{"id":81980,"date":"2017-10-16T00:00:00","date_gmt":"2017-10-16T00:00:00","guid":{"rendered":"https:\/\/www.corrosionpedia.com\/2017\/10\/16\/elemental-strategies-of-coatings-asset-management-terry-greenfield-qa"},"modified":"2017-10-15T11:43:22","modified_gmt":"2023-12-09T18:54:43","slug":"elemental-strategies-of-coatings-asset-management-terry-greenfield-qa","status":"publish","type":"post","link":"https:\/\/www.corrosionpedia.com\/2\/6653\/corrosion-prevention\/paints-and-plastics-coatings\/elemental-strategies-of-coatings-asset-management-terry-greenfield-qa","title":{"rendered":"Elemental Strategies of Coatings Asset Management: Terry Greenfield Q&#038;A"},"content":{"rendered":"<p><i>A <a href=\"https:\/\/www.corrosionpedia.com\/definition\/1255\/national-association-of-corrosion-engineers-international-nace\">NACE International<\/a> instructor and trainer in corrosion assessment, <\/i><i><a href=\"old.corrosionpedia.com\/contributors\/d-terry-greenfield-pcs\" target=\"_blank\" rel=\"noopener\">Terry Greenfield<\/a><\/i><i> has 40 years\u2019 experience in protective coatings across the marine, oil &#038; gas, transportation, military and other sectors. Through his company, <\/i><a href=\"http:\/\/www.corrometrics.com\/\" target=\"_blank\" rel=\"noopener\"><i>CorroMetrics Services, Inc.<\/i><\/a><i>, he currently provides program and project management, quality assurance, condition assessment, maintenance planning, specification development, and failure analysis. <\/i><\/p>\n<p>A proactive coatings management program collects condition data on every item in facilities in order to make smart decisions on maintenance. The key goals are to extend the <a href=\"https:\/\/www.corrosionpedia.com\/definition\/1789\/service-life\">service life<\/a> of coatings, reduce costly unexpected downtime incidents, and increase safety of operations. In this Q&#038;A, Terry Greenfield explains how facility managers often approach coatings and corrosion management in reactive ways that can lead to higher long-term costs and introduce undue risks to asset integrity, safety and the environment. <\/p>\n<p><strong>Q: How can facilities change this paradigm?<\/strong><\/p>\n<p><strong>A: <\/strong>The first step is to develop a strategy &#8211; a philosophy if you will. What are you trying to achieve? Some programs, even if they are trying to be proactive, are ultimately driven by how much money they have. <\/p>\n<p>There\u2019s a great story that illustrates this. After the Deepwater Horizon spill, the U.S. Minerals Management Service agency was restructured as the Bureau of Ocean Energy Management, Regulation and Enforcement (BOEMRE) and the Bureau of Safety and Environmental Enforcement (BSEE), which now has oversight for offshore platform operations. Before that time, I worked with those guys on inspection training for NACE International. We were talking with their head of structural engineering, and he said they had a simple A-B-C rating system for asset condition that owners were required to report to the MMS: <\/p>\n<ul>\n<li><strong>A<\/strong> \u2013 they don\u2019t have to do anything within 3 years<\/li>\n<li><strong>B<\/strong> \u2013 they have to do something within 3 years<\/li>\n<li><strong>C<\/strong> \u2013 they have to do something within 1 year <\/li>\n<\/ul>\n<p>This is the most fundamental condition assessment: A is good, B is generally OK (but plan now for some maintenance), and C is that there is a problem that has to be dealt with (and plan to address it this year). <\/p>\n<p>The MMS engineer and one of the owners were having a conversation and the engineer said, \u201cI\u2019ve looked at your surveys, and you have all Bs, but I\u2019ve seen your platforms, and you\u2019ve got some Cs.\u201d The owner replied, \u201cBut I don\u2019t have any money. If I report Cs, I have to have money to deal with it, so I\u2019ll make them all Bs.