Collaboration between Vicinay Marine and the Tecnalia technology center This has led to a new tool designed to address one of the major challenges facing the offshore industry: monitoring how steel degrades at sea. Both entities have developed a sensor that allows for close monitoring of corrosion in mooring lines, with the aim of improving the safety, reliability, and lifespan of floating installations.
The solution, initially conceived for chains and connectors of offshore wind farms and other floating offshore platformsIt uses electrical measurement techniques to provide real-time data on the wear of metallic components. This advancement aligns perfectly with the energy transition and the deployment of renewable infrastructure at sea, an area in which Europe, and especially Spain, aim to play a leading role.
A sensor designed for the most demanding marine environment.
According to both organizations, the Corrosion is a determining factor in the durability of the chains and connecting elements that keep offshore platforms anchored. The aggressiveness of saltwater, the temperature variations And the long periods of continuous service mean that, on many occasions, the forecasts made with theoretical models do not accurately reflect what actually happens underwater.
This situation creates uncertainty when it comes to sizing the components and defining the maintenance strategiesbecause it is difficult to anticipate when a link or connector may approach a critical state. Traditionally, the industry has relied on conservative calculations and periodic inspection campaignswhich are often expensive, complex and, sometimes, insufficient to detect certain failures in time.
To fill that gap, Vicinay Marine and Tecnalia have developed a sensor based on the measurement of electrical resistance of the material. Based on this variable, the system is able to estimate the loss of cross-section of the pieces exposed to the sea, model how the degradation progresses and predict the remaining useful life of each section of the mooring line.
Aintzane Expósito, head of the materials department at Vicinay Marine Innovation, emphasizes that corrosion directly affects the structural design and service life of mooring systems. Until now, he indicates, the sector relied on simulations and visual inspections or inspection equipment, while the new sensor opens the door to a continuous monitoring and more accurately describe the degradation process.
This detailed monitoring allows for better adjustment of component thickness and characteristics, preventing unnecessary oversizing and reducing the risk of unexpected failures. Furthermore, it facilitates a more refined maintenance planningThis can translate into significant cost savings and fewer unscheduled shutdowns in the medium and long term.
Validation at HarshLab and experience in extreme conditions
On behalf of Tecnalia, Raúl Caracena, head of Materials in Extreme Conditions, points out that the center has been researching for decades. advanced corrosion solutions in marine environments. For this purpose, it has specialized laboratories and HarshLab, a floating laboratory that allows technologies to be tested directly at sea, under real operating conditions.
This corrosion sensor has already been tested at HarshLab, a unique testing platform in Europe Located approximately 1,6 nautical miles from the coast, in this environment, subject to waves, currents, and the salinity typical of the Cantabrian Sea, the system has demonstrated its ability to provide continuous remote monitoring and to anticipate the future behavior of components subject to corrosion.
During testing, the sensor confirmed that it is possible to remotely detect how the cross-sectional losses of metallic elements evolve and relate that data to the remaining useful life of the mooring line. This facilitates informed decision-making, for example, when scheduling replacements before parts reach a compromised level of degradation.
Caracena emphasizes that the alliance with Vicinay Marine allows Tecnalia to apply its expertise in materials and in-service behavior to a challenge with significant industrial impact. The European offshore and naval sectors are increasingly demanding real-time monitoring technologies that contribute to reducing risks, complying with regulations and improving the competitiveness of their projects.
The development has been protected by a patent, which strengthens its potential for technological and commercial exploitation. This intellectual property protection puts both partners in an advantageous position to lead the implementation of corrosion monitoring solutions in the new generations of floating wind farms and offshore service platforms.
Key functions of the corrosion monitoring system
The new sensor is not limited to measuring, but is integrated into an approach of continuous remote monitoringThis allows for virtually real-time information on the status of supply chains and other critical components, without the need to send personnel or inspection teams to the location of the facilities.
Among the solution's key features are the reduction of complex and costly physical inspectionsThe sensor allows for adjusting predictions of the future behavior of corrosive elements and optimizing intervention planning. The information provided helps determine when action is truly necessary, preventing both premature interventions and dangerous delays.
Another advantage pointed out by its developers is the increase in the operational securityBy having continuous data and models that relate cross-section loss to the residual strength of components, it is possible to detect early signs of degradation that could lead to failure if not addressed promptly. This has direct implications for the protection of people, assets, and the marine environment.
The system also facilitates the implementation of strategies for Predictive MaintenanceThese are in high demand in the fields of Industry 4.0 and smart infrastructure. Instead of maintaining a rigid routine based on fixed schedules, operations managers can rely on real-time data to decide which component to inspect, repair, or replace, and when.
The project's promoters also point out that the electrical measurement and corrosion modeling approach offers scope for integrating the sensor with other digital tools, such as asset management platforms, data analysis systems, or digital twins, thus facilitating a global overview of the state of offshore facilities.
Applications in offshore wind energy, the naval sector and ports
Although development has initially focused on mooring chains and lines for offshore wind farms and other floating platforms, the technology's potential extends far beyond that. Corrosion is a critical problem in numerous metal infrastructures exposed to salt water or aggressive environments, both on the surface and while submerged.
Potential fields of application include projects in offshore wind powerOffshore installations of various types, naval sector structures, and elements present in ports and maritime terminals. In all these areas, being able to understand in detail how components wear down allows for improved reliability, reduced operational risks, and optimized maintenance plans.
The solution is shaping up to be a tool of interest to any agent that manages submerged or continuously exposed metallic structures to harsh environments, such as loading arms, fenders, piles, walkways, or mooring elements. Its modular nature and ability to send information remotely facilitate its integration into existing systems.
In the European context, where investment in marine renewable energy and port modernization is gaining ground, having access to proprietary monitoring technologies This contributes to strengthening industrial autonomy and generating solutions tailored to the specific conditions of the Atlantic and the Mediterranean. This can provide a competitive advantage over markets that depend on external developments.
Furthermore, this progress is part of a broader trend of digitalization in the maritime and offshore sector, in which the real-time data capture and analysis They are considered key components for improving the efficiency, safety, and sustainability of operations at sea.
Overall, the sensor developed by Vicinay Marine and Tecnalia represents a significant step forward in managing corrosion in mooring lines and other offshore infrastructure by combining continuous measurement, degradation modeling, and predictive maintenance. This approach allows the industry to more confidently address the challenges associated with expanding offshore installations, extending asset life, reducing operating costs, and minimizing exposure to unexpected failures in increasingly demanding marine environments.