3d laser scanning in the boatbuilding industry

© 2013 Diversified Business Communications. All rights reserved. 1

3D LASER SCANNING IN THE BOATBUILDING INDUSTRY

3D LASER SCANNING

IN THE BOATBUILDING INDUSTRY

Presented by: Sponsored by:

WorkBoat and WorkBoat.com are produced by Diversified Communications.

Produced by:

Contributors

Daryl Johnson, Engineering Manager, Summit Engineering and Design Sam Billingsley, Vice President, SmartGeometrics

©2013 Diversified Business Communications. All rights reserved. 1


Table of Contents Introduction ....................................................................................................................... 2

What is 3D imaging? ........................................................................................................ 2

What does 3D imaging produce? ..................................................................................... 2

Why use point clouds? ..................................................................................................... 3

How do you use point clouds? ......................................................................................... 4

Project level use ............................................................................................................... 4

Typical workflow .......................................................................................................... 5

3D facility configuration model ............................................................................... 6

Modeling ...................................................................................................................... 6

Drydock .................................................................................................................. 6

Ship ...................................................................................................................... 10

Surrounding facilities ............................................................................................ 14

3D modeling of ship hulls and interiors .......................................................................... 15

3D laser scanning for ship piping systems ..................................................................... 19

Conclusion ...................................................................................................................... 24



Introduction Are you looking to build more efficiently, while reducing waste and rework? Then it's time to investigate 3D laser scanning, technology that is revolutionizing engineering and design. In this report, we'll explore the technology of 3D data capture and how it's being applied to vessel construction, repair, and maintenance and operations. Learn about point clouds, 3D modeling, visualization, and much more, from experts in the field.

What is 3D imaging? In the simplest terms, 3D imaging entails utilizing a combination of measuring and recording devices that capture spatial information and other data about an object. This survey equipment can include total stations, laser scanners, or digital cameras, among other devices. Data captured by these devices can then be referenced together to create a unified point cloud, which will represent the data from all of those sources. And because these collection methods all capture a scene in its current state, they are often vastly superior to traditional survey methods that might represent objects or structures incorrectly, basing the information on as-built data as opposed to the current structure.

What does 3D imaging produce? Point clouds are the foundation of 3D imaging. These collections of points are comprised of X, Y and Z values, which define an object’s place in a three-dimensional location. All data in a point cloud is at a one-to-one scale. The point cloud also functions as the basis for spatial reference.

Figure 1



The thing that makes 3D data collection superior to traditional survey techniques is its ability to accurately collect vast amounts of points. In fact, a typical laser scanner can collect up to one million points per second. These millions of points make up the raw data in a point cloud that can define the current state of a vessel or structure. Because each of those points has an XYZ value, measurements can be calculated between points with a variety of software applications. This can be extremely helpful if you are trying to determine how do things to a vessel, such as retrofitting it for LNG gas conversion or just putting in new lines and motors.

Figure 2 is an example of a vessel point cloud.

Figure 2

Why use point clouds? Even though this whole process might seem impressive, you might wonder why you should use point clouds. After all, you’ve been doing things for years without them. The first thing to consider is the benefits that laser scanning can have on accuracy. Chances are, right now you are doing a combination of station work and tape measures and hand written notes about measurement. That’s a dangerous combination for accuracy. Miscalculations can lead to expensive mistakes and misused resources. On the other hand, some 3D laser scanners can provide a level of accuracy somewhere in the four-to-six-millimeter range.

This type of 3D data capture can also change your collection mindset. That’s because you’re not collecting data on individual things, you’re collecting from an area. You can also adjust your



point of view and move from place to place. Control networks and targets can be tied in together, providing an overarching view of the entire environment, not just the individual components.

Because this data is so rich in and of itself, it removes a level of obfuscation. You don’t have to decipher handwritten notes and measurements; instead, you can put the entire vessel into your computer, and design within the system at a one-to-one scale. This helps dramatically cut down on in-field retrofitting and custom fabrication.

In many cases, point clouds can also remove the need to model. Obviously, modeling is needed in some cases but at the bare minimum, 3D imaging allows you to just model what you need, instead of the entire scene. Colorizing can also add another layer of depth and context to a point cloud to help move a project forward.

How do you use point clouds? Point clouds can be utilized with various software programs and applications including point cloud-specific applications, standard CAD applications, visualization platforms and several tertiary applications, to register data from laser scans and digital imagery as well as to perform modeling. Some common examples of these programs are listed below.

Project level use Clearly, there are many ways data can be gathered, but how does this data fit into the typical engineering project? The first phase involves gathering 3D data from either laser scanning, photogrammetry, or surveying during fieldwork. The next step is to register the laser scans and digital imagery to create a point cloud, which can be used in a CAD program to create a 3D model, or simply viewed as geometric shapes - a lower cost option compared to regular 3D modeling. Other options include using point cloud data, both scans and images, to produce elevation models.

Figure 3



Modeling ship hulls and interiors in 3D has numerous benefits, particularly when it comes to documenting piping. The cost for piping rework can be substantial. Techniques such as 3D laser scanning can minimize cost substantially because it can minimize the need to be on site and other costs associated with traditional forms of piping rework.

