Traditional labour-intensive plant engineering and operations practices are giving way to data-driven digital workflows. LIDAR scanning is an invaluable tool to cost-effectively capture ultra-accurate 3D plant data to enable this digital transformation. This guide explores using LIDAR services for plant digitalization – how it works, planning best practices, processing data, and choosing a trusted scanning partner.
An Introduction to LIDAR Scanning for Plant Digitalization
Many industrial facilities still rely on outdated manual workflows for plant engineering, project controls, and maintenance based on 2D drawings and tribal knowledge. This introduces substantial inefficiencies, safety risks, and inability to effectively analyse performance. LIDAR-based plant scanning provides the digital framework to transform legacy plants into fully data-driven operations.
LIDAR rapid laser scanning quickly captures millimetre-accurate point cloud data to create digital twins of as-built plants. This 3D plant model integrates into engineering design tools, project controls, maintenance systems, virtual reality simulations, and more. Personnel can visualize and interrogate structures in 3D to streamline workflows.
The Multitude of Benefits Offered by a Digitalized Plant
Some major benefits unlocked by LIDAR plant scanning include:
- Greater engineering productivity and design quality by validating designs against real-world conditions. Clash and safety audits can be done virtually.
- Improved project control by comparing 3D as-built data to engineering models to assess constructability issues and track progress.
- Enhanced worker safety by identifying confined spaces, planning safe equipment moves, and virtual safety training.
- Reduced maintenance costs through condition monitoring, predictive maintenance, spatial clearances analysis, and maintenance planning.
- Optimized plant operations by creating virtual plant models for training, planning, and simulations.
- Complete digital documentation of the plant’s baseline condition.
The efficiency and productivity gains from digitalization are invaluable for aging plants.
How LIDAR Scanning Precisely Captures Plant environments
LIDAR scanners work by emitting thousands of laser pulses per second to map physical surfaces. Sensors capture the reflected light to measure range with millimeter precision. Repeated scans build up a dense 3D point cloud model.
Scanners are stationed throughout the plant to capture all angles. Technicians deploy target references to merge the scans into a unified model covering the entire plant in intricate detail. The 3D point cloud data integrates into engineering software for analysis.
The Components of a LIDAR Scanning System
A complete plant scanning solution requires:
- High-precision LIDAR scanners tailored to site conditions.
- Stable scanner tripods, transportation carts, and protective cases.
- Highly reflective reference targets for accurate scan registration.
- Control network of survey targets linking scans to coordinate system.
- Point cloud processing software to generate merged 3D model.
- Technical experts to operate the scanning equipment and perform QA.
Key Types of LIDAR Scanners Used for Plant Surveys
Stationary tripod scanners are most common and provide precision millimeter-level detail from a fixed position using a rotating laser head.
Mobile scanners are installed on carts or vehicles and traverse sites while scanning, best for outdoor areas.
Phase-based scanners use laser phase shift technology for long-range precision.
Time-of-flight scanners measure laser pulse time for shorter-range ultra-high accuracy.
Best Practices for Planning Efficient LIDAR Scans
Careful planning ensures complete, accurate data collection. Best practices include:
- Defining scope of plant areas for scanning along with the required level of detail.
- Selecting optimal scanner positions to cover the entire scope through line-of-sight while minimizing setups.
- Implementing safety controls like permits and barricades to restrict access on active industrial sites during scanning.
- Scheduling during plant downtime or low activity periods for uncompromised access.
Performing the LIDAR Scan – Setup, Capturing Data, Demobilization
The on-site scan process involves:
- Transporting scanners, tripods, targets, and control networks to scan locations.
- Setting up and calibrating scanners, positioning targets, and surveying control networks.
- Performing comprehensive scans with proper overlap and resolution settings.
- Monitoring scans and periodically recalibrating as needed.
- Demobilizing equipment safely once quality scans are captured.
The survey crew follows stringent protocols throughout for quality results.
From Point Clouds to Digital Plants: LIDAR Data Processing
Robust software workflows process the LIDAR data into deliverables:
- Point clouds are merged and cleaned to create a unified 3D model.
- Models are segmented to classify components like structural steel, piping, equipment, etc.
- Measurements verify model precision and validate against design dimensions.
- Photorealistic 3D plant models combine LIDAR data with digital photos captured onsite.
- Data integrates with engineering tools like AVEVA and AutoCAD for further analysis.
High-Value Applications of LIDAR-Based Digital Plant Models
The incredibly detailed LIDAR plant models drive significant benefits across engineering, project delivery, and operations:
- Digital twins visualize intricate plant conditions for streamlined engineering.
- Engineering verification by comparing designs to constructed conditions.
- Clash detection and safety analysis by virtually navigating 3D environments.
- Construction progress tracking by quantifying installed components vs engineering models.
- Maintenance planning through condition assessments, spatial clearance analysis, predictive maintenance, etc.
LIDAR scanning future-proofs plants by establishing accurate 3D digital baseline representations.
Choosing a Trusted LIDAR Scanning Services Provider
When selecting a LIDAR scanning partner for plant digitalization initiatives, be sure to evaluate:
- Technical expertise – Experience scanning industrial facilities with proven methodologies. Look for professional engineers on staff.
- Data quality – Guaranteed precision, proper point density, and comprehensive coverage.
- Safety record – Demonstrated commitment to safety with robust project hazard plans and controls.
- Quality assurance – Stringent QA procedures to deliver reliable scan data with complete documentation.
- Professionalism – Established workflows, trained personnel, industry reputation, and certifications.
By carefully vetting providers, you can be confident in capturing optimal LIDAR data to enable plant digitization.
Conclusion
Migrating from analog to digital workflows is now imperative for industrial plants to stay competitive. LIDAR scanning cost-effectively provides an accurate 3D digital framework of existing plants to drive this transformation. With careful planning and execution by experienced providers, plant owners can unlock immense benefits around engineering, project delivery, maintenance, and operations through plant digitization. The power of LIDAR is ready to elevate your facilities into the digital future.