\u201d <\/p>\n<p>That\u2019s the opposite of the proper approach. The object of a good program is to deal with the issues and not be driven by funding. If there isn&#8217;t a well-understood and well-engineered program, then it will just be budget-driven. Therefore, you may not have enough money to do what\u2019s really required to have an effective program. <\/p>\n<p>So those are two things that don\u2019t track when people say they have a coatings program, and both are purely reactive. One is driven by degradation; the other is driven by available funding. Neither of these will end up being ultra-successful. <\/p>\n<p>Therefore, the approach to success is to really look at the assets to understand the life cycle of the coatings. <\/p>\n<p>What\u2019s expected? We look at specifications and how to pick the right coatings for the particular asset: environment, service life, etc. Ultimately, when we make those decisions, we\u2019re considering the <a href=\"https:\/\/www.corrosionpedia.com\/definition\/1408\/service-exposure\">service environment<\/a>, where that asset has to live, and then we look at the type of <a href=\"https:\/\/www.corrosionpedia.com\/definition\/2270\/paint-system\">coating system<\/a> based on the expected life per the owner\u2019s expectations. Do they want it to last five years, 15 years, 20 years? The coating system decision is made accordingly. <\/p>\n<p><strong>Q: How do you &#8220;fix&#8221; coating systems that are nearing the end of their service life?<\/strong><\/p>\n<p><strong>A: <\/strong>This is where the reality of the situation becomes backwards. People are so driven to look at what\u2019s bad and the worst, they may miss the opportunity to extend the <a href=\"https:\/\/www.corrosionpedia.com\/definition\/2917\/life-cycle-assessment\">life cycle<\/a> of other old coating systems.<\/p>\n<p><strong><\/strong>This sounds counter-intuitive; having structures that are marginal may look really horrible, but in reality they are still performing. It may be a case where there is no risk of operational issues, safety issues, or anything else &#8211; they just look really bad. At the same time, you may have other areas where you could use this year\u2019s budget to do spot repairs and <a href=\"https:\/\/www.corrosionpedia.com\/definition\/2463\/overcoating-corrosion\">over coating<\/a>, thereby extending their coating life out maybe another 10 years. <\/p>\n<p>So in a well-understood program, we\u2019re not going to spend the money on the worst-looking areas; rather, we\u2019ll repair other assets where we have the opportunity to capture a large portion to push out for a longer service life, while always keeping safety and operational integrity at the forefront. <\/p>\n<p>But how do you go to your managers and say: \u201cHey, I\u2019m not going to paint that ugly thing you see every day on your drive into the plant. I\u2019m not going to deal now with that with the money you gave me this year. I\u2019m going to wait until next year. Here\u2019s why that\u2019s going to be a better approach\u201d?<\/p>\n<p>These are extremes. But this puts the finger on a necessary philosophy to develop what you\u2019re truly trying to achieve: longer service life from your coatings. However, most people don\u2019t grasp this, because it\u2019s counter-intuitive.<\/p>\n<p><strong>Q: What are some other basics to launching a successful coatings program?<\/strong><br \/><strong>A: <\/strong>For a program to be successful, it has to have corporate buy-in at the highest levels. They need to say, \u201cWe\u2019re going to develop a Coatings Asset Management program because we can save money, look better to our customers, and we can proactively address conditions in order to not have problems.\u201d<\/p>\n<p><strong><\/strong>If you look at five facilities and they were all rated Cs, then the objective every year would be to raise that rating. If all of the facilities are Cs, then the composite score is C. So the next year you do some work and have a few that are Bs, which means you raise your composite score to C+. <\/p>\n<p>The goal is to raise that grade every year while being safe and maintaining integrity, and while all operation issues are addressed. Then the program isn\u2019t ultimately just about plugging the dyke. It\u2019s about stepping up; where you\u2019re using the money in the best way you can to elevate your composite grade at all of your facilities on an annual basis. <\/p>\n<p>You may have to invest more in the beginning, but over a period of time, a good program can pay for itself. I\u2019ve got some graphs where you start to see a flat line where there\u2019s some incremental costs, but not all these huge spikes after major asset refurbishment costs. Instead of having to completely blast and paint an offshore platform every 7 years, you figure out how to make it go 15 years. <\/p>\n<p>There are two cases to illustrate that in the offshore industry: <\/p>\n<ol>\n<li>We were working with one of the offshore majors, and putting a program together for them. They told us, \u201cYou know, our program is real simple. Right now, it\u2019s every 7 years we just blast and our platforms get a new paint job.