Another area where 3D laser scanning can be an effective tool is with ship hull as-builts, specifically for docking plans. The majority of the ships don’t have good data on their hulls. This means that every time that ship comes into a drydock, a new docking plan must be created. A revised plan will also need to be completed once the ship has docked.

Typical workflow Workflow methods will vary from company to company, but a typical process might include using targetless scanning and registering point clouds using a number of software programs. Popular software such as Autodesk’s Navisworks is used to provide tools for Building Information Modeling (BIM), visualization, and 5D analysis. Figure 4 is an example of a drydock that looks like a model, but is actually just isolated figure sets presented in different colors.

Figure 4



3D facility configuration model Many shipyards do not have accurate representations of their facilities. Configuration models can provide an accurate representation of this information, allowing for better visualization of staged production configurations, simulation of crane reaches, throughput modeling, and material staging and handling. These models can also help avoid potential interferences in regard to welding access, hoists, and chain falls.

Modeling This process involves scanning the facility and aligning that data for accurate facility coordinates. Various structures and equipment can then be isolated, and pertinent items can be modeled. Those models can then be brought into production simulation programs.

Drydock Figure 5 is an example of an isolated point cloud that has been separated into systems and components.

Figure 5

Labeling components in this way allows elements that are not relevant to the project to be stripped away. Figure 6 shows the view that is left once these elements have been removed.



Figure 6

Figures 7 through 9 show the progression of how components inside the point cloud can be turned on individually.

Figure 7



Figure 8

Figure 9

Figure 10 shows a combination of scan data and model data.



Figure 10

The pink in Figure 11 shows how yard trash was separated out because it wasn’t relevant to the model.

Figure 11



Ship From this point, a model of the ship was created and placed back into the drydock area as shown in Figure 12.

Figure 12

Initally when the scans of this drydock were taken, the ship was docked. Scanning around the ship allowed the information to be isolated.

As shown in Figure 13, scanning the dock provided details about the area that could be examined closely or from a distance.



Figure 13

Different views of this data can reveal information about the area. Figures 14 through 15 show the different ways in which this data can be viewed.

Figure 14



Figure 15

Figure 16

Figure 17 shows how these different views compare.



Figure 17

Figure 18 is the ship model.

Figure 18



Surrounding facilities These types of models also allow data to be integrated from other data sets. For example, in Figure 19 the ship is from a Texas drydock and the cranes are from a dock in Panama. Combining these two data sets will show how the Texas ship will fit in the Panama drydock and how the cranes can reach the ship.

Figure 19

Figure 20



3D modeling of ship hulls and interiors Modeling inside of a ship can reveal some interesting information. The interior of a ship might be modeled for a number of reasons. First, this might be done to gauge the vessel’s hydrodynamics using a computational fluid dynamics-based analysis. Modeling can also be used to evaluate fuel economy optimization, for stability analysis, and to repair issues on hulls.

Figure 21

Just like modeling exterior structures, modeling interior elements follows a similar methodology. First, information is scanned and registered. Preparation for surface fitting of the hull involves isolating scan data, filtering, and cleaning invalid information and removing non-hull data.

Figure 22 gives a view of the entire ship, while Figures 23 and 24 show, specifically, how the hull was extracted and modeled.



Figure 22

Figure 23



Figure 24

Surface modeling of the hull was then performed.

Figure 25



Figure 26

Figure 27 is the cutaway of the ship.

Figure 27

Figure 29 shows a cross-section of the ship with the scan data and the model.



Figure 28

3D laser scanning for ship piping systems Laser scanning is typically used to capture 3D data of piping inside a ship. The scans are registered and a model is created. The next step is to isolate the piping in need or repair or upgrade using feature recognition CAD software. This defines the overall scope of the project, whether it’s piping repairs, upgrades, or installing new equipment altogether.

This process is beneficial because it allows for the pre-fabrication of pipe spools, increased bolt-ups, reduced field welds, where welders need to do the job on site rather than in the shop, and less down time. Figure 29 is an example of a machinery room.



Figure 29

Figure 30 is the registered scan data.

Figure 30



Isolated piping of scan data can be seen in Figure 31.

Figure 31

The model data was then added to the scope, which the client approved.

Figure 32



Figure 33 is a view of just the model.

Figure 33

A fabrication ISO was then created from Bentley Systems’ AutoPLANT plant design and engineering CAD software.

Figure 34



This particular ship had a single pump to service. The goal was to replace it with two pumps. The pumps delivered, but the client did not have any drawings. The pumps were scanned sitting on the pallet, so that the dimensions could be measured and fitted in with the new piping.

Figure 36 gives a view of the top of the model with revised items added in and Figure 37 shows just the model.

Figure 35

Figure 36



Conclusion In the marine industry, efficiency is everything. When it comes to engineering and design, few things can match the power and functionality of 3D imaging. From vessel construction to repair and maintenance, the uses for 3D imaging technologies are vast. The practice goes far and beyond traditional survey techniques, allowing for increased observation, extraction and modeling capabilities. And with precision accuracy and customizable deliverables, few documentation practices can compare to 3D laser scanning.

3d laser scanning in the boatbuilding industry

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