3d laser scanning technology in plant industries - … · · 2009-05-13overview of 3d laser...

3D Laser Scanning Technology in Plant Industries3D Laser Scanning Technology in Plant Industries

2

AgendaAgenda1. Overview of 3D laser scanning

2. Current Plant Market

3. HDS 3D Laser scanning applications

4. Demonstration of HDS Scanstation2

5. Questions and Answers

Leica ScanStation2 True Color Scan

Leica HDS6000 Scan

3

HDS 3D Laser ScannerHDS 3D Laser Scanner

Phase-based500,000 points per second(No.1)Range up to 79mIntegrated Battery / Data StorageBuilt-in Control Panel주요 용도 : Indoor 중심

TOF (Time of Flight) 50,000 points per second(No.1)Range up to 300m3D Scanner + Total Station주요 용도 : 원/근 거리 스캔, 실내/외

LEICA HDS 6000LEICA ScanStation2

4

Point size = < 6mmPoint size = < 6mm

Distance = (C xDistance = (C x T)/2T)/2

LEICA HDS Scanstation2

50,000 points per sec.!!Scan Cloud Processing

Software

5

Current Plant Market Current Plant Market

Historic industry expansion

Effecting All industries

Significant project backlogs

Extreme worldwide demand for engineers

Improved productivity needed

Lots of cash and willingness to spend

Boom is expected to continue for at least five more years

Laser Scanning value now generally understood and appreciated

6

HDSHDSCustomersCustomers

7

HDS Plant markets & applications

Oil & gas

Off-shore platforms

Ships

Refineries

Power plants

Nuclear plants

Pulp & paper

Automobile factories

Discrete manufacturingElectronics manufacturing

Aircraft assembly

Pipelines

What’s hot! What’s not

8

Facility / Asset Lifecycle Chain

Build /Construct

Manage /Operate

Renovate / Retrofit *

Decommission/ End of Life

3%-5% oflifecycle

95%-97% oflifecycle

* HDS Sweet Spot

9

Retrofit Project Complications

Complicated and congested environment

Inhospitable or hazardous environment

Many difficult and inaccessible locations

Missing plant Information

Existing drawings incomplete and inaccurate

Project scope changes

Process and design uncertainties

Unknown structural adequacies

Unforeseen space problems

Maintenance and operation considerations

Constructability issues

Identifying and managing ongoing new design Interferences

10

Where Traditional 3D As-built Model Methods Break-Down

Inaccurate As-built Model – Based on existing drawings, field measurements, assumptions, etc…

Simplified Model – Lacking detail

Incomplete Model – Existing documentation missing current information

Cost - Expensive to model from site collection data

Delay - As-built model to design team usually months later than needed

Problems with Old 3D As-built Model Technology – Many limitations with industrial photogrammetry

Retrofit Project Complications

11

12-person scanning services

Focus: North Sea oil platforms

Statoil, ConocoPhillips

>150 projects

10 Cyclone1 CycloneSoftware

1 HDS2500

2 HDS3000

1 HDS4500

2 Scanstation

Total stationTools

122# Staff

20062003

www.capnor.com

12

Plant Customer SuccessSantiago Y Cintra, Brazil

Dec. ‘01: began as dealer

2003: started separate scanning services business

2006: largest HDS customer

12 Leica HDS scanners

34 licenses MODEL

18 licenses CloudWorx

Markets: plants

Petrobras (oil company)

Off-shore + on-shore

www.santiagoecintra.com.br

13

Plant Customer SuccessFramatome ANP, USA

Bought first scanner March ‘01

Markets: nuclear power plants (100%)

By 2006

>400 HDS projects

2 @HDS2500

1 @HDS3000

2 @Scanstation

1 @HDS6000

1 @Scanstation2

+ Rent HDS4500 on project-basis

14

Process PlantsProcess Plants

AsAs--Built DrawingsBuilt Drawings

Piping, Tanks, Steel Piping, Tanks, Steel StructuresStructures

TOSCO Petroleum Refinery, Carson, California

15

Steam piping Steam piping retrofit retrofit

16

Model with Cloud of Points Model with Cloud of Points

17

Model of Piping System Model of Piping System at a Refineryat a Refinery

19

Microstation Drawing

20

Metrics: Creation of asMetrics: Creation of as--builtsbuilts

Work consisted of field scanning and creation of piping and structural members.

