Many investment companies, especially in the industrial sector, start working from the end. First, they order a contractor, then the assembly starts, and only at the start-up stage does it turn out that something is wrong: the pipelines collide with the structure of the hall, there is no space for service, and the technological installations need to be corrected – often after acceptance.
Meanwhile, the most savings can be made… at the very beginning, i.e. at the design stage. This is when it is decided whether the installation will operate without problems or will start generating additional costs at the first start-up.
The design of technological installations is much more than diagrams and descriptions. It is a holistic approach to the production layout, design of technological lines, analysis of explosion hazard zones (ATEX), selection of components and prediction of what could go wrong. And the better all this is thought out, the fewer corrections during the assembly of technological installations and the faster the start of production.
In this article, we will show you what to look for when planning a technological installation to avoid surprises, not overpay and calmly go through the start-up. Even if this is not your first investment, a few simple rules can save you nerves – and tens of thousands of zlotys.
5 typical mistakes when designing technological installations
The good news? Most problems that appear during the construction and start-up of the installation can be avoided. The bad news? Many investors and contractors still fall into the same traps – because they want to speed up the process or “finish the details later”. Meanwhile, it is at the stage of designing technological installations that decisions are made that can determine the success or failure of the entire investment.
1. Lack of analysis of basic processes
This is one of the most common mistakes. The project starts, there are the first sketches and diagrams, but… no one has really analyzed how the basic processes work in a given plant. Where are the critical points? What are the flows? How do temperatures and pressures change?
Without this knowledge, even the most refined design of technological installations may not match reality. And then modifications, downtimes, and sometimes the need to rebuild entire lines appear.
2. Ignoring explosion hazard zones (ATEX)
If your installation is to operate in an environment with dust, fumes or gases – the topic of ATEX should appear at the concept stage, and not only during acceptance. Unfortunately, it still happens that ATEX explosion hazard zones are taken into account too late or treated carelessly.
The effect? The installation may not meet the regulations, and its adaptation to standards means further weeks and tens of thousands of zlotys. Professional technical design of the installation always begins with the recognition of threats – and ATEX is one of the key ones.
3. Electrical installation design done “at the end”
Another classic: everything is drawn, technological lines are planned, assembly of technological installations is almost ready… and suddenly someone remembers about the power supply. And then improvisation begins – ducts, pulling cables, changes in the layout, collisions with pipelines.
The electrical installation design should be created in parallel with the technological design. Only then can costly collisions and downtimes be avoided. This is also one of the reasons why it is worth choosing multi-discipline design of industrial installations, where the team works together – not separately.
Concept stage vs. technical design – where do costs really arise?
At first glance, it may seem that you spend the most during construction: materials, assembly, acceptance. But the truth is that many costs arise much earlier – already at the concept stage of the technological installation.
This is when decisions are made that are later difficult (and expensive) to reverse: how the technological lines are to run, where key devices will be placed, how to plan installation zones and routes. If this stage is treated superficially, even the best technical design of technological installations may not protect against surprises.
A common scenario? The project starts quickly, without a thorough diagnosis of production needs. Then it turns out that there is no space for service, the electrical installation design clashes with the pipelines, and some routes have to be routed differently. All this means corrections, delays and additional costs.
Therefore, the design of technological installations should begin with a solidly developed concept – based on the actual production layout, knowledge of the processes and the involvement of all industries from the beginning. This is when it is also worth taking up the analysis of ATEX explosion hazard zones or planning future expansion.
A well-prepared concept allows you to catch collisions and errors in advance, which could cost much more in the implementation phase. This is not an “unnecessary stage” – it is the key to savings and efficient implementation of the entire technological installation.
The role of BIM and 3D simulations in reducing industry clashes
If you have participated in the implementation of any major investment, you are familiar with this scenario: installers enter the construction site, only to find that ventilation ducts intersect with pipelines, and the electrical cabinet is “hanging” where the main technological trunk line was supposed to run. The effect? Nervousness, corrections, delays and additional costs.
That is why more and more companies are now relying on BIM (Building Information Modeling) and 3D simulations – and for good reason. These tools allow you to plan the design of technological installations in such a way that all the disciplines – ventilation, electrical, sanitary and process installations – see each other already at the planning stage.
Instead of finding out about clashes during assembly, you can capture them in the model before anything is built. This is a huge advantage. Thanks to this, you avoid so-called “on the fly” changes, unnecessary rework and the risk of having to cut something off and weld it again.
For the investor, this means tangible savings – fewer corrections, faster assembly, fewer errors and better communication between contractors. And for the design team, it is the certainty that the designs of building installations and technologies are truly consistent.
An additional advantage? Technical design of installations based on BIM allows for precise planning of the details of the installation construction, which translates into more realistic cost estimates and schedules.
Value Engineering – how to reduce investment costs without losing quality?
