A robust commissioning process is your digital thread connecting early engineering design details to asset management systems used for the life of the new facilities. Without digitalized commissioning processes, project teams are left with unorganized and redundant PDF documents and reports, making it difficult for ongoing operation and maintenance of the new facilities.
Software systems used for mechanical, electrical, and control systems designs, such as 3D modelling systems, are your data source to supply high quality engineering data, and this data integrity must be maintained through all stages of projects.
The goal is to connect high-quality engineering data with asset management systems by implementing robust construction completions and commissioning data management systems for seamless and reliable operation for several decades.
What is 3D Modeling in Commissioning?
We’ve all heard of 3D modelling used for quite some time for detailed engineering and design activities. 3D modelling has been used for clash detection and design validation for a while. When 3D CAD systems are used properly, there should be no reason that your cable tray is planned to be installed in the same location as your HVAC ductwork.
But how is 3D modelling used for commissioning?
One of the main functions of a well-defined commissioning process is to facilitate the transition from area-based construction to systems-based completions, as defined in the ICA Commissioning Phases & Handover Model.
When approximately 60% to 70% of construction activities are complete, the build phase transitions to the construction completions phase, where installations are completed by systems.
This transition takes a lot of planning, and 3D modelling with high-quality engineering data makes this transition much smoother.
Projects are complex, and there are a lot of moving parts. On the surface, it may seem straight forward to determine subsystems and systems for completion. But when one small component gets missed, it causes costly delays later.
When systematization takes place within 3D software systems, everything is accounted for. Nothing gets missed. Every tagged piece of equipment is itemized and prioritized and sequenced within your construction completion and commissioning workflows. Systematization in 3D software systems sets the stage for high-quality data to be used in the field for completions and commissioning.
What data is being managed?
A common misconception is that the commissioning data to be managed consists of checklists, procedures, documents, and reports – and that all these documents can be managed within a document control system. The data to be managed are the reports to be sent back and forth between the various groups working on the project. While document control is certainly important, this is only one part of the dataset required for commissioning.
Equally important is the digital data representation of the equipment and systems that make up the project. This consists of the equipment tag numbers, the information deliverables associated with each tag ID (O&M manuals, etc), and the subsystem/system definition of how the project is broken up into manageable functional portions of work for completions and commissioning. This digital data is the digital twin representation of the real-world assets in the field, digitally modelled and tracked in software to complete projects using a systems-based approach.
The data being managed for completions and commissioning is much more than a set of PDF documents. The data being managed is the high-quality data produced from engineering design groups, supplemented with real-world operational data for a complete dataset deliverable to operations groups at the end of projects.
What is the Digital Thread?
The quality of data can degrade as projects progress without robust commissioning systems and processes. High-quality data produced from 3D models during detailed engineering processes can get lost during the project if project teams resort to paper and spreadsheets to manage commissioning. The concept of the digital thread is to maintain high-quality data through all stages of projects, with traceability and accountability from beginning to end, in order to deliver high-quality data that can be used in asset management information systems once projects are complete.
When the digital thread is maintained, all phases of projects, and groups responsible to operate and maintain the new facilities once the project is complete, benefit from high-quality data that is easy to use and easy to find, making everyone’s jobs easier and more efficient.
Key Applications of 3D Modeling and Data Management in Commissioning
Any project with multiple mechanical, electrical, and automation systems can quickly get lost during commissioning, with multiple systems at various stages of completion through commissioning workflows, and thousands of punch items to determine when each needs to be complete. Completing projects becomes much easier with an upfront definition of how the project will be completed when systems are being designed in 3D systems.
- Systematization and Segregation: Structuring systems for commissioning while being designed in 3D modelling software sets the stage for smooth handovers are each staged gate of your commissioning process, with high-quality digital information accompanying each system definition – this digital thread ensures traceability of data from design to operation.
- Simulation and Testing: Sophisticated “virtual commissioning” scenarios become possible when high-fidelity models of systems are created to allow real-time data inputs, to verify functionality and integration before equipment is even installed in the field. PLC logic can be integrated and verified in advance of on-site testing, significantly reducing delays due to troubleshooting in the field.
- Operator Training: It is becoming more common to use software simulated HMI controls enriched with data from asset management systems for immersive, scenario-based training, to prepare operators for operation of complex plant processes, and to support a software handover at the in-service date with teams ready for on-going operation and maintenance of the new facilities.
Benefits of Integrating 3D Modeling and Data Management
Plant process and energy system projects are a data-rich environment, and we must gather and use this data to our advantage to make commissioning more efficient. This data-rich environment is a best-use case for the emerging AI systems, since there is too much information for any one person to comprehend on a daily basis. By starting with high-quality data from 3D modelling information created during detailed engineering and design, and leveraging AI systems to manage all the data generated on projects, we can start to make sense of the information overload, and have systems push the data to us, rather than have to search for the information needed on a daily basis to make informed decisions.