Cyrax

Field scanning time 45 minutes

Modeling & dwg.prep 3.5 hours

Total time: 4.25 hours

21

Power Plant RetrofitPower Plant Retrofit

•• Project started Oct. 99Project started Oct. 99

•• $150 million project$150 million project

•• 1st unit: 51 scans in 1 week1st unit: 51 scans in 1 week

•• AsAs--builts to be created builts to be created

•• Export model to PDS for automated Export model to PDS for automated

clash detectionclash detection

•• Projected >$10 million savings (by Projected >$10 million savings (by

reducing rework & rereducing rework & re--design)design)

•• 50% faster creation of models50% faster creation of models

22

Refinery Project:Refinery Project:Piping Piping ““SnakeSnake--pitpit””, API, API--570 Compliance570 Compliance

•• 0.1 mile long0.1 mile long

•• Upgrade 2 pipesUpgrade 2 pipes

•• Tight scheduleTight schedule

•• Complex areasComplex areas

23

Scope of WorkScope of Work

•• Produce a 3D model of the ResidProduce a 3D model of the Resid

ue Catalytic Crackingue Catalytic Cracking unit unit for impfor imp

orting into AutoCADorting into AutoCAD..

•• Keys areasKeys areas

–– 50m x 40m x 85m high50m x 40m x 85m high

•• Reactor Reactor –– Regenerator StandpipeRegenerator Standpipe

•• Catalyst Cooler Circulation Water Catalyst Cooler Circulation Water

PumpsPumps

24

Catalyst Cooler Circulation Water PumpsCatalyst Cooler Circulation Water Pumps

•• Complex pipingComplex piping

–– Multiple levelsMultiple levels

–– Different diametersDifferent diameters

–– Different bend radiiDifferent bend radii

•• Provide 3D ACAD modelProvide 3D ACAD model

26

POSCO POSCO 제제11연주공장연주공장 개체공사개체공사

29

3D Visualization:Being able to view things

from a perspective uncommonfor human eyes

현대정유현대정유 서산공장서산공장

30

영영광광 원자력원자력

31

3D Design3D DesignCase Study 1: VECO Alaska Case Study 1: VECO Alaska TyonekTyonek ProjectProject

Project Information:

Company VECO AlaskaCompany Type: Engineering / Construction / SPClient: ConocoPhillipsLocation: Cook Inlet Alaska / Tyonek PlatformProject Type: Off-Shore / Oil and Gas3d Design S/W: 3D Bentley AutoPLANTDeliverable: 3D Model & 2D Drawings

Project Description:Installing 2 new coalescing filters with associated piping and supports. Adding new filter platform, modifying HVAC and walls to allow installation

2005 Bentley BE Award Winner!

ConocoPhillips - Tyonek Platform

32


3D Model and 2D Drawing Deliverable

Engineering & Design Benefits:

In-house 3D modeling - short cycle time3D model imported into Bentley AutoPLANTReduced field tripsOptimize pipe routing - ongoing piping interference checks - lighting, structural steel and existing pipingMany interferences re-routed without a shutdownPoint cloud data available for future projectsTechnology delivered:

Operations design reviewEfficient engineeringMinimum of construction re-work

33


Photo and 3D As-Built Cyclone Model

Fabrication / Construction Benefits:

3D model of new equipment created from vendor supplied documents

New equipment verified against point cloud for feasibility and to be interference free

Prior to fabrication physical changes were requested to the equipment configurations, which was based on information learned during the feasibility study

All spool pieces fabricated on shore

Industry expected field re-work of 30% to 40% Actual reduced to less than 1%

Post construction – ability to re-scan area and produce accurate as-built drawings

34

VECO Alaska – Tyonek Project SavingsDescription Estimate Actual Cost Savings

Site Trips 23 17 $18,000

Survey Site Trips 3 0 $18,000

Production separators - Fabrication & Construction $975,515 $769,832 $205,863



Engneering Savings - - $36,000

As-built Scanning $0 $30,210 -30,210

$485,399TOTAL PROJECT SAVINGS

Note: customer claims HDS3000 would have reduced field costs by 1/3!


35

3D Design3D DesignCase Study 2: Case Study 2: CapnorCapnor MST Odin ProjectMST Odin Project

Project Information:

Company Capnor Laser Scanning ServicesCompany Type: Service ProviderClient: Marathon Oil CorporationProject: MST Odin ProjectLocation: NorwayProject Type: Marine3D Design S/W: Aveva PDMSDeliverable: 3D Model & 2D DrawingsHDS Scanner: HDS3000

Project Description:Convert shuttle tanker into an FPSO (Floating production, storage and offloading vessel). Complete 3D As-built model to be imported into PDMS and used for engineering modification

MST Odin – 3D Cyclone Model

36

Case Study 2: Case Study 2: CapnorCapnor MST Odin ProjectMST Odin Project

Project Metrics:

Scanner: HDS3000

Site Scanning 10 days/nights (300 hrs)

3D Cyclone Modeling: 4 operators (9 Weeks)

Modeled Items: Over 35,000 objects

As-built 3D model completed and delivered to the customer at an early stage, long before the vessel is to arrive at FELS shipyard Singapore for retrofit.