\u201d The question is: how much money would he save if he could get it to 12 years? <\/li>\n<li>I did surveys on two offshore platforms in the South China Sea about 8 years ago. This was a joint venture project involving a U.S. major, and they did everything right: They had a program, they made good coating selections, used qualified people and NACE-certified coating inspectors, and when they built it, they did it right. They installed the coating and from the day it was installed, every year they would send out a maintenance crew. <a href=\"https:\/\/www.corrosionpedia.com\/definition\/940\/proactive-maintenance\">Proactive maintenance<\/a> was dialed into their annual program. So when I looked at the platforms after 12 years\u2019 service, they could have stopped doing another thing and gotten another 8 years out of their coatings. Their program included hand and power tools only (no <a href=\"https:\/\/www.corrosionpedia.com\/definition\/21\/abrasive-blasting\">abrasive blasting<\/a>); they just had a five-man crew out for a few weeks every year doing spot repairs. <\/li>\n<\/ol>\n<p>So their philosophy was pretty simple: \u201cWe\u2019ve learned a lot of lessons, let\u2019s do it right. We know there will be facility modifications; we know we\u2019re going to have damage to the coating system, so we\u2019ll bring somebody out once a year to do structured maintenance. We\u2019re going to accept that it was money well spent.\u201d So in the long run, they may be able to go 20 years without any major refurbishment. This program was in addition to the required annual surveys.<\/p>\n<p>How much money can a program like this save? Spread over 20 years, it would be less than 5 percent of the cost of doing those seven-year total refurbishments. <\/p>\n<p><strong>Q: Have you seen a coatings program that was the absolute ideal &#8211; cradle to grave?<\/strong> <\/p>\n<p><strong>A:<\/strong> Kennedy Space Center had a great program. The problem they had for a long time was the shuttle launch structures. They are located in an aggressive seacoast environment, and when the solid rocket booster went off, the exhaust residue produced an acidic environment. Then they used deluge water so they had all the acidic fallout in solution with water. A really aggressive corrosion environment. <\/p>\n<p>But more than anything, think about what they were doing. They were responsible for a launch structure with people on board the shuttle craft, and expensive equipment. <\/p>\n<p>They had all these problems and their program solved them. They were so dialed in to proactively managing their coatings and they used a software program to manage it. With coatings asset management, you have to have a tool to manage all the myriad complex things you\u2019re looking at over time. Costs and deferred costs. Problems to address. They needed to see it all and make decisions that would give them more bang for the buck. <\/p>\n<p>Coatings and corrosion degradation isn\u2019t linear; it\u2019s exponential. So if I look at seven items and determine what my degradation level will be next year, and the year after, I can figure what the associated costs would be. It may turn out to be three or four times the cost if we don\u2019t address the problems this year. <\/p>\n<p>BASE.COAT<sup>T<\/sup> allowed them to be dialed in, up to the highest level of detail. Everything had to have a green light from the software that the tower was dead-on and everything was good for launch. <\/p>\n<p>Before developing a corporate philosophy on how to manage the complexities, I don\u2019t think anyone really understands the details. But with the software, the numbers