- Enhanced Accuracy and Traceability: When the high-quality digital thread is maintained from the beginning to end of projects, project teams can get to the level of precision required to deliver high-quality systems that can be used for decades of reliable operation. When an issue is encountered in any stage of projects, the data exists for traceability right back to the root cause, incorporating lessons learned and continuous improvement along every step of the way for improved project performance each time.
- Improved Collaboration Across Stakeholders: Centralizing data in digital models to ensure all teams—engineering, commissioning, and operations—have access to the same information and are aligned. This is more than just dumping all you PDF document files into a share repository. Digital models represent each project system, with all data centralized where is needed. With a 3D model of systems, the information you need is organized by system, information is at your fingertips, rather than having to search a document database trying to find what you need.
- Risk Reduction: When information flows more easily, it becomes much easier to be proactive, rather than continually chase issues. We’ve all had many days, weeks, or months of constant fire-fighting. But when project teams leverage data-driven 3D model simulations, they are able to easily predict and prevent issues in advance, and reduce or even avoid constant fire-fighting of daily issues.
- Streamlined Documentation: A 3D model representation of project assets automatically generates and links documentation. For example, when commissioning test results or compliance reports are generated, these are automatically linked to the commissioning plan/procedure, linked to the tagged piece of equipment, all withing the 3D model. Nothing gets lost, and everything is in the place it should be for easy reference.
- Operational Readiness: 3D modelling systems in a data-rich environment enable smoother transitions to asset management systems, giving plant operators everything they need for easy access to information on a daily basis.
Challenges and Considerations
Now these data management systems do not come without their challenges. Project teams are often hesitant to implement more sophisticated data management systems because of these reasons.
- Quality of Data: Garbage-in, garbage out, right? This common saying definitely applies in this case. Without the upfront effort to have high-quality data produced in 3D modelling systems during detailed engineering design, then these systems are not much use. The cost and time required for implementing 3D modeling and robust data management systems can be intimidating to project teams. And when projects only last 3-5 years, some project teams don’t think it’s worth the effort. But without robust data management systems, project timelines can easily double, or worse, the entire project fails to achieve its original objectives. If a second or third project follows the original project effort to establish robust data management systems, that’s when enormous efficiencies are achieved as lessons learned from past projects are incorporated for continuous improvement.
- Data Integration: There is a lot of data produced on projects, and it can seem challenging to ensure seamless connectivity between 3D models, engineering data, commissioning management systems, and asset management platforms. But with a robust digital data management strategy, data doesn’t get lost, and all information flows between all stages of projects. Construction completions and commissioning becomes much easier when integrated with engineering data.
- Model Accuracy and Updates: Keeping the digital thread unbroken as the project evolves, including handling late-stage changes, can be challenging. When time and cost pressure increase at the end of projects, it can be tempting to break the digital thread just to get things done. Keeping models intact, updated, and accurate becomes everyone’s responsibility to maintain the digital thread.
- Cybersecurity: While protecting sensitive engineering and asset data used to be challenging in the past, today’s modern server systems utilize the most sophisticated security algorithms. The big data companies like Amazon AWS, Google, and Microsoft, with teams of thousands of people, have implemented advanced cryptography to protect cloud-based data systems. While you may still hear of smaller systems being compromised, these big data companies are at the leading edge of data security.
Future of 3D Modeling, Data Management, and Commissioning
The current systems being used are only the beginning – with advances in AI, it’s hard to predict how quickly things will change in the short term and in the long term.
- Emerging Technologies: AI Agents are coming. How will this change the construction and commissioning industry? It seems like 2025 is the year to declare the end of old/outdated methods for data management. The integration of AI, and digital twins for real-time commissioning insights, is clearly the way of the future. Will project teams still be using paper and spreadsheets to manage their data in 5 years from now? Or will companies still using legacy methods still be around in a few years?
- Sustainability: We have a lot of projects to build in the next few decades to accomplish our global objectives – with climate change initiatives, electrification of our infrastructure, clean energy, and much more. The role of data-driven modeling in green commissioning and operational efficiency will clearly be part of the solution to accomplish these goals.
- Unified Digital Ecosystems: The goal is to advance the digital thread to ensure that data from commissioning seamlessly transitions into long-term asset management and operational systems. And this is only possible with an upfront effort to establish high-quality data during detailed engineering design.
Conclusion
3D modeling and advanced data management are revolutionizing the commissioning process, transforming it into a streamlined, efficient, and data-driven practice. By maintaining a robust digital thread, projects can connect high-quality engineering data through every stage—design, commissioning, and long-term operations—ensuring traceability, accuracy, and seamless transitions.
The projects industry must embrace these integrated technologies to achieve better outcomes, meet future sustainability goals, and remain competitive in a rapidly evolving landscape. Now is the time to implement these practices and future-proof commissioning strategies, setting the stage for a smarter, more connected, and resilient project ecosystem.
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