Sustainability of Infrastructure: A Crux of India’s growth
By Dr. Anand Kumar Tewari, Former Executive Director Indian Oil, Pipelines Division; Chairman AMPP India (Formerly NACE) and Member Governing Council of Natural Gas Society
Infrastructure landscape
India has witnessed an accelerated growth trajectory for more than a decade. The unprecedented development is associated by majors’ sectors of industry like transport sectors, power and renewable energy, Oil & Gas, Defense production, Fertilizer, Chemicals, Petrochemical, Steel and Cement etc. India is prioritizing infrastructure growth to become a $5 trillion economy soon and a developed nation by 2047. India’s infrastructure sector is all set to become the biggest driver for the country’s economic growth, with plans to invest ₹ 143 trillion on infrastructure between 2024 and 2030. World longest highway tunnel “Atal Tunnel”, world’s highest railway bridge at Chenab River, world’s tallest Statue, Asia longest tunnel, Atal Setu over sea at Mumbai, vital bridges recently built in NE region, are only few examples of infrastructure marvel. Besides creation and modernization of new airports, modernised trains like Vande Bharat, Expansion of Gas Pipelines distribution system, creation of hydrogen eco system, creating space for bio fuels, ethanol, coal bed methane, coal gasification projects etc. The Government of India has embarked upon an ambitious journey to revolutionize the country’s infrastructure landscape, aiming to bolster economic growth, enhance connectivity, and improve the quality of life for its citizen. With a focus on modernizing transportation networks, upgrading urban amenities, and expanding digital infrastructure, the government has launched several transformative initiatives. From the development of highways, railways, and airports to the promotion of waterways and ropeway systems. The efforts are aimed at fostering inclusive and sustainable development across the nation. To foster economic growth and development, government has allocated Rs 11.11 lakh crores towards capital expenditure (3.4% of GDP). Government has repeatedly emphasized its commitment and focus on creation of world-class, excellent-quality infrastructure assets. These crucial assets are being funded through high component of debt and equity, hence sustenance of these infrastructure is essential , not only through its designed life but much beyond. This is not only for driving out the economic value from asset but also providing continued, safe and unhindered intended service to nation through its fitness and longevity.
Role of Carbon steel / metals and corrosion susceptibility
Metals in alloyed forms particularly Carbon Steel (CS) and its derivatives occupies larger share in infrastructure development be it railways, bridges, ropeways, tunnels, marine / off shore. Oil & Gas Pipelines, tankages, Chemicals, refining industries etc. In my professional journey I have learnt that while larger emphasis is made by project owners, for exclusive engineering design, adoption of best engineering specifications , quality materials, construction practices and design validation etc. However, at several occasions particularly during expeditious completion of projects, in time overshot projects, compromise are made, either in terms of quality of execution, inadequate placement of skilled or certified work force by executing agency, or adopting short cuts in inspection & testing. This invariably leads quality issues which turn experiences in-service failure of structure, thus causing at times loss of precious human life and property besides shadowing the reputation of project proponent. There are numerous examples of several bridge collapse before even inauguration. Roof collapse, roads caves in , tunnel collapse etc.
The metal particularly carbon steel is critical common element of infrastructure be it truss at airport canopy, reinforcement bars, structures, column, shed, bridges pipeline network etc. The metal is refined after extraction from their ore state and brought into high energy state, it has tendency to go back to least energy state of ore, through process of corrosion because of interaction with environment.
Corrosion is worst known enemy of the metals and carbon steel in particular, often refers as unavoidable but impact can certainly minimised. It affects nearly all the engineering metals and non-metal to some extent. So corrosion mitigation assumes greater significance in any structural element and required to be addressed, right from engineering design stage. The corrosion affects irrespective of geography. However, India’s corrosion maps development was undertaken by CECRI Karaikudi in the past, indicates that while the Indian coastal region is high corrosion prone but hinterland too has many corrosive areas due to high level of pollution, effluents discharges, high salinity, acidic soil, emissions of all kinds etc.
Sustainability of Asset
Sustainable asset management involves strategically maintaining assets to maximise the asset’s useful life. Sustainable asset management and maintenance practices can decrease operating costs and create efficient & profitable organizations through effective leverages from asset .
The approach to sustainability required right from its design stage to execution stage and then through entire life cycle of an asset. This requires clarity in thought process, deployment of skilled and experienced designer, trained and skilled gross root level work force, certified and qualified personnel for construction monitoring /inspection.
The three vital pillars of sustainability are economic, environmental, and social. The asset are crafted to meet these obligations, Once asset is created planned operation and maintenance strategy drives asset, through its designed and extended life. For example the Oil & Gas Pipeline designed life is 25 years but India is still efficiently operating more than six decades old buried Oil pipelines, similar is case with railways, shipping, power, transport and other industries where age old assets are performing effectively. However, man behind the machine is vital and updated knowledge, skilling, up-skilling and re-skilling, of work force is essential for adoption of economic means for prolonged sustainability of assets.
