Overview
A leading healthcare and consumer goods manufacturer partnered with our engineering team to modernise their outdated P&ID documentation. With a major control system upgrade approaching, the client required drawings that were accurate, comprehensive, and reflective of the real plant installation—something their legacy documents could no longer provide.
Using advanced surveying and 3D capture technologies, we delivered a complete, future-proofed P&ID package while reducing on-site engineering time.
Project Initiation
Defining the Challenge
The existing P&IDs had become unreliable after years of system changes, undocumented modifications, and incomplete revisions. Missing and outdated information posed a significant risk to the upcoming control system upgrade.
Our objective: Conduct a full plant survey and produce accurate, fully updated P&IDs that represent the true installation.
Key Stakeholders
The project brought together the client’s engineering and operations teams and our CAD, surveying, and project management specialists.
A clear agreement was established, detailing milestones, deliverables, review processes, and drawing standards.
Project Planning
Structured Planning for a Complex Site
A detailed Work Breakdown Structure (WBS) and 6-month timeline were developed following the project kickoff meeting. Planning activities included:
- Reviewing and cataloguing of existing drawings
- Site survey planning and coordinate strategy
- Configuring Plant 3D and Vault for collaboration
- Establishing workflows for markups, revisions, and approvals
- Scheduled milestone reviews with the client
High-Accuracy Digital Scanning
To ensure maximum accuracy, we used Matterport 3D scanning, capturing 650+ scan points across the plant. This provided:
🔹 Comprehensive visual documentation of all accessible plant areas
🔹Remote collaboration, reducing the need for repeated site visits
All drawings and models were controlled through Vault, ensuring the entire team worked from the latest version at all times.
Project Execution
Our engineering team divided responsibilities across modelling, drafting, verification, and technical review.
- Task lists and schedules were maintained through structured project meetings
- Regular project meetings ensured schedule adherence and issue resolution
- Survey findings were consistently cross-checked against draft P&IDs
- Vault management ensured seamless collaboration and version control
This structured approach kept the project running smoothly and aligned with planned milestones.
Project Control
To maintain accuracy and limit risk, the following controls were applied:
- Multi-stage survey planning to capture complex, hidden, or uncertain areas
- Iterative updates to ensure P&IDs always reflected the latest verified data
- Resurvey protocols for areas where details were unclear
- Error mitigation strategies for common Plant 3D and Vault synchronisation issues
- Documentation of uncertainties for later clarification with the client
These controls ensured the final dataset was robust, accurate, and ready for future use.
Outcomes
By combining traditional engineering expertise with digital scanning technology, we achieved an exceptional level of accuracy while reducing site disruption and engineering hours.
Delivered to the Client
- 70+ updated P&IDs, covering:
- 50 vessels
- 10+ filling lines
- All utilities and site services
- 5,000+ tagged items (valves, instruments, equipment) in a structured smart database
- 10,000–15,000 mapped objects for future digital asset integration
- Automated equipment schedules produced directly from P&ID intelligence
Business Impact
The client now has:
✔ Accurate, reliable documentation for the control system upgrade
✔ A unified, structured dataset for maintenance and future projects
✔ Reduced long-term maintenance effort
✔ Enhanced visibility into their process infrastructure
Conclusion
This project highlights how modern surveying tools, combined with disciplined engineering workflows, can transform outdated plant documentation into a high-accuracy, future-ready asset. The client now has a complete and dependable documentation suite that supports both current and long-term operational needs.