Do you know this? The project looks great, everything is correct – until you get the cost estimate. And suddenly it turns out that the budget must be either stretched significantly or… something must be given up. But what? And can it be done wisely?
This is where Value Engineering comes in handy – an approach that allows you to optimize the investment so as not to lose quality or functionality, but still reduce CAPEX. It is not an art to cross out items, but to find solutions that will fulfill the same purpose, but in a simpler, faster or cheaper way.
Examples from real life?
instead of non-standard components – technological solutions available immediately,
instead of complicated systems – a more flexible, modular design of technological installations,
instead of sticking to the only right version – analysis of several variants and selection of the best price-to-quality ratio.
Importantly – in order to have something to choose from at all, the design must be flexible. That is why it is worth ensuring that the technical design of the installation takes into account the possibility of optimization from the very beginning. Otherwise, every change is a cost, not a saving.
And this is where the question arises: does the cost of the installation design have to mean choosing between “expensive but good” and “cheaper, but anyhow”? Fortunately, no.
Installation of technological installations – 3 moments when it is worth stopping
Installation is the stage where everything gains momentum. The schedule is tight, teams take turns, and in the background the pressure: “to make it fast and work”. But this is exactly when it is easiest to overlook something – and pay for it at the end, when corrections hurt the most.
Therefore, during the assembly of technological installations, it is worth planning three specific “control moments” – such points at which it is simply worth stopping for a moment and checking whether everything is going according to plan.
1. Before welding begins – check the routes and supports
This is the moment when the pipelines are not yet hanging, and you have a chance to see whether the installation layout matches the design. Are the supports where they should be? Does the design of the technological installations not conflict with the structure of the hall or with other industries, such as the electrical installation?
At this stage, changes are still simple. Later – they start to cost money.
2. Halfway through the work – intermediate control
When the installation is already starting to take shape, it is worth stopping “halfway” and checking whether everything is in accordance with the specification. Are the components in accordance with the documentation? Do the technological solutions that were planned actually work?
This is a good time to catch any inconsistencies – before they reach the stage of “nothing can be done anymore”.
3. Before start-up – the final call
When everything is installed, it is time for the most important question: is the installation ready for start-up? This is when we check, among other things, the markings, documentation, tightness, access to service and a whole list of “little things” that are very important.
This is where we can see whether the details of the installation construction have been perfected – whether it will work or whether something needs to be fixed at the last minute.
Pilot installation vs. executive design – or why it is worth testing before you build everything
Imagine a situation: a food company plans to implement a new technological line. The process seems simple, the layout has been designed, the equipment has been selected, and the deadlines are tight. It is time to act, right?
But instead of building the whole thing right away, a decision is made to first launch a pilot installation – a smaller, test section that will allow you to check how everything works in practice. And that is a blessing.
Because after just a few weeks, it turns out that in one of the process phases, the medium needs more flow time than the original plan assumed. The pipelines turn out to be too narrow, and the positioning of the devices requires correction. If this had only happened at the stage of starting up the entire line, the cost of corrections would have been enormous – not to mention the delays.
Thanks to the fact that the pilot installation had been implemented earlier, the changes could be implemented calmly. The team corrected the design of the technological installations, the routing was improved, and the appropriate pipe diameters were selected. Ultimately, the executive project was much more refined, and the whole thing started without any stress or surprises.
Maintenance of technological installations – why it is worth thinking about service today
At the design and construction stage of the installation, most companies focus on one thing – to get everything up and running as quickly as possible and according to plan. This is understandable. But very often, they forget about one very important aspect: what next?
Because when the line is already up and running, everyday realities begin – inspections, minor repairs, replacement of elements. And suddenly it turns out that access to the service valve is an acrobatic challenge, and to replace the sensor, you have to dismantle half the structure. Why? Because no one thought about it at the design stage.
Meanwhile, maintenance of technological installations is something that can be predicted and well planned. It is enough that when designing technological installations, you take into account everyday life:
can you conveniently access key elements?
will maintenance of sanitary installations not require extinguishing production?
does the layout of components take into account ergonomics and safety?
Sounds simple? Because that’s how it should be – but only when you think about it in advance. Instead of focusing only on the start-up, it’s worth asking: how will this installation work in a year, two, five?
A good installation is one that you think about in advance
When planning a new installation, it’s easy to focus only on the here and now: to build, start-up and meet the deadline. But the truth is that you gain the most when you think a few steps ahead. About how to avoid corrections. About how to prevent the start-up from dragging on forever. About how to prevent the service from being a torture.
A well-planned technological installation is not a coincidence – it is the result of talks, good analysis and a practical approach to the project.
If you want someone to look at your idea from a technical perspective, advise where you can optimize and where it’s better not to save – we are at your disposal.
Order an initial consultation – no strings attached. We will talk, analyze the needs and check how to approach the topic so that the installation works well not only on paper, but above all in reality.
