3D Laser Scanning Technology Benefits Pipeline Design

The primary benefits realized by ENTRUST Solutions Group relate to brownfield sites where
pipeline and facilities already exist.
THE WORLD ISN’T FLAT
The prolific Greek mathematician and
geographer Eratosthenes came to
understand that the world wasn’t flat when
he calculated the circumference of the earth
in the third century BC. Portuguese explorer,
Ferdinand Magellan — 1,800 years later —
again reminded us that the earth was not flat
when his fleet successfully circumnavigated
the globe in 1522 AD. Awareness that the
earth is not flat has existed for centuries, yet
we continue to constrain our engineering
design efforts to two dimensions.
The world consists of three dimensions and
we have reached a point where engineering,
design and planning should follow suit. 3D Laser Scanning provides a highly accessible tool that now
enables engineers and designers to think, design and evaluate intuitively in a three-dimensional world
with even greater ease. This article will explore the application and benefits of 3D Laser Scanning
technology with gas and oil pipelines.
WHAT IS 3D LASER SCANNING?
3D Laser Scanning is a terrestrial-based data acquisition system that captures high-density 3D geospatial
data from large-scale, complex entities. Laser scanners are non-contact devices that incorporate two
components for data capture: a laser and a camera as shown in Figure 1. A Class 3R1 laser scans all
physical components in its field of view and assigns an XYZ coordinate to each captured point. The laser
records the relative position of everything in view, capturing nearly 1 million data points per second1
.
entrustsol.com
3D Laser Scanning Technology
Benefits Pipeline Design
By Michael Garvey, ENTRUST Solutions Group
As published in
PIPELINE & GAS JOURNAL October 2012
3D Laser Scanning Technology
Benefits Pipeline Design
The data appears as a “point cloud” which
accurately represents the surface of the physical
objects scanned as seen in Figure 2. The laser
captures exact size and shape and converts real
world objects into 3D digital representation for
storage and manipulation on a computer. The
system utilized in subsequent examples, the FARO
Focus3D, is extremely accurate, capturing data at
±1.0 mm1 accuracy with a range of up to 120 m1.
The scanner can capture a horizontal field of view
of 360° with a vertical field of view of 315°, ensuring
an almost all-encompassing analysis from a single
scan.
After the measurement phase of the process is
completed, a photo-realistic digital camera then
captures a panoramic photograph of the objects within the field of view. The quantitative elements of
the laser-captured data are overlaid coincident to the “photographic” element to generate a virtual tour
that imbeds 3D information. The resultant virtual tour may be accessed via 3D Scanning Visualization
Software supplied by the laser scanner manufacturer or other third-party freeware suppliers. The software
allows a user to analyze facilities remotely and quickly gather quantitative information by taking 3D
measurements from within the freeware viewer. As well, users may analyze elements of facilities and
achieve the majority of benefits of an actual site visit without ever leaving their desk. Chris Anderson, a
designer at ENTRUST Solutions Group, suggests that implementation of laser scanning technologies has
made his pipeline design team much more efficient:
“The 3D scanning visualization software is an outstanding tool because it allows people to virtually travel
to the project site. Traditional photographs often miss important details; scanning visualization files
cut down on these misses by allowing users an interactive panoramic view from multiple points, which
minimizes the need for additional field verification beyond the initial scanning effort. The ability to measure
the images using the integrated point data is also extremely useful, since it makes dimensional data on
facilities available without using a CAD program or a tape measure.”
3D laser scanners measure very fine details and capture complex shapes. The scanners are ideally
suited for capturing contoured surfaces, complex geometries, and high density of infrastructure where
massive amounts of measurement data are required to ensure accurate depiction. For complex surfaces,
inaccessible components and hazardous environments, manual data acquisition is neither effective nor
practical.
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3D Laser Scanning Technology
Benefits Pipeline Design
BENEFITS OF LASER SCANNING ON PIPELINES
The primary benefits realized by ENTRUST
Solutions Group relate to brownfield sites where
pipelines and facilities already exist. This is not to
say that benefits do not exist for greenfield sites
where no infrastructure exists. However, the totality
of ENTRUST Solutions Group’s experience has
been confined to application in existing pipeline
facilities. The use of laser scanning technologies
has rapidly demonstrated an array of benefits that
have resulted in greater efficiency, greater accuracy,
improved safety, improved product output and
potential cost savings.
Several of the benefits realized to date include:
1) increased data collection efficiency and accuracy, 2) rapid and accurate development of “true built”
documentation, 3) money saved due to improved design accuracy and quality control, and 4) improved
project visualization and collaboration.
