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3D Plant Modelling & Digital Twin Services.

ProSIM partners with energy asset owners, facility operators and EPC contractors to construct highly accurate, data-rich digital replicas of their physical sites through industrial 3D plant modeling. These digital twins streamline the entire project execution phase while guaranteeing reliable traceability of the facility over the long term.

3D plant model — equipment and structural framework
3D Plant Modelling
Spec-driven piping routing detail
OUR EXPERTISE

Data-Rich 3D Plant Modelling Across Every Discipline

From intelligent equipment and structural modelling to spec-driven piping, multi-discipline clash resolution and multi-platform toolsets, ProSIM builds digital replicas that carry a facility through its complete lifecycle.

Intelligent Equipment & Structural Modelling

Using sophisticated 3D design techniques, we translate vendor data sheets and initial layout concepts into highly exact models of process assets and their supporting framework. Our approach seamlessly merges practical space management with complex structural demands to deliver logical, well-organized plant layouts.

01

Specializations

We focus on critical elements such as nuclear containment structures, power generation components, and oil and gas facilities, alongside rotating and static equipment, secondary steelwork, pipe racks, civil foundations, walkways, and access platforms.

02

Sector Compliance

Our expert consultants design tailored layouts that adhere strictly to the hazardous zone classifications, spatial limitations, and specific regulatory standards required by refineries, thermal power plants, and nuclear installations.

Spec-Driven Piping & Routing

ProSIM specializes in developing comprehensive 3D routing for intricate energy systems. We leverage professional CAD-based workflows to ensure your final 3D models align perfectly with the original engineering schematics, effectively eliminating translation errors.

01

Data-Driven Integration

By letting intelligent P&IDs directly govern the routing process, we automate specification compliance across HVAC ductwork, electrical cable trays, and complex, multi-sector piping runs.

02

Deliverable Extraction

We pull fabrication-ready outputs straight from the finished model. This includes precise General Arrangement (GA) drawings, Material Take-Offs (MTO/BOM), and Isogen isometrics. This flawless extraction process solidifies our reputation as a dependable outsourcing provider for plant design deliverables.

Multi-Discipline Clash Resolution

To prevent costly rework and on-site modifications during plant assembly, we run exhaustive interference checks that pinpoint spatial conflicts long before fabrication begins. For brownfield projects, our highly accurate as-built modeling ensures that new modifications fit flawlessly within the existing physical constraints of the site.

01

Clash Audits

We conduct ongoing, multi-disciplinary coordination reviews covering electrical, structural, civil, and piping layouts to systematically eliminate clearance, soft, and hard clashes.

02

Tools Utilized

Our teams rely on Autodesk Navisworks and Aveva Review to perform automated clash detection, advanced interference mapping, and final conflict resolution.

Technical Expertise & Methodologies

To smoothly accommodate a wide variety of project demands, our project managers and engineering teams are highly proficient across multiple software platforms:

01

Advanced Intergraph SP3D

We bring deep knowledge of SP3D environments tailored for massive, data-centric enterprise megaprojects, ensuring full schema synchronization and multidisciplinary database integration.

02

Aveva E3D Mastery

Our team excels in Everything3D and traditional PDMS environments, enabling collaborative global design efforts that yield incredibly accurate, clash-free structural layouts and routing configurations.

03

Autodesk Plant 3D Capability

We utilize versatile modeling techniques for modular designs and fast-turnaround projects, prioritizing intelligent workflows, rapid asset setup, and efficient spec creation.

04

CADWorx & OpenPlant Flexibility

We are highly skilled at handling component-dense processing facilities using open-data architectures, ensuring intelligent routing, customized modeling, and full BIM readiness for your project.

Projects

3D Plant Modelling Projects

OIL & GASFitness-for-Service Assessment of a Pipeline During Lifting Operations
Duration · 6 Months

Fitness-for-Service Assessment of a Pipeline During Lifting Operations

Fitness-for-Service assessment of a live pipeline affected by Corrosion Under Pipe Support (CUPS), validating structural integrity during a 50 mm lift for UT inspection. Reusable lifting guidelines were developed defining safe criteria for multiple pipe sizes and configurations.

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OIL & GASPipe Stress Analysis of a 44-inch Incinerator Line
Duration · 6 Weeks

Pipe Stress Analysis of a 44-inch Incinerator Line

Static and dynamic pipe stress analysis validating a proposed incinerator piping design modification, enabling the customer to approve and proceed with site modifications while improving incinerator efficiency and minimising the risk of future operational failures.

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RENEWABLE ENERGYFEA of a Wind Turbine Generator (WTG) Transformer
Duration · 5 Weeks

FEA of a Wind Turbine Generator (WTG) Transformer

FEA-based structural validation of a WTG transformer under transportation, lifting and extreme-wind acceleration loads. Critical stress regions were identified and the lifting arrangement, tie-down configuration and weld design were optimised for a manufacturing-ready design.

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NUCLEARSeismic Qualification of a 3.2 MW Induction Motor for a CCW Pump
Duration · 5 Weeks

Seismic Qualification of a 3.2 MW Induction Motor for a CCW Pump

Equipment qualification for Operating Basis Earthquake (OBE) loading, giving the customer the confidence to release the motor for manufacturing and supply it to a nuclear power plant site — a decision that could not be made without seismic qualification proof.

