The Problem with Guesswork in Brownfield Design
Upgrading or modifying an existing processing plant is never straightforward.
Whether it’s a coal handling preparation plant (CHPP) in the Bowen Basin, a water treatment facility on the Central Coast, or a manufacturing plant in Sydney, every brownfield project faces the same challenge: nothing is ever exactly where the drawings say it should be.
Over time, structures settle, pipe runs are rerouted, and maintenance crews make unrecorded modifications. When a new chute, tank, or platform is designed on old drawings, these discrepancies become expensive mistakes.
That’s why industry leaders are embracing digital twin technology — accurate, data-driven 3D replicas that bring the real world into the design space.
At Hamilton By Design, we turn laser-scanned point clouds into SolidWorks 3D models, giving engineers the confidence that every new component will fit — before fabrication begins.
What Is a Digital Twin?
A digital twin is more than a 3D model — it’s a living digital replica of a physical asset or environment. Built from LiDAR-based 3D scans, the twin mirrors the as-built geometry of the plant, allowing engineers to test, model, and validate upgrades in a risk-free digital space.
When used in mechanical and structural design, the digital twin becomes a single source of truth — integrating point cloud data, SolidWorks 3D design, and FEA validation into one seamless workflow.
For brownfield engineering, this approach eliminates uncertainty, reduces design iteration time, and provides a data-rich foundation for future asset management.
Step 1: Capturing Reality – 3D Scanning and Point Clouds
The process starts in the field. Using a FARO Focus or equivalent LiDAR scanner, Hamilton By Design captures millions of data points across the plant in just minutes.
Each scan produces a high-resolution “point cloud” — a dense 3D map of the environment that captures every surface, structure, and detail with millimetre-level accuracy.
Multiple scans are then registered together, creating a unified 3D dataset of the entire facility.
This digital foundation eliminates the need for risky manual measurements, allowing site teams to capture geometry safely from the ground — even in areas that are difficult to access during shutdowns.
Step 2: From Scan to SolidWorks – Building Accurate 3D Models
Once the point cloud is complete, the next stage is reverse engineering.
Our team imports the scan data into SolidWorks, using it as the base reference for modelling equipment, structures, and assemblies.
Every new design element — from chutes, platforms, and handrails to entire processing modules — is created directly within the scanned environment.
This means the new model fits exactly within the existing plant, ensuring alignment, clearance, and accessibility are verified digitally long before site installation.
By combining mechanical trade knowledge with advanced CAD integration, Hamilton By Design bridges the gap between the site and the screen — delivering models that work in the field, not just in theory.
Step 3: Verifying Fit and Function
With the digital twin in place, the design team can perform full interference checks and clash detection.
SolidWorks allows engineers to simulate installation sequences, check for obstructions, and validate maintenance access zones.
This pre-emptive digital validation reduces the risk of on-site surprises — no more cutting steel or shifting structures during shutdown because a bolt hole was 20 mm off.
The result is faster installation, fewer delays, and safer working conditions.
Step 4: Visualisation and Collaboration
Another major advantage of digital twins is communication.
Gone are the days of handing over static 2D drawings and expecting everyone to visualise how the upgrade will fit.
Using e-drawings and interactive 3D viewers, Hamilton By Design delivers models that clients, fabricators, and site teams can explore in real time.
Project managers can rotate, zoom, and measure within the model — improving collaboration between engineering, procurement, and construction teams.
For EPCM firms and asset owners, this level of transparency builds trust and eliminates ambiguity across the project lifecycle.
Digital Twins in Action: A Bowen Basin Retrofit Case Study
A CHPP client in the Bowen Basin recently engaged Hamilton By Design to support a debottlenecking project.
The goal: replace a series of ageing transfer chutes and install new dust-suppression ducting during a single 72-hour outage.
Traditional methods would have required weeks of manual site measurement and still left uncertainty about alignment.
Instead, the plant was 3D-scanned ahead of time, and the resulting point cloud was used to model the new chute assemblies directly within SolidWorks.
During digital fit-up, the team identified several interferences with an adjacent walkway and pipe rack — issues that would have caused at least two days of rework during installation.
By resolving these digitally, fabrication could proceed with confidence.
The outcome:
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Zero rework on site
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All chutes installed within schedule
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Measurable reduction in shutdown duration and cost
That’s the value of precision modelling — turning what used to be reactive problem-solving into proactive engineering.
