Introduction

In the context of engineering, a Project Audit, also known as a Design Review or Cross Check, consists of a wide-ranging verification of the project in different disciplines such as mechanical, civil and structural. And this audit can be carried out at different times in the project cycle of a given asset, whether it is new, in the design phase or even already in operation.

In large structures and equipment, failures can lead to major accidents with human, environmental, social and economic impacts. In financial terms, a study by the American Society of Safety Engineers [1] points out that for every dollar spent on prevention, three to six dollars are saved in associated losses, as shown in Figure 1. Considering property damage, this amount could reach $50. In this way, investing in design checks is significantly less costly when you bear in mind the potential for damaging consequences that an accident can bring.

Figure 1: Iceberg of accident costs [2].

Stages of the Project Audit

The audit complements routine engineering services by identifying possible deficiencies in the project design. If the service is carried out considering the entire life cycle of the asset, it can be carried out in five distinct phases, illustrated in Figure 2.

Figure 2: Stages of the Project Audit [3].

1 - Support for drawing up technical specifications

It is the first stage of the auditing process, responsible for specifying the project requirements, such as the standards that must be met and the conditions expected throughout its useful life. A specification error at this early stage can jeopardize all the other associated stages and cause serious damage. 

Technical support also allows the client to gather all the engineering documentation that makes it possible to verify compliance with the items requested and any corrections to identified non-conformities. From the data generated in the process, a database is created that allows lessons learned to be incorporated into the company's intellectual capital. It also acts as a protection mechanism for the client against future demands or claims from competitors, as it allows premises to be defined for carrying out the contract.

2 - Technical Evaluation bidders

Once the technical specification has been drawn up, the bidders need to be critically assessed to see which companies are capable of meeting the technical requirements. Kot can provide technical support to the client during the meetings to clarify and equalize the bidders, issuing its technical opinion at the end of the process.

Steps 1 and 2 are therefore applicable to the design phase of the project and can provide the benefits of mitigating the risk of accidents and better technical leveling between competitors in the process. Furthermore, as in the case of the technical specification, the client can be protected from possible inconveniences during the supply of the asset.

3 - Suggestions for the Basic Conceptual Project

Drawing on its experience, Kot will also be able to work on the conceptual and basic phase of the project, checking its adherence to the technical specification and pointing out any deviations identified. The aim at this stage continues to be to support the client with technical assistance in the interface with the bidders, avoiding divergences in future, more advanced stages of the project and consequently impacts on costs and deadlines due to possible rework.

4 - Structural and mechanical verification of detailed engineering

The most comprehensive stage of the study refers to the evaluation of the complete technical documentation, including manufacturing drawings, bill of materials and equipment specifications. At this point computational analyses of the asset are carried out in order to identify mechanical and structural non-conformities, generating design optimization suggestions.

A recent study conducted by Kot involved checking the detailed design of railway bridges made up of metal spans of 25 to 35 meters, for later manufacture in China. After carrying out calculations to verify the safety criteria, involving analyses such as pseudo-static analysis of the steel structure, panel buckling analysis and fatigue analysis due to the passage of the train, design changes were indicated resulting in modifications to the geometry of the stiffeners. The safety factors recommended by the standard were maintained and the weight of the bridge was reduced by approximately 50% in the case of the 35-meter span, as shown in Figure 3.

Figure 3: Railway Bridge Design Optimization [3].

However, the most common occurrence observed in the design verification stage refers to cases of undersizing, i.e. when components are not robust or capable of performing the function for which they were designed. In these cases, reinforcements or modifications are added to the design with a view to the Structural Integrity and mechanics of the asset. An example of this can be seen in Figure 4, which shows the area of the trailer where reinforcement was proposed to reduce the structure's utilization rate, which exceeded the standard limit for the static analysis.

Figure 4: Reinforcement proposed by Kot for a forklift trailer [3].

5 - Checking installed reinforcements

At the end of the design review, the proposed improvement recommendations can be validated on site by suitably trained structural engineers. Incorrect practices associated with the installation of reinforcements are frequently found, which compromises the previous stages, even if they are carried out in accordance with the applicable technical criteria.

If deviations are found in the field, solutions will be proposed to resolve the non-conformities. On the other hand, if no deviations are identified, the asset will be in line with the client's requirements.

Conclusion

It is clear that numerous benefits are generated by carrying out a design audit of structures and equipment and, when compared to the costs of a hypothetical accident, the cost is considerably lower. In addition to the financial issue, non-conformities in projects can generate even greater damage, involving lives, environmental problems, as well as intangible aspects related to branding.

Ideally, the audit should be carried out as comprehensively as possible to reduce the risks involved in the project as much as possible. In this way, carrying out the five stages presented gives the client a greater degree of protection against the occurrence of unwanted events. However, the limitations of each project may make it impossible to fully validate all the stages and it is possible to contract the audit partially. Contact our team for more information!

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References

 [1] American Society of Safety Engineers (2010). Reducing/Ignoring Workplace Safety Programs During Economic Downturn a Wrong Move for Business.

[MINE SAFETY AND HEALTH PROGRAM TECHNICAL STAFF (Colorado) (org.) Accidents - The Total Cost: a guide for estimating the total cost of accidents. Golden: Colorado School Of Mines, 2011. 29 p. Available at: https://www.mines.edu/emcis/wp-content/uploads/sites/185/2018/07/total-cost-of-accidents.pdf. Accessed on: 22 Apr. 2021

[3] Kot Engenharia Collection.