are in black and white on paper. <\/p>\n<p>It wasn\u2019t just Bob or Peggy trying to pitch their case. At that point in time, they started to see that the coatings <a href=\"old.corrosionpedia.com\/definition\/47\/asset-management\">asset management<\/a> budget needed to have a certain value. With the data in hand, they were able to get the money they needed to do it effectively. In the long term, it was much more efficient and saved a lot of money for the agency. <\/p>\n<h2 id=\"conclusion\">Conclusion <\/h2>\n<p>Coatings asset management starts with a proactive philosophy and a high-level decision to take responsibility for the integrity of every item in a facility. Doing this over a period of time can extend coating life cycles and maximize uptime, which in turn provides greater returns on coating installation investments. Software solutions are often needed to keep tabs on the vast details involved in monitoring and maintaining facility-wide coatings and their associated costs. In the next articles in the series, we will look at the seven fundamental components of a coatings asset program. <\/p>\n<p>***<\/p>\n<p><strong><u>More in the <strong>Coatings Asset Management Best Practices<\/strong> s<\/u><\/strong><u><strong>eries:<\/strong><\/u><\/p>\n<p><a href=\"https:\/\/www.corrosionpedia.com\/2\/1783\/corrosion-prevention\/corrosion-management\/what-is-coatings-asset-management-terry-greenfield-qa\">What is Coatings Asset Management? Terry Greenfield Q&#038;A<\/a><br \/><span class=\"redactor-invisible-space\"><a href=\"https:\/\/www.corrosionpedia.com\/2\/1821\/prevention\/monitoring\/8-fundamentals-of-a-good-coatings-program\">8 Fundamentals of a Good Coatings Program<\/a><br \/><span class=\"redactor-invisible-space\"><a href=\"https:\/\/www.corrosionpedia.com\/2\/1917\/corrosion-prevention\/paints-and-plastics-coatings\/how-to-plan-facility-coatings-condition-assessments\">How to Plan Facility Coatings Condition Assessments<\/a><\/span><\/span><\/p>\n","protected":false},"excerpt":{"rendered":"<p>A NACE International instructor and trainer in corrosion assessment, Terry Greenfield has 40 years\u2019 experience in protective coatings across the marine, oil &#038; gas, transportation, military and other sectors. Through his company, CorroMetrics Services, Inc., he currently provides program and project management, quality assurance, condition assessment, maintenance planning, specification development, and failure analysis. A proactive [&hellip;]<\/p>\n","protected":false},"author":11640,"featured_media":81981,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"topic":[2987,2940,2921,2948,2912,2908,2928,2930],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v20.3 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Elemental Strategies of Coatings Asset Management: Terry Greenfield Q&amp;A<\/title>\n<meta name=\"description\" content=\"Elemental Strategies of Coatings Asset Management: Terry Greenfield Q&amp;A\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.corrosionpedia.com\/2\/6653\/corrosion-prevention\/paints-and-plastics-coatings\/elemental-strategies-of-coatings-asset-management-terry-greenfield-qa\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Elemental Strategies of Coatings Asset Management: Terry Greenfield Q&amp;A\" \/>\n<meta property=\"og:description\" content=\"Elemental Strategies of Coatings Asset Management: Terry Greenfield Q&amp;A\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.corrosionpedia.com\/2\/6653\/corrosion-prevention\/paints-and-plastics-coatings\/elemental-strategies-of-coatings-asset-management-terry-greenfield-qa\" \/>\n<meta property=\"og:site_name\" content=\"Corrosionpedia\" \/>\n<meta property=\"article:published_time\" content=\"2017-10-16T00:00:00+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2023-12-09T18:54:43+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.corrosionpedia.com\/wp-content\/uploads\/2023\/10\/gear-machine-spoke-wheel-oilfield-dock-pier-transportation-vessel-wate.jpg\" \/>\n<meta name=\"author\" content=\"Alan Kehr\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:title\" content=\"Elemental Strategies of #Coatings #AssetManagement - 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