The Silent Culprits of Industrial Operations: Corrosion and Erosion

Did you know? In a study by NACE International, corrosion costs the global economy approximately $2.5 trillion annually, or 3-4% of the world’s GDP. This staggering figure highlights the immense importance of addressing these issues before they escalate.

What is Corrosion and Erosion?

Corrosion is the gradual degradation of materials, usually metals, due to chemical reactions with environmental elements like water, oxygen, or chemicals. It primarily affects equipment, pipelines, and structural components, often leading to leaks, failures, and catastrophic accidents.

Erosion, on the other hand, refers to the physical wear and tear of materials due to mechanical forces such as fluid flow, abrasive particles, or high-velocity gas. It's commonly seen in pipelines, valves, and reactors.

Both corrosion and erosion significantly reduce the lifespan of assets, increase the risk of safety hazards, and drive up maintenance costs. Without proper assessments, industrial plants are vulnerable to unexpected breakdowns, unplanned shutdowns, and safety incidents that can affect both human and environmental health.

Why Corrosion and Erosion Assessments Matter

1. Minimizing Unplanned Downtime: One of the main reasons companies invest in corrosion and erosion assessments is to avoid unplanned shutdowns. For example, in oil refineries, a small undetected crack due to corrosion in a pipeline can lead to a leak or explosion, resulting in a significant loss of production, severe safety hazards, and environmental damage. Regular assessments can identify vulnerabilities early, reducing the risk of these costly and dangerous incidents.
2. Enhancing Safety: Safety is always a priority in industries like petrochemical plants, where equipment and pipelines carry hazardous chemicals under high pressure. Corrosion can weaken the structural integrity of critical assets, leading to potential leaks, explosions, or fire risks. Routine inspections for corrosion and erosion enable industries to maintain safety standards and prevent accidents that could harm workers, the environment, and the surrounding communities.
3. Cost-Efficiency: It’s no secret that proactive measures are far more cost-effective than reactive ones. According to Corrosionpedia, corrosion prevention strategies can save companies up to 50-70% of the maintenance cost compared to reactive repairs. By investing in regular corrosion and erosion assessments, industries can avoid costly repairs, replacements, and insurance claims in the future.
4. Increasing Asset Life Expectancy: Equipment and infrastructure can last much longer when corrosion and erosion are properly managed. Consider a chemical processing plant where tanks and pipes are constantly exposed to corrosive substances. Without routine assessments, these components could fail prematurely, forcing costly replacements. By continuously monitoring these assets, companies can extend the life expectancy of their equipment, saving millions over time.

Real-World Incidents and Their Impact

• The Deepwater Horizon Oil Spill: One of the most catastrophic examples of how unchecked corrosion and poor maintenance can lead to disaster is the Deepwater Horizon oil spill in 2010. The explosion, caused by a blowout due to faulty equipment, was exacerbated by corrosion in the drilling pipeline. The result was not only a $61.6 billion cost to BP but also irreversible environmental damage and loss of life.
• The Collapse of the Algo Centre Mall: Another example occurred in Canada, where the Algo Centre Mall partially collapsed in 2012 due to corrosion of the steel beams supporting the building. This incident highlights the importance of regular structural inspections in ensuring safety and preventing disaster.

Global Trends in Corrosion and Erosion Management

Industries worldwide are recognizing the significance of proactive corrosion and erosion management. According to the World Corrosion Organization, the global corrosion management industry is projected to grow at a compound annual growth rate (CAGR) of 5.2%, reflecting increasing awareness and regulatory push across various sectors.

Smart Technologies are making a significant impact. With the rise of IoT-based monitoring systems, corrosion and erosion assessments can now be performed in real-time. Sensors are attached to critical assets, constantly tracking changes in pressure, temperature, and material integrity. This data-driven approach helps companies stay ahead of potential failures, offering a cost-effective, real-time solution to maintenance.

Conclusion: Protecting the Future of Industry

Corrosion and erosion are natural but highly destructive processes that can cause significant damage to industries. By investing in regular assessments, companies can reduce risks, prevent costly downtime, enhance safety, and extend the life of their assets.

Ignoring corrosion and erosion will only lead to higher costs and increased risks. As industries across the world are moving towards more sustainable and efficient practices, proper management of these issues is no longer optional — it’s essential.

APS Group provides comprehensive inspection services to evaluate the condition of equipment and infrastructure, helping businesses maintain safety and reduce operational risks.