Industrial facilities are very complex structures. In large interconnected and intertwined installations, each separate unit should be controlled individually. The complexity of the structure often causes difficulties and challenges for the staff responsible for controlling the facility.
As an example of our work, a client (facility management) requested a 3D model of an onboard industrial facility that produces, transports, and unloads petrochemicals. Structural deformations were frequently seen upon the structure was located in a vehicle moving on the sea. The client needed detailed 3D information of all the structures in the facility, separated from each other in terms of their technical features.
Role of 3D Laser Scanning Technology
Industrial facilities, unlike all other structures, create measurement difficulties due to their unique and challenging site conditions. Because of the complexity of the structure, it is quite difficult to position the device that enables the scanner to get every part of the interconnected and intertwined installation into its visual angle. Besides, many of the operating mechanisms in the facility can reach quite high temperatures, which also increases the ambient temperature. 3D laser scanners can operate at specific temperatures, therefore, some industrial facilities may need to stop these mechanisms during the measurement process.
Before measuring such a complex structure, the laser scanning expert conducted a series of reconnaissance surveys and developed the “measurement strategy” as a result of the analysis. During the examination of the field conditions, the expert obtained the necessary information from the responsible staff of the facility and analyzed the purpose of 3D information requested. A 3D Terrestrial Laser Scanner (TLS) was considered the best option for this case because the client should have as accurate information as possible due to the pipelines, steel structures, and machineries, as well as the industrial environment. (Van Genchten, 2008; Aygün, 2018)
TLS may be used for similar projects to obtain the entire structure geometry, including locating plumbing connections and anchor bolts and verifying the dimensions and positions of piping systems. In case of damage caused by a storm, structural damages should be documented quickly for repair or decommissioning procedures. (Van Genchten, 2008; Aygün, 2018)
The use of TLS in industrial facilities provides an advantage to the client in terms of ensuring accurate, reliable, and comprehensive digital information of the current situation from design to manufacturing and assembly processes, as well as short measurement times.
Through the 3D point clouds obtained with laser scanners, it is ensured that very important operations for the facility such as new productions, designs of very small or very large parts, and assembly operations are carried out more accurately. Performing local measurements of such facilities each time required may cost 10% or more of the total capital of a project. However, the cost of measuring the entire facility with a 3D laser scanner for once is typically less than 1% of the total project cost. In other words, once high-resolution laser scanning measurement is performed, it will result in a significant reduction in data reproduction and processing; according to the calculations, with a 2% gain for measurements and 4% for project renewals, the total cost of the project is reduced by 5%. (Van Genchten, 2008)
In addition, using a laser scanner has a positive effect on reducing current and potential safety issues:
- Since measurements are made from a distance, surveying teams can choose the most suitable scanning locations and
- Due to the high speed of the laser scanning system, risk exposure possibilities are reduced.
Figure 1: Device installation in industrial facilities. (Van Genchten, 2008)
The laser scanning expert carried out a meticulous preliminary study of such a complex structure and received a lot of help from the facility staff during the process. After the analyzes made in the field, the information to be used in the measurement process such as the measurement team and equipment information, the type and number of targets to be used, the places where the device will be installed was collected and measurements were made. This information was stated in the method description documents prepared by the expert. In addition, every scan data before and after the measurement were checked, taking into account the “Quality Assurance (QA)” and considering the possibilities of moving or displacing the scanner during the measurement under the facility conditions. These controls were made by examining the point clouds and measurements were made with a total station for general control. These controls were made by examining the point clouds and measurements were also made with a total station for general control. (Van Genchten, 2008; Aygün, 2018)
After scanning at the specified resolution and number, the point clouds were combined and after the controls were made, the final product preparation studies were started.
Figure 2: Converged point cloud of an industrial facility. (Van Genchten, 2008)
Modeling such industrial facilities using point cloud is considered one of the most difficult modeling studies. Many modeling softwares have developed special tools for these types of objects. These special tools can perform various controls for complex piping as well as pipe modeling.
Figure 3: Modeling study of industrial facility. (Van Genchten, 2008)
The interconnected and intertwined structures in the installation draw attention at first glance from the outside. These installations may not be connected to each other. Point clouds may contain many errors in objects, such as metal, dense objects painted in different colors, and objects with high temperatures. Errors that may occur in the 3D geometry of objects can cause difficulties for experts during modeling. For this reason, there are tools in pipeline modeling programs that control the clash detection of custom-modeled pipelines. (Aygün, 2018)
Figure 4: Project drawing over the pipe model. (Van Genchten, 2008)
The project drawing in the figure above is familiar to the facility staff. These data are an indication that both the measurement strategy has been created correctly and that client demands have been taken into account.
Many industrial facility owners are interested in 3D documentation of their facilities. The reason for this interest is due to increased safety regulations and the desire to minimize errors in the operations performed at the facility. Extremely successful results have been obtained in such studies using TLS for years. The 3D model of the facility, which is presented as a final product, and the project drawings produced through this model, allowed the operations carried out in industrial facilities to be kept under control.