1

EXPERIENCE DURING “AS-BUILT” SERVICES IN INDUSTRIAL PROJECTS USING LASER 3D TECHNOLOGY

by Eng° Marcos GuandaliniAlezi Teodolini Consultoria3D

2

• Alezi Teodolini Consultoria 3D presentation

• Experience during “As-built” services execution in a oil and gas refinery in Brazil, followed by 3D modeling using VANTAG PDMS (Plant Design Management System)

• CAE model procedure and an example of a successful case.

• Conclusions

3

Alezi Teodolini Consultoria3D is aHEZOLINEM Group´s company,located in São Paulo, Brazil.Hezolinem was the pionner of surveyequipment deal and it is a well-knowncompany in all Brazilian market since1975.

The Alezi Teodolini Consultoria3D newbusiness area has 5 years and alreadyhave committed team with 25professionals for the AS-BUILT projects.

Alezi Teodolini headquarters in São Paulo

4

Company:

– Consolidation as the best supplier of CAE creation using cloud points and projects of engineering in PDS or PDMS platforms

– Maintaining the data entirety and the speed during the project model execution with high quality.

Presentation:

– Demonstrating the method of our job using CAE model in PDMS;

– Presenting the cloud points and the Modeling in PDMS of Brazilian refinery.

5

Offered Products

CLOUD POINTS FOR

CLASH DETECTION

CAE/CAD MODELS

DIMENSIONAL

CONTROL

6

7

Project experience during As-Built servicesin a Brazilian refinery followed by PDMS modeling.

The Project

8

Refinery - Summary

The Refinery:• The most complete

refinery of PETROBRÁS system;

• Located: Brazil

• Area of 13km2;

• Production of lubricant, diesel, GLP, nafta, kerosene, etc.

9

Refinery – Contract Resume

The Agreement:• The biggest project was done using 3D Laser Scanner;• A total of 500 milions points;• 361 Stations, 3800 piping and 250 equipment;• Complete PDMS Model and engineer as-built plants.• Contract Time Frame: 13 months – start: 12/12/2006.• The agreement total value : U$ 900 000,00.• It is considered as a reference project in Brazil.

The main object of our contract with the refinery

10

Material and Survey Time

Materials used in the Project– 02 units of 3D Laser Scanners GS200;– 01 Total Station;– 02 Notebooks;– 10 Flat targets;– 15 Reference spheres.

Site Surveying duration:– 3 months.

Station number:- 361 stations.

Grid- 10 mm at 10 meters for all 360°

scanning.

Total of the points collected:– 500 millions.

11

Planning/Execution:– The estimative was:

• A total of 1,5 hours per 360 degreesstation;

• The use of 7 stations per day duringthe site surveying based onphotography's,

• Plants and technical visits in theproject area;

• 3 months with one scanner.– It was spent:

• 1,5 hours per 360 degrees station;• The production averages was only 4

stations per day due to the problemsoccurred with the batteries andequipment temperature;

• It was finished in 3 months using 2equipment.

Field Crew – working in the Refinery

Survey Direction

12

Field Crew

• 1 Leader Enginering – 8 months

• 2 Surveyors – 3 months

• 2 Assistants – 3 months

• 1 Driver/Assistant – 3 months

• 1 Senior Piping – 8 monthsField Crew – working in the Refinery

13

Survey Direction

Survey– Flat and spherical targets

were used in order to helpduring the consolidationprocess;

– Total Station: Conventionalsurveying in order to putcloud points in the correctcoordinate system of sitesurveying plant;

– Consolidation or register.Field Crew– working in the refinery

14

Site Surveying Description

Targets were located in order to position the cloud points in the refinery coordination system using the refinery landmarks;

361 stations were scannedto obtain cloud points inreal color.

Field Crew – working in the Refinery

15

Collected cloud points making easy the scanned data interpretation

Photo taken using thescanner in the same positionof the cloud point surveying.

Cloud Points Collection

16

Cloud Points Collection

The biggest cloud points done with a 3D Laser Scanner – 500 millions of points

17

A project specialist was hired in order to update all documentation regarding to 1210 unit: 95% concluded.

18

Field Advantage Points

Field Advantage Pointsusing GS200:

– The scanner weight;

– The equipment does a complete 360º using a half of the time with reference to HDS3000;

– The color of the cloud points helps during the object identification;

– The scanner transportation is easy because of its backpack. Field Crew – working in the Refinery

19

Field Work Difficulties

Battery:– Weight : 14 Kg ;– Autonomous : 4 h ;– Transport difficult

Temperature– Due to the high temperature

the equipment stopped to work several times during one day

Series GS– Good conditions are essential

for the scanner work.– Field vertical view is restricted

to 60°Field Crew – working in the Refinery

20

Cloud Points/Consolidation

Difficulty• More than 500.000.000 points to

manage;• RWS is able to open only 60.000

points.

Result• 500.000.00 points in the same

coordinate system.

