Engineering Consultancy Brownfield Digitisation at Indian PSU Refinery

8,400 P&IDs spanning multi-decade baseline: 1980s original commissioning era (faded scans and hand-drawn paper), 1990s early CAD-era PDFs, 2000s digital P&IDs from prior revamp, 2010s capacity expansion drawings, 2020s recent debottlenecking scope. Each era used different drawing conventions, symbology versions, and revision-block formats.

PSU client required CFIHOS-aligned structured output plus IBR Form IV register (pressure equipment scope across CDU, VDU, hydrocracker reactor, hydrotreater scope), OISD 118 HAZOP register digitisation across 4 study cycles, PESO Form XIV / XV documentation, and CCOE licence-condition mapping. Four concurrent regulatory regimes against a single asset master.

Indian PSU procurement protocol required Indian PSU rate-card pricing compatibility and Indian regulatory expertise embedded in the delivery team. Generic engineering AI vendors had been disqualified at prior procurement rounds.

Aggressive 18-week digitisation phase window before the next turnaround cycle, with no extension flexibility. Missing the window meant the digitised asset register would not be available for turnaround planning.

Ingested 8,400 P&IDs across five drawing-era cohorts. Pre-processing handled scanned paper baseline, faded blueprint heritage, early-CAD PDF artefacts, modern intelligent P&ID conventions, and hand-annotated field redlines.

Extraction models parsed every tag using ISA 5.1 native symbology plus Indian PSU-specific tag convention extensions (refinery-specific instrument loop numbering, IBR-scoped equipment tag suffixes, OISD HAZOP node reference conventions).

Built consolidated asset master across the five drawing-era cohorts with superseded-node detection: tags renamed during revamp, equipment replaced during capacity expansion, lines re-routed during debottlenecking, all reconciled against the most recent revision.

IBR Form IV register auto-populated from extracted pressure equipment tags, cross-referenced against mill test reports for material traceability per Chief Inspector of Boilers requirements.

OISD 118 HAZOP register digitised from 4 study cycles spanning 6,200 pages of completed PDF study documents. Every recommendation mapped to current P&ID revision with superseded-node flagging.

PESO Form XIV / XV documentation populated for petroleum storage and compressed gas scope. CCOE licence-condition mapping completed across the refinery's 18 CCOE licences.

Output delivered to consultancy in CFIHOS-compliant structured format for owner-operator handover; consultancy delivered to PSU client per their rate-card-compatible commercial terms.

8,400 P&IDs digitised in 16 weeks against 6-9 month manual baseline. 85% cycle-time saving on the digitisation phase critical path.

47,200 tags extracted, classified, and cross-referenced across five drawing-era cohorts with superseded-node detection.

IBR Form IV register populated for 4,600 pressure equipment items with mill cert traceability links.

OISD 118 HAZOP register digitised across 4 study cycles (6,200 pages) with action-to-P&ID-revision mapping.

PESO Form XIV / XV documentation and CCOE licence-condition mapping completed across 18 refinery CCOE licences.

Turnaround planning team received the structured asset register 6 weeks before the turnaround start date, enabling P&ID-driven turnaround scope definition for the first time.

Consultancy retained the engagement for the next two revamp cycles based on the digitisation phase results.