In general, structural risk management in large industrial environments requires a systematic approach that integrates inspection, technical analysis, and reliability-based decision-making. In this context, the CARE methodology emerges as a tool applied to the assessment and revitalization of critical assets, especially in scenarios of high operational severity, such as port terminals. Throughout this article, a Succes story is presented Succes story demonstrates the practical application of this methodology, highlighting gains in safety, physical availability, and operational reliability. Continue reading to learn more.

Introduction

In general, it is known that risks are inevitable in any type of business. In this sense, especially from the perspective of large-scale industrial bulk handling structures and equipment, it is essential to have efficient risk management. In this context, however, even if the occurrence of a given event may be low, the consequences are usually high.

First, one of the steps in the risk management process is risk identification [3]. In the context of Structural Integrity, risks mainly arise from three contributing factors, namely:

• • Inadequate design of a structure or piece of equipment. In this case, the asset has already been designed with an associated risk;

• • Condition of the equipment or structure in the field: degradation mechanisms, cyclical loads, improper use of the equipment and extreme weather events are factors that can compromise the resilience and structural safety of the asset [4];

• • Improper maintenance of assets. Equipment requires a series of procedures for its maintenance and durability. When this process is not properly executed, it becomes another source of risk to be considered.

Therefore, based on this identification, management should consider an analysis and then define strategies for the proper control of offenders. In this scenario, therefore, the CARE methodology: Asset Control for Structural Revitalization, created by Kot Engenharia, is a tool that combines the fundamentals of the main references in risk and asset management to provide operational safety for equipment. The stages of the CARE methodology are presented in Figure 1:

 

Therefore, this article aims to clarify the application of all stages of the methodology created by Kot and showcase the gains in reliability and security for operations at one of its clients.

The Succes story about one of Brazil's leading port operators for iron ore exports. Port logistics systems must have high physical availability to meet the supply needs of ships while dealing with a severely corrosive environment. Consequently, this context, when associated with existing machinery and structures that are exposed for long periods without proper maintenance of Structural Integrity results in operational losses caused by emergency corrective shutdowns.

Structural Integrity maintenance audit

Maintenance is a combination of technical and administrative actions, including inspection and supervision, aimed at maintaining or adapting an item to its required assignment [1]. For Structural Integrity, maintenance aims to prevent failures or other compromises at the level of equipment, civil or metallic constructions. These stages range from inspections to the installation of reinforcements or renovations.

For this reason, in an environment where degradation mechanisms are present, maintaining Structural Integrity a fundamental role in establishing adequate risk levels for the continuity of operations. Thus, Kot Engenharia the first stage of implementing the CARE methodology at the port terminal: auditing the Structural Integrity maintenance processes.

The audit process consisted of visits and monitoring of daily maintenance activities, interviews with employees, and a thorough analysis of documentation regarding assets and their maintenance plans. This work identified vulnerabilities in the client's internal process and then provided detailed recommendations to ensure procedures capable of preventing undesirable scenarios that could lead to loss of life, financial losses, damage to the environment, and even reputational losses [2].

Inspection of assets

In addition, a key step in the CARE methodology is the inspection of assets. During the 10-month on-site monitoring period, 100% of the 26 structures that make up the port terminal's production process were inspected. Thus, at this stage, any critical non-conformities were promptly addressed.

Inspections were carried out visually and sensitively, complemented by non-destructive tests such as ultrasound and liquid penetrant. During this stage, shown in Figure 2, structural non-conformities are identified, such as: paint degradation, corrosion, deformations, cracks, as well as other non-conformities visible to the naked eye.

 

Detailed inspections, using non-destructive testing, were carried out at key locations, identifying possible structural non-conformities that could not be detected by visual inspection. Figure 3 shows an ultrasound test being performed on a high-responsibility weld, as in Figure 4, where the penetrant test was able to detect a crack with a high potential for collapse. Therefore, these timely detections are critical to Structural Integrity business safety.

 

 

Structural verification of projects

Structural (metal and concrete) and mechanical design checks were then carried out on all 26 of the port terminal's assets. The design checks involve the use of technical engineering knowledge, combined with computer resources to check against regulatory criteria, in order to ensure that the assets adhere to a level of risk considered acceptable.

The structural verification process consists of an evaluation stage of all the asset documentation, followed by the preparation of a computer model using finite element software . As an example, Figure 5 shows the finite element model of a bucket wheel reclaimer, responsible for extracting material from the product stacks and loading it from the shipping line to the loading pier.

 

In the computer model, the material properties, geometric properties and boundary conditions are defined, such as the constraints and acting loads. The verification analyses are then carried out, such as the acting stress analysis (Figure 6) and the local buckling analysis (Figure 7), which were used to evaluate the bucket wheel reclaimer.

 

 

The results of the structural analysis are taken as the basis for defining the strategy for adapting and revitalizing the asset. Factors such as the criticality of the failures, the likelihood of an undesirable event occurring and the possibility of adopting immediate prevention and/or mitigation measures should be taken into account until the intervention strategy has been defined and duly implemented.

Monitoring

Whenever structural analysis indicates the need for monitoring or field confirmation of the actual need for reinforcement, data acquisition techniques can be employed. Figures 8 and 9 illustrate a situation in which it was necessary to calibrate the computational model based on the methodology of obtaining stresses/strains using extensometers.

 

 

In this way, the data collected in the field for the different operating regimes are compared with the numerical results obtained via the computational model, indicating the need for calibration and adjustments in the calculations to represent the field conditions with greater accuracy.

Proposing solutions

In cases where structural analysis, monitoring or inspections indicate the need for structural intervention in the equipment, the best reinforcement alternatives are evaluated, taking into account aspects such as cost, efficiency, time and risk in the implementation process. For the design non-conformity identified in Figure 6 and Figure 7, at the bucket wheel reclaimer portal, the reinforcement shown in Figure 10 below was proposed:

                                                                                          Figure 10: Example of a Structural Reinforcement proposal.

Monitoring the implementation of solutions

As part of the support provided by Kot for the structural revitalization of the assets, in addition to designing the reinforcements, on-site monitoring of the installation was carried out. In this way, it is possible to assess adherence to regulatory requirements, and consequently the effectiveness of the proposed reinforcement. Figure 11 shows the location of the reinforcement previously shown in Figure 10. Figure 12 shows the monitoring and validation of the implementation of the reinforcement by means of the non-destructible liquid penetrant test.

 

 

Conclusion

In summary, the example presented of Structural Calculation, reinforcement proposal, and monitoring is just one example of the CARE methodology implemented at the port terminal. Finally, all 26 assets responsible for handling material, from receipt to shipment on ships for export, had their integrity inspected and audited, with a view to revitalizing the assets. Figure 13 shows a compilation of the actions carried out during the application of the CARE methodology.

 

The reconditioning of the 26 assets allowed for greater physical availability, resulting in a reduction in costs with emergency corrective stoppages and mitigating risks to the business and the people involved in the process. In addition, the audit of maintenance procedures resulted in the creation of a new sector within the port operator, exclusively dedicated to Structural Integrity maintenance. The creation of this new area will allow the support provided by Kot Engenharia for the reconditioning of assets to be extended to the required operating time, with the necessary maintenance.

 

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