Digitalization of the process industry is changing the way companies operate and how design tasks are implemented in projects.

Information digitalization is rapidly expanding within process equipment condition monitoring and preventive maintenance, spare part stock management, operator training, and process simulation. It extends to the complete digital copy (Digital Twin) of a process plant.

These systems benefit from data integrability. For example, all information related to equipment (operation model, characteristics, condition, spare part stock, etc.) can be accessed directly by clicking the component rather than searching for related data from various sources.

The role of information digitalization in the industry

Traditionally, various disciplines have had their own specific information models and ways of storing data having their own program families and data storing practices. As a result, it can be hard to share data between disciplines in a way that is usable within the company or by partner companies. This integration issue can lead to a significant amount of information being lost when sharing data. One typical example is when sharing P&IDs.

Any further design and development steps are now made with database-oriented tools; this often causes mismatches if the existing information is from the “old era” before the data integration.

Old P&IDs to digitalized information sources in the industry

One of the most common ways of representing and sharing data in the process industry is with Piping and Instrumentation Diagrams (P&IDs). Traditionally, P&IDs have been created and stored in document form, illustrating the process rather than in machine-readable datasets. The process-related information is stored in separate lists, e.g., Excel.

To utilise modern data integration and easy access to data related to the process, the graphics in the P&IDs and the data in the lists need to be integrated, and connections built between the process objects and the data. To enable this, a complete redrawing of the P&IDs has traditionally been necessary, using modern database building programs and updating the list data into them.

Automating the redrawing process for information digitalization

The process of converting process diagrams from unintelligent formats (such as P&IDs in DWG, PDF, or even paper format) to intelligent ones, where process information is stored in a database, is highly resource-intensive. Significant investments are required when converting tens or even hundreds of diagrams.

Fortunately, there is now a solution for this resource-intensive challenge. At Sweco, we have the knowledge and expertise to automate the conversion of P&IDs from graphics-only drawings and lists to intelligent AutoCAD drawings, including the database with all its functionalities. This automation significantly reduces the resources needed for the conversion process, allowing for quicker updates to digital formats at a lower cost. As a result, this automation will substantially decrease costs in design projects. The program also enables sharing data in a machine-readable format.

The conversion step can be divided into three main steps:

1. Object recognition & connection determination
2. Extraction of process information in the drawings
3. Generation of a machine-readable file
4. Uploading the other process data (originally stored in the various lists) using certain common unique key between the P&ID database and the lists. Usually, the common key is the Tag identification code.

In the first step, all items in the P&IDs are recognised, and connections between them are created automatically. The result of this step is illustrated in Figures 1 & 2. Thereafter, process information is extracted from the P&IDs and related lists and stored in the correct process equipment. Once these steps are completed, a machine-readable file is automatically generated, containing all the collected process information along with the representations of the P&IDs. As the information is stored within the equipment database, it can be:

1. Accessed with ease
2. Kept up to date from a single source
3. Connected to other Mill Information Systems (e.g., maintenance and storage information)

Digital data storage is crucial for the process industry

Legislation related to occupational and process safety also requires that correct and up-to-date flowcharts are available. Also upcoming EU initiatives such as the NIS2 Directive and Digital Product Passport emphasise the importance of interoperability and automated data exchange.

As both possibilities improve and requirements tighten, the digitalization of both new and existing information and easy accessibility to it is a current and future trend. The automated digitalization of old P&IDs and lists will make this challenging first step of converting existing data much smoother.

Tobias Waris, Process Designer, tobias.waris@sweco.fi
Niko Ruokolainen, Specialist, niko.ruokolainen@sweco.fi