PC Configuration• Pentium D 3.0 Ghz;• 2.0 GB RAM memory;• Graphic Card 256 Mb. Field Crew – working in the Refinery

21

Cloud Points/Consolidation

• This kind of project has a lot of points and being its consolidation very complex;

• The control of the surveying work points is very important.

Alezi Teodolini´s office – São Paulo, Brazil

22

Cloud Points/Consolidation

PROCEDURE

• The total area was divided up among 35 sub-areas;

• 3 teams working during 2 months:– 30% using cloud based on

registration tool of RWS and 70% using spheres and targets

– In order to put the cloud points in the real coordinate system, it was made a topographic surveying to collect flat target coordinates.

23

Modeling/Engineering team

• 1 Leader Engineer

• 1 PDMS Manager - 8 months

• 1 Senior project professional – 5 months

• 8 Professionals of CAD Modeling–8 months

• 2 CAD designers – 3 monthsAlezi Teodolini´s office – São Paulo, Brazil

24

The Modeling Team

• Our team is trainned according to the following stages:– First Stage:

• Professional with notions of the basic CAD • 3Dipsos training = 2 months• Piping/structure and general industrial concepts training =

2months• 15 lines are produced in 3Dipsos per day.

– Second Stage• PDMS training = 3 months• PI&D concept training = 1 month• 15 lines are produced in PDMS/PDC per day.

25

3Dipsos – Modeling Alowed

• We made a series of modeling demos in order to genarate a PDMS model two years before closing the agreement.

• After the modeling demos, our customer has approved 3Dipsos software.

A part of our agreement with the customer

26

Office Job Direction

STEP 1: Team planning and definition per subjects (Piping, Equipment, Metallic, Civil and Electrical);Modeling team = 8 professionals

Office in São Paulo – Alezi Teodolini Office in São Paulo – Alezi Teodolini

27

Working with Specs

STEP 2: PDMS Management of data base configuration,users and password creation;

STEP 3: SPEC importation including customer specifications;

Standard Catalogues (SPECS):Possible to import and work with

diferent specs On the same project

28

Cloud points

STEP 4: Cloud point segmentation;

Raw Data of the Cloud Points

Cloud Points divided up on separated groups for modeling.

29

Senior Piping Project and PDMS Administrator

STEP 5:

The senior project professional after the field surveying updated the P&ID in order to give the real information to the modeling team.

SPEC´s and catalogs creation using the PDMS software.

Senior Project Professional – working in Refinery

30

Modeling with the SPECS for PDMS

Associating a segmented structure with a reconized semi- automatic spec

If the pipe is isolated by thetemperature, it will be possibleto model using only the pipedimensions.

Creating Branches associated with catalogs (SPEC).

31

PDMS interface

STEP 6:PDMS modeling;3Dipsos software / PDC (Point

Cloud Data Center) use with PDMS direct interface;

32

Modeling Tools

– Automatic method use with exclusive modeling tools that improve the production capacity;

– easypipe® is a cloud points tool that can model all pipe components without operator interference increasing the productivity 3 (three) times.

33

Checking the PDMS Model

STEP 7: Model check and validating during all the modeling process described before;

34

PDMS Model

STEP 8: Delivery of 3D model in PDMS

•Equipment

•Pipes

•Electrical

•Civil

•Metallic structures

35We have to up-date the model every month to the customer

Modeling Progress

36

Modeling Progress

62% of the complete job - PDMS Model. Delivery time: March-2008

37

38

39

40

41

Engineering Update

STEP 9: Updated plant generation and delivery (using ADP);STEP 10: Updated PI&D delivery.

42

3D Laser Scanner used and its importance during an 3D AS-Built project

Cloud PointsX

Project

PDS Picture – We will need to delivery the solution for PDMS.

43

Cloud PointsX

As-built model

PDS Picture – We need to delivery the solution for PDMS.

44

As-Built Company advantages

• Piping modeling associated to the SPECs offering speedy and entirety;

• Recognition of automatic structure profiles associated to the charts;

• Modeling time optimization tools as such as: EasyPipe® (automatic extraction of tubulation), Beam Extraction (automatic extraction of structures);

• 3D model updated;

• Clash Detection;

• Accuracy of the model.

45

Advantages Refinary

• Stop time reduction at the refinery;

• Cost and time reduction during the building and assembly;

• Risk simulation possibility;

• Facility and efficiency to the future project development;

• Plants and PI&D up to date;

• Smart models generating automatically the Isometrics and Materiallist.

46

Pipe Isometric

47

Piping Plan

48

PI&D

49

Conclusion

• The new 3D Laser Scanner technology allows a CAEmodel that shows the real situation in the field, offeringa lot of benefits in the industrial plant management'sday by day ;

• The use of 3Dipsos/PDC software allows to reduce themodeling time that causes a direct impact in theproject cost ;

• The service cost is irrelevant if compared on its cost-benefit vantages.

50

Eng. Marcos Guandalini

São Paulo/SP, Brazil

Phone: (55 11) 3868-0825

www.hezolinem.com/consultoria3D

consultoria3D@hezolinem.com