Grassroots Refinery Handover Documentation Package
Major EPC Contractor — Gulf Region
Zero QA Rejections. 11 weeks ahead of deadline.
12,000
P&IDs Processed
47,000
Tags Extracted
1,847
Conflicts Resolved
Zero
QA Rejections
A major EPC contractor in the Gulf region needed to build a complete handover documentation package for a grassroots refinery. The package — containing the tag register, instrument index, and all associated documentation — had to be delivered before a fixed milestone date tied to a contractual payment event worth crores.
The Challenge
12,000 P&IDs spanning eight engineering disciplines, each with different conventions, symbology standards, and revision histories.
The internal team estimated nine months to build the tag register manually at 95% accuracy — not enough for plant operations.
A fixed handover deadline in 14 months with a contractual payment event. Missing it meant deferred revenue plus liquidated damages.
The client had failed handover QA on their previous project due to tag discrepancies between P&IDs and the instrument index.
Our Approach
Ingested all 12,000 P&IDs across eight disciplines — PDFs, DWGs, and scanned drawings from multiple engineering teams.
Our extraction models parsed every tag, instrument, line number, and equipment reference using ISA 5.1 symbol recognition.
Reconciled extracted tags against 3,200 datasheets — flagging every parameter mismatch, orphaned tag, and missing document.
Cross-validated the C&E matrix against the extracted tag list. Found and corrected 23 SIL classification inconsistencies that would have surfaced at SIL verification.
Domain engineers reviewed every safety-critical field — design pressure, temperature, safety classification, and SIL level.
Loaded the verified tag register directly into SAP PM S/4HANA — no intermediate Excel files, no manual upload.
Results
47,000 instrument tags extracted and verified across all eight disciplines.
1,847 discrepancies between P&ID and Instrument Index identified and resolved before QA review.
23 SIL classification inconsistencies corrected in the C&E matrix.
Tag register loaded directly into SAP PM S/4HANA — zero manual data entry.
Completed 11 weeks ahead of the handover milestone.
Zero QA rejections at handover — the first time this client achieved a clean handover.
“We had conducted internal trials on our engineering documents but felt the difficulty of achieving the accuracy required for actual operations. The leap in accuracy Pathnovo delivered compared to conventional approaches was dramatic.”
VEVP Engineering
Major EPC Contractor, Gulf Region
Documents Processed
P&IDs
Datasheets
Instrument Indexes
C&E Matrices
Capabilities Used
Target System
SAP PM S/4HANA
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