MST Odin – 3D Cyclone Model

37

Retrofit Project ComparisonRetrofit Project Comparison

Washington Group International – Birmingham, Alabama USA

CompanyAker Kvaerner

Australia VECO Alaska Capnor ASWashington Group

International

ClientSantos Limited / O&G

SolutionsConocoPhillips

Marathon Petroleum Company Norway

Confidential

Industry ChemicalOil & GasOffshore

Oil & GasFSPO Conversion Pulp & Paper

Project TIC Unknown 2.3 MIL USD Unknown Unknown

Engineering Use of Data

Engineering Directly in the Point Cloud 3D As-Built Model 3D As-Built Model

Partial 3D As-Built and Engineering Directly In the Point Cloud (In an External

Applicatrion)

Data Collection Time 4 Days 6 Day 11 Days 3 Day

Data Preparation Time 26 Hours16 Hours - Registration4 Weeks - 3D Modeling

40 Hours - Registration9 Weeks - 3D Model

30 Hours - Registration2 Weeks - Partial 3D Model

Site Data Collection Budget

-40% -26% -40% -31%

Engineering Budget -10% -12% Unknown -12%

Total Project Savings Unknown-19%

($449,000 USD)Unknown Unknown

Start-Up On Time On Time On Time On Time

Comments

Extreme Heat, Congested, Hazardous Area, Unreliable

As-Built, Remote, Increased Shop Fab

Very Remote, Extreme Congestion, Hazardous

Area, Unreliable As-Builts,

Short Window for Site Data Capture, Extreme

Congestion, Poor As-Built Information

Extreme Congestion, Inaccurate Existing

Dwgs,New Large Bore Piping Being Routed

• Extremely difficult site conditions

• Reduced site trips (Safer project)

• Easier and better engineering design

• Under budget

• Shut-downs and start-ups on time

• Successful projects leading to additional projects

What these sample projects have in common?

38

Summary Summary –– Plant Customer BenefitsPlant Customer Benefits

• Safer project

• Start-up on-time or ahead of schedule

• Reduced risk

• Answers for critical unknowns

• Reduced shutdown duration

• Better design and end product

• 2D, 3D, small or large projects

• Virtual site presence (Interactive Design)

• Proven technology – Rework cost 0.1% to 0.4% of TIC

• Cost savings

• Proven HDS work processes

• Creates new business opportunities

39

Top 3D Plant Design SystemsTop 3D Plant Design Systems

Company Product Leica Interface

Alias(Intergraph) I-Sketch PCF

AVEVA PDMS CloudWorx for PDMS

Bentley Systems AutoPLANT CloudWorx for AutoCAD

Bentley Systems PlantSpace CloudWorx for Microstation

CAE Plant4DCloudWorx for AutoCAD

CloudWorx for Microstation

COADE CADWorx CloudWorx for AutoCAD

Dassant Systems CATIA PTS Import

Intergraph PDS CloudWorx for Microstation

Intergraph SmartPlant 3D3D As-Built Model Import

(or SmartPlant Review Interface)

Intergraph SmartPlant Review CloudWorx for SPR

UGS FactoryCAD CloudWorx for AutoCAD

40

Leica HDS system and CAD 3D modeling PartnersLeica HDS system and CAD 3D modeling Partners

41

3D Design: 3D Design: CloudWorxCloudWorx for Intergraph SmartPlantfor Intergraph SmartPlant®® ReviewReview

Product Released May 16, 2005

Product is deployed in Intergraph’s next generation review and walk-through platform.

Some delays with shipping – temporary licenses available in interim.

CloudWorx for Intergraph SmartPlant®

3D expected Summer 2006 when Intergraph makes this functionality available.

Bentley CloudWorx is used with Intergraph PDS (Intergraph’s current 3D Detailed Engineering Design software)

42

3D Design: 3D Design: CloudWorxCloudWorx for Aveva PDMSfor Aveva PDMS

This product is designed for Aveva’s PDMS design environment.

Prototype product announcement and public demonstration at SPAR May 23, 2005

PDMS marketing video distributed to HDS sales organizations May 23, 20

Projected release target date 2H 2005.(Important Qualifier: Dependent on Aveva’s resource availability.)

Customer BETA Test opportunities for CloudWorx for PDMS for late July/early August.(Important Qualifier: Dependent on Aveva resource availability.)

43

Leica TruViewLeica TruView

Leica TruView

44

HDS DemonstrationHDS Demonstration

45

Question & AnswerQuestion & Answer

3d laser scanning technology in plant industries - … · · 2009-05-13overview of 3d laser...

Documents