Industry insight

Innovation has the power to radically change the way we live and work. From how we power our homes to how we travel; modern technology has transformed our lives across every touchpoint.

But how can legacy meet innovation? What lessons can we take from the past as we move into a digitally enabled future? To explore this, hear from Jack Ball, Senior Project Engineer at Primary Power:

Integrating innovation with legacy systems

“Many advancements have been made in integrating new technologies with older infrastructure, particularly in the energy sector. However, complexities do exist, the primary one being that legacy systems weren’t designed with modern technologies in mind.

“Some substations we encounter have far outlived their intended lifespan and are prime examples of considered engineering in action. However, you often find unreliable data sets because, when these systems were created, the technologies we use today simply didn’t exist.

“There can also be reluctance to introduce new technologies, and rightly so. No one wants to compromise safety or reliability. Integrating innovation can be a double-edged sword; you don’t add it for the sake of it. You need intention and a tool that will not only benefit the system but also be safe.”

Thinking ahead to the future

“In engineering, you want something to last at least 40 years. You don’t want to create something that is a one-hit wonder; longevity is key.

“When introducing new technologies, we consider that things might go wrong in ways we don’t expect. Innovation can cause unforeseen issues, and mistakes are easy to make without clear guidelines.

“It’s also important to consider whether a new product or system will still be supported over the required life span, with considerations on long term availability of spare parts, replacement and ongoing product support. This ensures the longevity of your system and again, protects safety and reliability.”

Learning from legacy engineering methods

“Historically, engineers designed and built by using conservative estimates on well understood theory. The engineers of the past understood the intricacies of everything that they were designing as they would often draw by hand.

“Now, most things are automated and created using digital software. But when you design through automation, it’s easy to take software and tools for granted. If something goes wrong, you need to know precisely what it is and how to resolve it.

“You still need to understand what it is that you are doing and be able to show your clients that you have this knowledge, providing reassurance and building trust. Don’t implicitly trust the software to do everything for you; take the time to explore what it is doing and how to deal with any problems that may arise.

“Designing with intent is something we must learn from the past. It enables you to work reliably and safely. We can often overcomplicate solutions, but maintaining intent keeps you on track.”

Understanding risk in innovation

“When it comes to innovation, there is an always an element of risk. Systems need to be clearly tested, and trial products are essential; they expose hidden factors that otherwise may be overlooked.

“There is also the risk of technology outpacing business readiness. If it isn’t clearly understood or maintained, issues can arise. You must understand the advantages of the innovation being implemented and why it exists.

“However, there are many benefits to innovation in engineering. For example, improved visibility allows you to see how an asset is performing, where faults lie, and whether an upgrade is required.

“Another key benefit is the ability to monitor asset condition more easily, reducing the number of routine site visits engineers need to make. Safety remains paramount, but technology can support engineers in doing their jobs more effectively.

“Innovation also enhances decision-making thanks to the vast amounts of data it can collect. This helps improve the overall safety of an asset and maintain consistency. These are just some of the benefits that add real value.”

Looking to the future

“Innovation is simply doing something in a different way and getting more out of what already exists. Not everything has to be shiny and new. Some older, legacy assets have worked for decades and we must remember that.

“Innovation is also about solving problems effectively; you don’t need to do new things constantly you just need to do them well. When integrating innovation, we must always remember that it should add value, not simply replace things. Maintain a strong understanding of what it is and the theory behind it.”

Thanks for your insights, Jack. To find out more about Primary Power’s work in action, visit our services page here.