CHALLENGES AND LIMITATIONS
Laser scanner technology appears to have many applications that can benefit our industry. However, the
limitations of the technology should be understood. Laser scanners cannot see “through” objects and
must have line-of-sight vision to capture associated data. As an example, a four-sided building must be
scanned in multiple scans to capture all associated data. Laser scanners are also limited by distance
range and peripheral range. The FARO Focus3D unit is limited by a maximum scanning distance of 120
meters1
.
Because of distance, peripheral and line-of-site constraints subject sites are typically captured in multiple
scans. The scans are then stitched together by the operator via a registration process that produces
a single contiguous “point cloud” that may be utilized for design and analysis. Registration of separate
scans is achieved by establishing common control points via “registration spheres” that are temporarily
deployed across the scan site.
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3D Laser Scanning Technology
Benefits Pipeline Design
Separate scans must have three common
“registration spheres” or similar targets in common
in order to effectively stitch scans together. Figure
3 shows the scanner operator locating “registration
spheres” on site. The scanner is further limited by
wind and excess vibration. As with any precision
device, the quality of data capture is improved by
maintaining a stable and static position. While the
scanner photographic capture is not effective without
ambient light, the laser data capture is fully effective
without any ambient light.
Finally, caution should be exercised when the laser
scanning device is utilized in a potential flammable
environment. It is customary to obtain a “hot work
permit” when the device is utilized on gas and oil
pipeline facilities and may be considered similar to
operation of a digital camera.
THE LASER SCANNING PROCESS
The laser scan process is rather simple, yet can
provide a significant array of product output. Figure
4 demonstrates the typical scanning process and
potential product output. The process initiates with
capture of data via the laser scanner. Single scan
files may be utilized in raw format for manipulation of
point clouds via licensed Point Cloud Tools software.
Single scan files may also be reviewed via the Scan
Visualization Freeware in a virtual tour format with
measurement capabilities. Separate scan files must
be registered to produce a single contiguous file for
further manipulation.
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3D Laser Scanning Technology
Benefits Pipeline Design
After registration, the point clouds may be deployed
directly into most leading CAD platforms from
manufacturers such as Autodesk®, Bentley® or
Intergraph. Many common CAD programs have
been specifically designed to accept “point cloud”
data directly into 3D platforms. As well, many thirdparty software suppliers are providing convenient
modules that overlay CAD platforms to greatly
facilitate manipulation and modeling of point clouds.
Products such as Kubit PointCloud post-processing
software have been utilized by ENTRUST Solutions
Group to generate 3D models and greatly facilitate
manipulation of point cloud data within AutoCAD.
Figure 5 demonstrates usage of Kubit PointSense
Plant to rapidly generate 3D piping configurations
from laser scan point clouds. Once the scanned
data has been merged into a CAD program it can
be utilized to generate a variety of product outputs
including: 2D CAD drawings, 3D CAD models, or
static images.
It should also be noted that in many cases where
only a discrete analysis is required it is not
necessary to model point cloud data or produce
drawings.
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3D Laser Scanning Technology
Benefits Pipeline Design
PIPELINE APPLICATION EXAMPLES
Laser scanning technologies provide significant benefits for a variety of industries. ENTRUST Solutions
Group’s business concentrates on the energy industry with specific focus on gas and oil pipelines,
storage and production. We have experienced a wide array of applications for laser scanning on gas and
oil pipelines and suggest that the benefits are potentially limitless. We have provided a handful of recent
examples below that demonstrate how laser scanning has benefited our clients.
CLIENT: Liquid Petroleum Pipeline Storage Terminal
ISSUE: Client revised existing pipeline terminal manifold to increase capacity. As-built documentation of
facility was poor or non-existent.
APPLICATION: The client utilized laser scanning technology to generate efficient and accurate as-built
documentation in 3D format to ensure optimum accuracy of the new facility design. The entire existing
pipeline manifold was captured via laser scanning and a discrete portion of the system was modeled in
3D format to rapidly produce highly accurate as-built drawings of the interface point between existing and
new piping construction. Capture of data required approximately two hours and modeling of the manifold
was completed within one day. Inconsistencies in the existing pipe design were revealed due to the
extreme accuracy of the laser scanning model. The ENTRUST Solutions Group design team was able to
establish “true-built” drawings with unparalleled speed and accuracy and begin the process of designing
the new manifold tie-in configuration almost immediately. The design team further benefited from the
laser scanning process by being able to “virtually” return to the client site to gather more data without ever
leaving the office. This allowed design engineers to develop the new manifold design with great accuracy
and no delay.
Upon completion of the new manifold interface, a fabricator utilized the ENTRUST Solutions Group design
to manufacture pre-fab modules for “plug in” with the existing pipework at the client site. A greater degree
of accuracy and quality control was achieved by scanning the existing facility rather than relying on limited
as-built drawings of questionable accuracy. Upon receipt on site, the client was able to seamlessly bolt on
the pre-fabricated piping modules without any field rework.
