Bringing safety, productivity with laser scanning

Author:Anzhelika Kuznetsova

Oil refineries, smelters and other plant environments are very complex structures and can present major hazards. Any construction and rebuilding of highly complicated plants and shops require detailed engineering based on actual site data, and strict dimensional monitoring of construction and installation activities.

In most rebuilding projects, new structures and utilities to be installed are connected to the existing infrastructure, so high tie-in precision is necessary. It is quite common in the industy that the as-built drawings are not available, or the construction and installation works do not meet quality standards. There is a great need to collect actual field data on the existing structures and utilities.

IBCON是一家高质量输入数据的提供商，用于调查，设计和构建全新和重建项目，已参与了过去11年提供IT支持的大型工业项目。今天，IBCON使用Leica Geosystems技术和AVEVA软件专注于炼油厂和冶炼厂。

重新建设信任

One of IBCON projects efficiently using these technologies is the IT support for a smelter construction, the Kola Peninsula. As the customer worked on the project, it faced certain negative factors that prevented it from meeting the deadline, and led to financial losses. To rectify the situation, the contractor hired IBCON construction and rebuilding IT support services, enabling project completion in due time.

工作是重建要尽快建造/重建现有结构的几何形状和位置。总面积95,200 sq m. The data were presented as a number of reports for the customer. The reports indicated any deviations between设计和建造geometry and position of the structures. These reports have helped the customer to make smart project decisions.

The project faced many challenges, such as:

• Huge scope
• Tight schedule
• Harsh working conditions on the operating facility (vibrations, steam, dust, hazardous releases)
• Many running vehicles and operating equipment on the site (welding machines, cranes, trucks, etc.)

Conventional land surveying in such conditions is extremely difficult, and just impossible in some cases. A fast, highly efficient process without compromising survey accuracy and high resolution was needed.

交付的结果laser scanning

The IBCON team used a Leica ScanStation laser scanner. Laser scanning technology最小化测量时间even for sites as large as tens of thousands sq m, and inaccessible areas while preserving high accuracy and resolution.

Laser scanning technology does not require an exact scanner orientation as is the case with the conventional surveying. It enables scanning in restricted view conditions andacquires more information关于任何隐藏的结构。只有三名公司专家在IBCON进行了现场和内部激光扫描项目，从而大大节省了努力。

Leica Cyclone software用于主激光扫描数据处理。之后，它们与设施的坐标系保持一致。激光扫描被标记或点云匹配缝制。

The mean measurement error is ≈ 7 mm per 100 scanner locations. Subsequently, the scanned point cloud is exported to AVEVA E3D that builds a 3D model. Each object (reinforced concrete structures, steelworks, equipment, etc.) is identified within the cloud point to build the geometry of the 3D model. Attributes taken from the as-designed and as-build documentation, a unique index, and a hierarchy level are assigned to each 3D object within a model.

生成的扩展3D模型是客户根据客户要求生成报告的工具。由激光扫描数据构建的3D模型与项目开发人员提供的3D模型匹配。通过这种方式，在报告中很容易识别并列出安装结构与预期位置的任何偏差。

In the context of today’s extensive construction environment and its demand for prompt and mass-scale data acquisition about each structure built on a site, laser scanning technology provides complete visibility of any construction object. Such projects cannot be implemented with conventional land surveying tools as the data acquisition rate is very low.

“Surveying with the Leica ScanStation P20 laser scanner makes site surveys easy and visualises complex structures in a simple way,”米特拉科夫说。

The above described services are performed as cycles, prior to project completion, and commissioning. IBCON’s construction and rebuilding project IT support services help the customer make prompt decisions at every stage using accurate and timely reports to monitor project completion, and reduce extra error rectification costs.