GASCADE: Brownfield digitalisation with CADISON

How GASCADE is digitalising an existing plant using laser scanning, intelligent P&IDs and a 3D as-built model, creating a reliable data foundation for future plant modifications.

At older industrial plants, the available drawings do not always fully reflect the actual as-built condition. Technical information is also frequently stored in different systems and formats or may still exist only on paper.

Together with ITandFactory, GASCADE therefore carried out a comprehensive brownfield digitalisation of the Reckrod compressor station. Within around nine months, the project delivered 36 intelligent P&IDs, digital models of more than 600 pipelines and a detailed 3D as-built model. More than 1 TB of laser scan data was processed.

The Reckrod compressor station has been in operation since 1994 and has been expanded continuously over the decades. As a result, discrepancies had developed between the existing drawings and the actual condition of the plant.

To create a reliable digital record of the as-built condition, the plant was captured using 3D laser scanners. The scan data was used to generate a point cloud, which then formed the basis for the detailed 3D as-built model.

In addition to piping and equipment, the digital model includes I&C systems, steel structures, 17 buildings, roads and the surrounding terrain. This provides an accurate digital representation of the plant for future design and engineering tasks.

In parallel with the 3D capture, the existing AutoCAD P&IDs were converted into intelligent CADISON P&IDs and aligned with the current condition of the plant.

Throughout the project, the CADISON database served as the central information foundation. P&IDs, 3D data, pipelines and existing technical documents could therefore be linked within a shared plant structure.

Existing pipe records were also linked to the corresponding pipelines. This allows users, for example, to access the relevant piping documentation directly from the P&ID.

With several hundred pipelines involved, purely manual data processing was not practical. The project team therefore used a range of automation and data validation functions in CADISON.

Missing information in P&ID elements could be flagged automatically and compiled in reports for further processing. Documents and objects were also partially assigned using predefined rules.

Project progress and data completeness were evaluated systematically. This made it possible to track which pipelines had already been modelled, reviewed or approved in the 3D model and how completely individual components were represented across the P&IDs and the 3D model.

CADISON therefore supported both the digitalisation process itself and quality assurance throughout the project.

For GASCADE, the benefit of digitalisation lies in particular in the later reuse of the engineering data created.

Updated P&IDs support, for example, documentation tasks. Current 3D and piping information is also available for future plant changes. Isometrics can be generated from the digital plant structure for further design tasks.

Additional information on piping classes, materials and wall thicknesses was also captured. GASCADE expects clear efficiency gains on upcoming brownfield projects and modifications of existing plants.

The GASCADE case highlights four key factors for the successful digitalisation of existing plants:

• Capture the actual plant condition digitally when historical drawings no longer fully reflect the as-built condition.
• Link P&IDs, the 3D model and technical documentation instead of creating new, isolated data silos.
• Use a central engineering data foundation to manage information systematically and enable its long-term reuse.
• Plan for automation and data validation, particularly when working with large volumes of piping data, objects and documents.

The digital twin thus becomes more than a visual representation of the plant: it provides a reliable information foundation for future engineering and operational tasks.

The approach developed in the project is intended to serve GASCADE as a basis for further digitalisation projects.

At the same time, existing applications and databases are to be connected more strongly in future. From previously separate “data islands”, a connected information environment is to arise step by step, as a basis for the further digitalisation of plant design and plant operation.