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WATERPipe Stress Analysis of a 40 MLD Desalination Plant
Duration · 6 Months

Pipe Stress Analysis of a 40 MLD Desalination Plant

Pipe stress analysis of critical piping systems under operating and environmental loads for a 40 MLD desalination plant, ensuring piping integrity, safety and code compliance to support safe and reliable plant execution.

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FAQ's

Frequently Asked Questions

By partnering with us to construct highly accurate, data-rich digital twins of your physical sites, you eliminate the guesswork from the project execution phase. Our 3D models provide a unified, unambiguous source of truth that optimizes space management, prevents expensive on-site rework, and guarantees reliable traceability for long-term facility management.

Yes. For brownfield projects and site expansions, we provide highly accurate as-built modeling. This ensures that any new modifications, equipment, or piping fit flawlessly within the existing physical constraints of your site, eliminating spatial conflicts before field assembly begins.

We run exhaustive interference checks long before fabrication to pinpoint spatial conflicts. Using advanced industry tools like Autodesk Navisworks and Aveva Review, our teams conduct ongoing clash audits across electrical, structural, civil, and piping layouts to systematically eliminate clearance, soft, and hard clashes.

Our flawless data extraction process ensures you get exactly what you need for fabrication and procurement. We pull precise outputs straight from the finished, spec-driven model, including General Arrangement (GA) drawings, Material Take-Offs (MTO/BOM), and Isogen isometrics, solidifying our reputation as a dependable plant design outsourcing partner.

To ensure seamless integration with your existing enterprise databases and global design efforts, our engineering teams are highly proficient across multiple industry-leading platforms. Our capabilities include Intergraph SP3D for massive megaprojects, Aveva E3D and PDMS, Autodesk Plant 3D, as well as CADWorx and OpenPlant for BIM-ready, open-data architectures.

We leverage professional CAD-based workflows where intelligent P&IDs directly govern the 3D routing process. This data-driven integration automates specification compliance across complex, multi-sector piping runs, HVAC ductwork, and electrical cable trays — effectively eliminating translation errors between original schematics and the final model.

Absolutely. Our expert consultants design tailored, spec-driven layouts that adhere strictly to specific regulatory standards, spatial limitations, and hazardous zone classifications. This rigorous data compliance makes us a preferred partner for highly regulated sectors like refineries, thermal power plants, and nuclear installations.

We translate your initial layout concepts and vendor data sheets into exact 3D models covering both primary and secondary infrastructure. Our structural modeling specializations include rotating and static equipment, secondary steelwork, pipe racks, civil foundations, walkways, access platforms, and critical power generation components.

We partner directly with energy asset owners, facility operators, and EPC contractors across the broader energy sector. Our core industry specializations include:

  • Process plants
  • Nuclear containment facilities
  • Thermal power plants
  • Offshore platforms
  • Complex oil and gas facilities

Beyond the initial construction phase, a data-rich digital replica serves as an enduring source of truth that spans the entire lifespan of your engineering assets. This guarantees reliable, long-term traceability of the facility, making future maintenance, safety audits, and operational upgrades significantly more efficient and cost-effective.

Blog

Insights from Our 3D Plant Modelling Desk

Technical explainers and case notes on digital twins, spec-driven routing, multi-discipline clash detection, as-built modelling and platform selection.

Digital Twins: From Vendor Data Sheets to a Live Plant Model

Digital Twins: From Vendor Data Sheets to a Live Plant Model

How initial layout concepts and vendor data become a data-rich replica that lasts the full asset lifecycle.

  • Vendor data integration
  • Digital twin fidelity
  • Lifecycle traceability
Letting Intelligent P&IDs Drive Your 3D Routing

Letting Intelligent P&IDs Drive Your 3D Routing

Data-driven integration that automates spec compliance across piping, HVAC and cable trays.

  • P&ID-governed routing
  • Spec compliance
  • Translation-error removal
Clash Detection Before the First Weld

Clash Detection Before the First Weld

Running clearance, soft and hard clash audits in Navisworks and Aveva Review to kill on-site rework.

  • Clearance / soft / hard clashes
  • Navisworks & Aveva Review
  • Coordination reviews
As-Built Modelling for Brownfield Energy Sites

As-Built Modelling for Brownfield Energy Sites

Capturing existing constraints so modifications fit flawlessly the first time.

  • Brownfield constraints
  • As-built accuracy
  • Tie-in planning
SP3D vs. Aveva E3D vs. Plant 3D: Choosing a Platform

SP3D vs. Aveva E3D vs. Plant 3D: Choosing a Platform

Matching the modelling toolset to project size, data model and enterprise database needs.

  • Enterprise megaprojects
  • Modular fast-track
  • Schema synchronization
Extracting Fabrication-Ready Deliverables from a 3D Model

Extracting Fabrication-Ready Deliverables from a 3D Model

GA drawings, MTO/BOM and Isogen isometrics pulled straight from a spec-driven model.

  • General Arrangement drawings
  • MTO / BOM
  • Isogen isometrics