This resulted in reduced downtime and significant savings by returning the facility to service without
delay. Lost production time in petroleum projects where energy densities are high can costs hundreds of
thousands of dollars per day. The assurance of fit and quality control could have been further enhanced
by scanning the pre-fabricated piping modules and mating the pre-fabricated scan to the existing manifold
scan. This would ensure perfect fit prior to shipment to site.
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3D Laser Scanning Technology
Benefits Pipeline Design
CLIENT: Natural Gas Distribution Company (LDC)
ISSUE: Client required rapid evaluation of clearance of overhead electrical power transmission lines to
facilitate egress of construction equipment to job site.
SOLUTION: The gas company utilized laser scanning technology to rapidly and cost-effectively capture
relative clearance between electrical transmission lines and topography of gas pipeline as shown in
Figure 6. Necessary maintenance and rework of the gas company’s transmission assets adjacent to a
major interstate highway was complicated due to overhead electrical power transmission lines. The gas
company needed to confirm adequate clearance for large excavation and material handling equipment
to ensure safe egress to construction site. The client’s objectives were to efficiently and cost-effectively
produce an analysis of the “clearance profile.” A laser scanning operator was able to collect all necessary
data related to the overhead transmission lines and a complete topographical analysis within one hour.
Processing and analysis of the scanned data produced an accurate analysis within a day following the
scan. The laser scanner met the desired objective safely because it utilized a non-contact technology that
enabled measurement of live power lines from ground level. Additionally, the laser scanner was able to
capture a complex contour image of the terrain below the power lines. The end result was a very rapid
and very cost-effective analysis of the client’s site.
CLIENT: Liquid Petroleum Pipeline Storage Terminal
ISSUE: Client to revise existing pipeline terminal facility to increase capacity, add storage tanks and add
pumps. Current as-built documentation of facility is limited to 2D format complicating design analysis.
SOLUTION: Client is conducting large-scale redesign of existing liquid pipeline terminal facility.
As-built drawings exist but are limited to 2D format. Based upon previous experience utilizing ENTRUST
Solutions Group laser scanning services the client requires 3D “true-built” documentation in order to
ensure more accurate, efficient and cost effective execution of the project. Because of the large scale of
the project, the sensitivity to design error and construction schedule delays will be greater. Hence, the
potential benefits of laser scanning will be greater.
ENTRUST Solutions Group personnel were able to capture significant amounts of data in a fraction of
the time with greater accuracy than conventional methods. The project is in progress and it is anticipated
that laser scanning benefits will be significant. The anticipated costs of laser scanning and subsequent
modeling should be easily offset by cost savings during construction of the project.
CLIENT: Natural Gas Distribution Company — Propane-Air Injection Facility
PROBLEM: Existing propane-air injection facility does not have as-built documentation
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3D Laser Scanning Technology
Benefits Pipeline Design
RESOURCES
Author: Michael Garvey is vice president of Business Development at Chicago-based ENTRUST
Solutions Group, a full-service engineering and consulting firm to the gas and oil pipeline industry.
He holds a Mechanical Engineering degree from Purdue University and has more than 20 years of
technology implementation, system design, and marketing experience in the gas and oil industry. He can
be contacted at (630) 353-4012 or mgarvey@entrustsol.com.
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SOLUTION: Significant revisions to existing propane-air injection facility require creation of accurate
and updated as-built documentation to facilitate redesign and creation of a demolition plan. Significant
parts of the existing facility will be demolished and rebuilt with optimized design that will include addition
of new piping configuration, new heaters, and new vapor retaining wall for increased safety. Creation of
highly accurate as-built documentation in 3D format will allow for a more effective demolition plan and
ensure efficient installation of the new configuration. The existing piping design is complex and difficult to
visualize with current limited 2D as-built documentation. In addition to the new piping design, the client
intends to construct a new vapor retaining wall to mitigate risks associated with propane leaks. Grading
challenges exist with the current topography that must be addressed in order to produce an effective
vapor retaining system. ENTRUST Solutions Group’s design team will capture the topography and
segregate it for 3D analysis, to produce an effective grading plan for the new design. Furthermore, the
client wishes to control costs during construction by monitoring quality control on a real time basis. The
client will execute regularly scheduled deployment of the laser scanner in order to accurately analyze
actual construction vs. the engineering design. Scanning technicians will tie in to survey control via GPS
coordinates to mesh existing scan data with new scan data. This will minimize scanning necessary to
capture subsequent phases of construction. By scanning on a regular basis, schedule creep can be
minimized. This will ensure tracking of actual product against design and minimize rework. Ultimately a
high-quality design will be constructed with close adherence to initial project costs and schedule.