Corrosion Management
Corrosion process is a biggest enemy of metals, which is however, inseparable part of infrastructure. Metal if not protected properly, has tendency to corrode thus weakening the structure of application, be it railway bridges, road bridges, tunnels, concrete structure, process columns, heat exchanges, vessels coastal areas jetty, marine infrastructure or buried pipelines and tankages etc. all are affected by severity of corrosion. As per India specific study undertaken by National Association of Corrosion Engineer (NACE) a US body for corrosion standards, the corrosion cost is approximately 4% of GDP. As per steel industry estimates it costs around $100 billion annually. A fastest growing economy, India can ill afford such huge cost due to corrosion. The studies indicated that out of new steel produced in country almost 15-20 % is utilised against replacement of corroded steel structure. Steel industry is one of the most carbon emitting industry. The steel industry in India is responsible for 10 % of total Carbon-di-oxide emission. The additional steel production for offsetting the corroded steel, thus significantly affect the environment and our eco system.
The emerging research and latest technological developments have created an eco-system for prompt identification of corrosion potential, real time monitoring and development of corrosion resistant materials, substitute of metals eg FRP pipes in place of steel pipe, advanced coating and paints. However, corrosion still continues to be dominant reason of premature failure of structure. Hence management of corrosion requires simultaneous focus on various protocol
- Adherence to proven design codes for design and materials selection, fabrication like MPP (NACE) , API ,ASME, Canadian and other standards bodies , DNV, OISD , PNGRB
- Skilling work force and mandatory certification for executing work force , in line with codes / standards like NACE Certified Coating Inspector for Coating Paining , Cathodic Protection certified professionals for managing CP system of underground buried assets . Including professionally qualified team for handling latest challenges like AC/ DC transmission lines interference and impact on buried infrastructure
- Deployment of professionally qualified / certified work force for inspection during execution, design validation during execution and post execution the various training and certification bodies like AMPP India (Formerly NACE) India, Corrosion Management Division of CII, Central Electro Chemical Research Institute (CECRI), Karaikudi, IITs, Hydrocarbon Council of India, Few Petroleum Universities , Leading Oil & Gas Public Sector Undertakings
- Certified professional for Operations, Maintenance and inspection of assets on defined periodicity as per guiding codes/ standards and regulatory framework
- Development Of latest corrosion resistant materials like Corrosion resistant steel, growing application of, SS FRP Pipelines, HDPE and MDPE pipes, Selection of materials based on corrosiveness of area like jetty’s, LNG Infrastructure , marine and shipping industry in coastal areas
- Monitoring and Mitigation of Assets through latest technology-based system like LPR. EN probes for process, sensors and GPRS system, AI enabled tools for real time monitoring. Modelling and simulation etc.
- Regulatory Frame work, to ensure strict compliance of quality work through mandatory training, certification, competency mapping
Skill Development
In the developed world and also in middle-east Asia, valid certification is prerequisite for engaging in any workforce for engineering work execution like Coating Inspector for coating painting, Tank credited professional for oil tanks, blasters for metal surface preparation, Cathodic Protection experts for O&M of CP system, Welders for high pressure welding and structure fabrication etc. Accordingly executing agency’s have obligation of placement of only certified and trained workforce at grassroot level.
In India the regulators Oil & Gas mid and downstream regulator Petroleum and Natural Gas Regulatory Board (PNGRB) is known for development of strict guidelines. The regulations are periodically revised for its relevance to changing environment of industry. It provides the framework to asset owners for guidance and strict compliance. However, often skill of working force is not mandated or strictly enforced. Hence Inspection agency takes leverage of engaging cheaper work force rather than hiring certified and experienced personnel. This results in quality compromise in execution, inspection, testing and supervision, which has direct impact on the asset’s life. Additionally, the asset owner’s obligation of periodic inspection and validation is done to meet regulatory compliance. But done often through hired agencies on lowest quotation basis, and obviously results in compromises rather than reflection of true condition.
In our professional journey, ISO quality certification was accepted with reverence. This India adopted in mid-nineties as hallmark of Gold today , but ISO 9000 could not sustain the test of time, mainly due to dilution in quality auditing manpower , cheaper alternatives etc. I have cited Oil & Gas example above as being from same industry. However, similar is the case with other regulatory bodies, though intension is fully sacrosanct but spirit of implementation has own limitations due to ground realties, which also includes ethics of personnel at front end.
Conclusion:
The infrastructure being built at high-cost for country’s development. sustenance of same is essential for leveraging full benefits through its entire life cycle. The compromised quality, poor workmanship, inadequate protection from corrosion, deviations from standard protocol etc are one aspect of asset’s life deterioration. The infrastructure is required to be equally protected from other enemies like natural calamities, cyber-attacks (Colonial Pipeline cyber-attack in US ) , manmade disasters, public agitations etc. As citizen it is responsibility of all and most importantly “the user”. We look forward to see or Gen NEXT to see India as developed world. Thus the on-going process of asset creation, calls for greater awareness of poor quality consequences, development of attitude for quality and no compromise to standards, our aligned ethical behavior and adoption of all feasible means for prolonged, sustainable, safe and economic life of asset in Atma Nirbhar Bharat.
