DEMM Engineering & Manufacturing
Opinion: Learn from your mistakes
INTRODUCTION
It is common to see a mistake is repeated by an operator or engineering company, even if that same mistake was reported as lessons learned in previous projects. It seems even engineers and operators in the same company do not spend time to fully read, understand and implement all lessons learned and mistakes of previous projects of that company. This is a challenge in many countries and companies. Another observation has been that a mistake by a firm or operator in the past can be repeated several times by other engineering companies, operator or contactors.
This article discusses some key lessons learned and mistakes in design, installation and commissioning of different industrial, manufacturing and mining facilities in Australia and New Zealand.
LESSONS LEARNED & FORMER MISTAKES
Working on lessons learned and past mistakes and trying not to repeat them is usually challenging and difficult. This is a continuous and persistent process. The first step is to evaluate lessons learned and former mistakes and make sure proposed solutions or modifications were actually suitable, efficient and cost-effective. The second step is to incorporate solutions, precautions, etc. in specifications, project documents, design procedures, engineering standards and others. The third and most important step is to make sure everybody is aware of them and will follow the proper path to avoid those past mistakes. All these may seem not so difficult on paper, but dealing with long lists of lessons learned and past mistakes, processing them and informing many different engineers and experts in each design team of each project can be really challenging.
ASSUMPTIONS, OPINIONS, FACTS & MISINTERPRETATIONS
It is recommended not to use assumptions in the design, engineering and operation as far as possible. Assumptions and opinions have been responsible for many mistakes, problems and issues in plants and facilities. Realistic simulations, proper engineering calculations, test works, pilot plan operation, and similar should be used for design purposes, avoiding assumptions, opinions and guesses. However, if some assumptions are really necessary, they should be first examined and properly evaluated and risk assessed. The assumptions should be kept at an absolute minimum. More importantly, they should be clearly indicated as assumptions. Simulations, studies and test works have been the basis for design and engineering of plants and facilities. It is not wise to blindly accept the results of such tests, studies, simulations, etc. Some examinations, cross checking and parallel studies are needed. A key point is if two or three completely different and independent methods come to the same conclusion, then that could be reliable. It is usually necessary to make certain that design data, simulations, and calculations are correct by asking different engineers and experts to check them independently or using different/independent methods of calculations and simulations.
Accepting opinions and assumptions as facts have led to many problems and issues.
There have always been risks and dangers in accepting false information and misleading data. The best way is just to stick to facts. High quality test works and realistic simulations are extremely important to bust myths and false information.
Misinterpretation of studies, simulations, and tests led to mistakes and serious problems. It is vital to not jump to conclusions. When uncertain to results, more accurate calculations, simulations, tests, and studies should be implemented. There have been tendencies to jump to conclusions in certain areas of industries. One is the assumption that a longer processing time would result in higher recovery. Although it may be correct for many processes, it may not be right for some others.
If tests or simulations should be done in an outside firm or lab, it is a very good idea to send one or a few representative(s) there to monitor works. It is not wise to leave everything entirely to an outside contractor or lab.
LATEST TECHNOLOGIES & INNOVATIVE EQUIPMENT
It is necessary to plan to check and use latest available technologies and best methods with proper and successful references in the design, installation and operation of a plant. The design team then should check with other operators and equipment/machinery suppliers to identify, examine, evaluate and get the best and latest for any plant under design. However, there are two key observations/precautions.
The first is proper technical and commercial evaluation is needed for any new/innovative equipment, machinery or technology based on the specific plant requirements. A modern development might be beneficial for many plants, but not the best option for some others.
The second is for when a vendor or a supplier may want to introduce (or sell) a new/ innovative development for the first time. These equipment or technologies may not have sufficient operating references in industry. There have been some difficulties with some new/innovative machineries, equipment or technologies which came to market for the first time. A modern technology or development may be promising, cost effective and superior to old ones on paper. However, many problems and issues are surfaced when it operates in actual long-term plant operation for first time. Then the R&D section or similar teams in the supplier should work on these problems and try to solve them (too often one by one). This is often a long and painful process, and some led to trail & error exercises. Of course, after several successful operating references (after long-term operation in different plants), the refined and upgraded equipment or technology is really superior to the old ones. However, it is wise not to be among the first plants to test new technologies and machineries.