Retrofit and Debottlenecking Made Simple
In existing facilities, every upgrade is a retrofit — and retrofits mean unknowns.
Digital twins remove those unknowns, simplifying retrofit engineering by aligning new design intent with existing geometry.
Typical applications include:
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Chute and bin replacements – modelled within existing support frames
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Conveyor transfer upgrades – validated for accurate belt alignment
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Pump and pipework retrofits – ensuring perfect tie-ins
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Platform and access redesigns – verified for clearance and compliance
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Dust control and ducting systems – fitted seamlessly into congested layouts
Whether it’s a single component or a full process module, designing within a digital twin eliminates guesswork and ensures efficient integration.
Why EPCM Firms Choose Hamilton By Design
EPCM firms and asset owners often juggle multiple contractors, tight deadlines, and high-stakes budgets.
Partnering with Hamilton By Design provides a trusted mechanical engineering partner that understands both the digital tools and the practical realities of plant work.
Our advantages include:
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25 + years’ mechanical and design experience
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Trade background in fitting and machining for practical engineering judgement
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Proficiency in SolidWorks and FEA since 2011
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Field scanning and modelling capability using advanced LiDAR systems
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Focus on brownfield projects in mining, manufacturing, and construction
When we model your plant, we’re not guessing — we’re designing with data.
The ROI of Getting It Right the First Time
It’s easy to underestimate the cost of poor fit-up.
A single misaligned flange or interference during installation can cascade into lost production, emergency rework, and safety risks.
By using a digital twin workflow, the cost of scanning and modelling (typically < 1 % of project cost) can save days of unplanned downtime worth hundreds of thousands of dollars.
| Activity | Traditional Approach | With Digital Twin |
|---|---|---|
| Measurement & Verification | Manual site survey | LiDAR scan (1 day) |
| Design Basis | Old GA drawings | Accurate as-built geometry |
| Fit-Up Risk | High – frequent clashes | Minimal – verified digitally |
| Rework Cost | 5–10 % of fabrication | < 1 % (if any) |
| Installation Time | Extended shutdown | On schedule or early |
| ROI | Variable | Consistently > 500 % |
Digital accuracy isn’t a luxury — it’s an investment in certainty.
Beyond Design: The Future of Asset Management
The benefits of digital twins extend far beyond project completion.
Once the scan and 3D model are established, they form the basis for ongoing asset management.
Plant owners can track modifications, plan future expansions, and link operational data (like vibration or flow metrics) directly to the 3D model.
As a result, maintenance, safety, and capital planning teams share a unified, visual platform for decision-making.
It’s a step toward true Industry 4.0 — where physical and digital systems work hand in hand to optimise plant performance.
Sydney’s Engineering Advantage
While Hamilton By Design supports projects nationwide, our Sydney base gives EPCM firms and asset owners in Chatswood, Parramatta, and the Eastern Suburbs direct access to digital engineering expertise.
For construction projects, fabrication workshops, and manufacturing facilities across the city, point-cloud modelling provides a competitive advantage in accuracy and presentation.
Our digital twins are particularly valuable for council approvals, BIM coordination, and client visualisation — ensuring every stakeholder understands the proposed upgrade in full 3D.
Collaborative Design, Real-World Precision
At Hamilton By Design, we believe the best engineering happens when designers, fabricators, and site crews speak the same language.
That’s why our deliverables go beyond drawings — we provide fully navigable 3D models, e-drawings, and markup views that make collaboration simple.
Every stakeholder — from EPCM engineers to on-site trades — can see exactly how the upgrade will install, reducing ambiguity and improving project flow.
From Point Cloud to Precision
Every successful plant upgrade begins with accurate information.
If you’re still relying on legacy drawings or manual measurements, you’re gambling with time, cost, and safety.
By transforming point clouds into digital twins, Hamilton By Design delivers:
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Perfect-fit upgrades every time
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Reduced rework and shorter shutdowns
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Seamless coordination across design, fabrication, and construction
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A digital asset that supports future operations
Get your plant upgrade modelled in 3D before you order steel.
It’s faster, safer, and smarter — and it starts with a scan.
👉 Visit www.hamiltonbydesign.com.au to discuss your next upgrade or request a capability statement.
