The Challenge

For years, the client operated their chemical manufacturing units (CNA-1, CNA-2, CNA-3, and the cooling tower) using outdated and fragmented documentation. Paper-based P&IDs, legacy GA drawings, and years of undocumented field changes had created significant discrepancies between the actual plant conditions and engineering records. This led to critical inefficiencies: delayed shutdown planning, higher maintenance costs, and rising safety and compliance risks. Their internal teams spent too much time validating data through field visits. What they needed was not just a digital record, but a reliable, intelligent system that reflected the reality on the ground.

Client’s Initial Hurdles

• The site was already partially constructed, making traditional manual measurements inefficient and error-prone.
• Structural details like lintel beams were difficult to detect visually.
• The deadline was strict just one month for a 3 lakh sq. ft. facility.
• The only input provided was a master plan image in PNG format, with no access to existing CAD or Revit files.

Why This Was Critical

Why were precise as-built drawings necessary?

The client was mid-way through construction. Any mismatch between actual site conditions and drawings could lead to misaligned interiors, service clashes, and rework all of which are costly.

Why not use traditional survey methods?

Traditional methods could not meet the required sub-3mm accuracy or match the speed needed. With parts of the structure already built, access was limited, making laser scanning the only viable option.

Why was lintel beam detection a sticking point?

Lintel beams are often partially or fully embedded, and even reality capture has limitations when elements are concealed. Still, the client needed these for structural validation and interior anchoring.

How did the timeline affect decision-making?

The 4-week deadline pushed for simultaneous workflows scanning, registration, modeling, and drawing production all had to overlap to deliver on time.

What would success look like for the client?

A reliable, intelligent 3D as-built model and structured document system that enables informed decision-making and safer, faster operations.

Gaps in Existing Information

In paper form, Scanned PDFs or JPGs, Most drawings were incomplete, outdated, or handwritten, No reliable mapping or tracking of field modifications over time, Over 700 documents were scattered across. disconnected formats and locations.

No centralized or unified system to: Validate engineering data, Cross-reference design changes, Ensure consistency across teams and tools

Why Specific Requirements Mattered

Client needed a model that wasn’t just a visual representation, but a functional, engineering-grade asset. It had to align with ISO 19650 standards, support operations and maintenance, reduce downtime, and provide traceability for audits. Every component from valves to panels, had to be accurate, intelligent, and easy to locate.

The Desapex Solution

Desapex stepped in with a comprehensive digital engineering approach.

The first step was high-precision 3D laser scanning across CNA-1, 2, 3, and the cooling tower. Control points ensured accuracy, and point clouds were registered meticulously. The result? An intelligent 3D model in Autodesk Plant 3D, covering every detail from piping and equipment to electrical and instrumentation.

In parallel, over 700 legacy documents were digitized using OCR tools and converted into editable CAD files. Desapex worked closely with the client’s team to validate and synchronize these documents with the model. Isometric drawings and asset tagging were completed per ISO 19650 guidelines. All deliverables, including point clouds, 3D models, 2D drawings, and photographs, were handed over in both digital and physical formats.

Project Timeline & Milestones

• 21 days – On-site scanning and data capture
• 10 days – Preliminary model review and progress checkpoint
• 40 days – Final delivery of intelligent 3D model, digitized drawings, and isometrics

Software & Technology Used

• Autodesk Plant 3D – for intelligent 3D model development
• Autodesk Navisworks – for model review and coordination
• Autodesk ReCap – for point cloud processing
• AutoCAD – for 2D drawing generation and digitization
• OCR tools – for scanning and indexing hardcopy documents

The Real Business Value Delivered

• The client’s engineering and maintenance teams now operate using a reliable digital twin of their chemical plant.
• Repeated site visits for basic asset verification have been eliminated key data is accessible in just a few clicks.
• All documentation is now synchronized, standardized, and ISO-compliant, improving audit readiness and regulatory alignment.
• Shutdown planning has become faster and more predictable, reducing downtime and resource strain.
• Cross-functional collaboration has improved, thanks to centralized access to validated engineering data.
• Legacy documents once scattered and unstructured are now digitized, indexed, and easily searchable, reducing ambiguity.
• The shift from paper to a structured digital environment has led to a clear operational uplift:
  • Higher efficiency
  • Fewer errors in maintenance
  • Faster decision-making
  • Improved transparency across departments

What This Means for Future Projects

For the client, this wasn’t just a one-time documentation exercise, it marked a turning point in how they manage and interact with their plant data. What began as a response to inefficiencies evolved into a foundational step in their digital transformation journey. They now have an intelligent model they can trust one that reflects reality, scales across units, and supports safer, faster decision-making across operations.

From Desapex’s side, this project reaffirmed our role not just as a service provider but as a digital transformation partner. Working with legacy documents, aging infrastructure, and fragmented records demanded precision, patience, and deep technical expertise. The outcome proved that even the most complex, timeworn environments can be brought into the future with clarity, intelligence, and structure.

This collaboration laid more than just digital groundwork. It built mutual trust. It demonstrated the power of combining technology with industry knowledge. And it created a blueprint for smarter shutdowns, predictive maintenance, and data-backed decisions. Together, we’ve set the stage for a future where industrial plants are no longer defined by paper trails, but by connected, intelligent systems that evolve with every need.