OVER OR UNDER ESTIMATION OF POWER REQUIREMENT & UTILITY CONSUMPTION
The correct estimation of electrical power and utilities (such as cooling water, plant water, instrument air, etc.) is key for the success of the design of a plant. However, there have been many mistakes in the past on these estimates. Often little attention was given to such estimates and it led to serious delays and issues. Obviously, over-estimation is a waste of money and resources as the
reason for such an over-estimation was usually short-cuts in the calculation or estimation. However, a more common issue has been under-estimation when one or a few users were neglected, or the consumption(s) of one, several or all were underrated due to negligence, over-simplification, etc. Thorough checks and verifications, and proper risk assessments have always been required for any estimation of electrical power or utilities. It is better to slightly over-estimate power or utility rather than underestimate them. Gross over-estimation is as bad as underestimation.
PREPARATION VS NEGLIGENCE
In each design exercise, there are hot spots and significant issues where engineers and experts know their criticality and importance. Therefore, resources are allocated to them and many hours spending to study them. The things, topics and issues which were thoroughly checked, calculated, and simulated in the design, even most difficult and challenging ones, have usually been fully solved and often do not cause delay or problem. The key is to be prepared for them and arrange everything in the design, installation and commissioning for them. On the other hand, serious problems in design, commissioning or start-up are often those which were neglected and not prepared for.
An example is the operational and start-up parameters which will be needed soon in the commissioning process. These parameters should be prepared in advance during the design process and they should be properly checked, evaluated, and reviewed. These parameters should not be left for later stages. In some projects, this was delayed to last weeks of detail design and there was no time to review and check them.
DIFFERENT EXPERTS & INTERACTIONS
In each project, there have been different people, engineers, experts and specialists. Too often they are from different backgrounds, nationalities and expertise. Some of these people have significantly different interests and points of view than others. Such differences and even disagreements first should be acknowledged and then properly resolved and concluded. As teams and players go through the design and development process, it should be remembered that other players and people may see things somewhat differently and everybody should be aware of this important fact. All people and experts should play well with others. The interaction with each other is an important consideration in design, installation, commissioning and operation. However, this is often overlooked. There have been many problems, issues, delays and difficulties related to this area of concern. There has always been need for improvement in this area.
SECURITY MEASURES, SAFETY GUARDS & SUFFICIENT MONITORING
Safety measures and guarding are extremely important for plants and facilities. Many rotating equipment, machineries, material handling units, moving parts, etc. need extensive guarding to protect operators and site people and enhance safety. Effective guarding, protections and safety measures are very good investments which pervert costly and very expensive accidents.
Any plant should be very pleasant and safe place to work. Sufficient safety devices, access, air-conditioning, facilities and utilities are needed as the plant should be a very pleasant, safe, comfortable and convenient for operators to work there many hours per day.
All plants require some level of security to protect the employees and facilities from harm, damage and steeling. This should be developed by experts based on the risks and potential dangers associated with the plant. It is far better to be conservative on this topic. At the same time, security provisions should not hinder operation or increase the costs significantly.
POLLUTIONS, DUST, WASTE DISPOSAL & ENVIRONMENT
Nowadays, strict rules are in place everywhere in the world to reduce pollutions, reduce dusts and protect environment. If these are not considered in the design at early stages, later the cost of incorporation would be several times more. It is now far cheaper, easier and better to include pollution control, dust suppressions and environmentally friendly technologies at basic design and early design stages, even with some safety margins to code or standard requirements to further protect environment. This is significantly beneficial to plant’s reputation and its perception in the community.
Disposal of wastes in all different forms (solid wastes, liquids, etc.) has always been a great challenge. There have been different methods for such different disposal of various wastes. Thorough investigations and proper risk assessments have always been needed. This should not be left for later stages, at the very end of detail design or even during plant installation. Such disposal concepts should be developed and thoroughly checked and verified during early design stages to have enough time and resources for proper studies and design reviews.
WEAK GROUND & STRONG FOUNDATION
There has traditionally been many complaints about high costs of concrete foundations by non-experts. Some ill-informed people even discussed why should money buried in soils in the form of expensive foundations? Similarly, one of myths in industry has been small or medium machinery skids or equipment can be installed on very shallow foundations/footings to save money. Author even heard false assumptions that some small machinery skids could be installed on compact gravel without foundation. The fact is all of these have been wrong.
Faulty foundations and weak ground have been responsible for many failures and problems. Equipment or machineries have been collapsed and damaged due to weak foundations. In many other cases, there have been operational issues, high vibration and other problems due to inadequate foundations. Root causes of those have been carelessness or excessive cost cutting. High-quality ground geometrical studies are required for any plant and facility. And adequate and strong foundations are needed for any equipment or machinery. The costs of such ground geometrical studies and adequate foundations are usually small compared to ones of equipment and machineries or financial losses due to their collapses. This is not the place for saving money.