment values in engineering this type of solution are tiny compared to the possible misfortunes that could occur. The following losses/costs can be avoided with the proposed solution:

• Loss of profit from downtime;
• Fines and demurrage due to late deliveries of products;
• Urgent labor costs for renovations, salvaging structures, replacing components/equipment, handling equipment, etc. Vale noting that these urgent costs are generally higher than scheduled activities.
• Financial:

It is possible to generate advantages related to reducing the number of unscheduled stops. As a result, it is possible to achieve a higher level of productivity which, in turn, is capable of generating a greater financial return on investment. In addition, OPEX can be reduced due to the reduction in future preventive and undesirable corrective stoppages.

• Branding and Image Management:

One of the most precious assets a company has is its brand and reputation among its stakeholders and society as a whole. Accidents can cause irreparable damage to the corporate image, and it is difficult to assess this damage in financial terms due to its intangible nature. Therefore, concern for the sustainability and perpetuation of the organization involves concern and mitigation of potential business risks. Investing in preventive methodologies is a reinforcement of the ethical, sustainable positioning and concern for its micro-environment (employees, environment, society).

CARE in practice

The CARE method in question is at a very mature stage and is currently being developed in different clients of the company, allowing for greater control in Asset Management.

This service is applicable in plants of different sizes and processes that involve a range of structures and equipment such as belt conveyors, wagon turners, forklifts, reclaimers, transfer houses, buildings, among others.

The aim of its implementation is to guarantee the maintenance of Structural Integrity and the control of assets covered by CARE, acting on existing non-conformities, predicting possible occurrences of undesirable events and extending useful life in accordance with the best engineering practices.

In order for equipment to achieve the expected performance until the end of its useful life, it is necessary to identify relevant aspects that involve a series of events related to the asset's life cycle, from its operation to its maintenance plan. 

To illustrate what has been explained above, here are the main phases that make up the CARE methodology:

• Structural Integrity maintenance audit  

Its aim is to audit the existing Structural Integrity inspection, planning and execution processes, as well as related processes that influence the integrity condition of assets, such as detective, sensitive and predictive inspection routines that contribute to their preservation and good operating conditions. The items checked by the Audit take into account the requirements of ISO 55.001 and good engineering practices, in both the management and technical dimensions.

• Inspection of assets

To check the condition of assets, one of the methods initially applied is to carry out sensitive structural inspections. This can be done at âvisual and with the aid of non-destructive tests (liquid penetrant, ultrasound, magnetic particle) to identify discontinuities that are not perceptible to the human eye, such as internal cracks and weld flaws. If any deviation is classified as critical, emergency action can be taken to act immediately and prevent structural collapse.

• Civil, structural and mechanical checks

This is usually the longest stage of the study, which involves using technical engineering knowledge combined with computer resources to carry out checks on steel, civil and mixed structures, as well as checking the main mechanical components. Most cases involve computer simulation using the Finite Element Method (FEM).

• Monitoring

Occasionally, it is necessary to acquire data in the field to verify the behavior of the structure in the operating condition to which it is subjected. Various techniques are used for this, such as the installation of strain gauges to obtain stress/strain and monitoring the vibration condition, either by installing an accelerometer or by using trationing.

• Proposing solutions

Once the non-conformities have been identified and analyzed, solutions are proposed that are in line with the client's needs. Alternatives can be discussed in terms of cost, efficiency and implementation time to assist in the decision-making process. In general, drawings are provided for the reinforcements and/or modifications required to maintain Structural Integrity. 

• Monitoring the implementation of solutions

In order for the Structural Integrity assets to be achieved, in accordance with the recommended standards, and for risks to be mitigated, the correct installation of modifications or reinforcements is necessary. Incorrect practices are common when reinforcing, for example, which can represent a major structural risk. The main literature on the subject recommends that this service be carried out under the supervision and monitoring of structural specialists, thus avoiding the incorrect practices mentioned above.

Ideally, the six steps presented should be carried out to increase the reliability of Structural Integrity. Any deviations identified and resolved by an efficient Structural Inspection , for example, may not be sufficient on their own if maintenance planning is not adequate to monitor and act on the critical points mapped.

For various reasons, it's not always possible to work on all the fronts envisaged by the methodology. Kot therefore seeks to understand the specific needs of each client and work on the stages appropriate to each situation. Contact our team for more information!

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