3D Point Clouds: Bringing Older Facilities Into the Digital Age

Introduction As our systems and plants age and the wealth of knowledge from the current staff is slowly being lost due to retirement, it is now more critical than ever to ensure that facilities are being brought into the digital age. One of the most efficient ways for doing this is the use of 3D scanning technology. Objectives The use of 3D LiDAR scanning technology is not necessarily new technology, however the use of this data in a real time visualization over conventional 3D modeling is. In this presentation we will propose the use of 3D LiDAR in a less conventional method to allow for a more dynamic facility management plan. Leveraging speed and efficiency facilities can be more agile in their use of the technology and better distribute the prohibitive costs of generating a true Digital Twin of their facilities over multiple projects. Status One of the projects this technique has been implemented in is a water treatment facility in Baltimore MD. They have multiple upgrade projects happening on the facility at this time, so this was an ideal solution to help manage them. The initial responses are quite positive, as the engineering design team can quickly access the data and make revisions as needed to their designs without having to go back out to the field. To date we have scanned seven areas of the facility for upcoming design projects. As work is needed in each of the areas the engineering team can digitize the parts in real time without having to redeploy a survey crew or MEP team to collect additional information. Methodology Using a combination of scanning techniques, imagery, and data fusion, a facility can generate a complete as-built point cloud of their facility inside and out. Using high resolution UAS LiDAR and imagery is one of the most efficient ways to collect the exterior elements of facility grounds. Combining this with terrestrial and indoor mobile scanning for the interior or covered areas will allow for a total site point cloud. When compared to conventional survey methods the overall cost of 3D LiDAR collection is quite comparable, however you can collect more data at the same time. For a facility to start this process the first step is identifying the current need from the final model. Are they looking for a complete Digital Twin of their facility with all data being generated in a final Revit model? Or are they just looking for a model that will aid in future facility planning and upgrades. Figure 1: On the left you can see a colorized 3D point cloud model, on the right, you have a full Digital Twin Revit model extracted from the point cloud. With the combined point cloud and imagery properly aligned and adjusted to survey control points the facility can then use this data like a living model of their facility. With software like FusionMap, Ivion, or other web-based point cloud viewing platforms a facility can interact with the data in a light weight easy to use web environment. The key to this is that the data is spatially accurate due to all the dimensions being generated from the point cloud and not just the imagery. Figure 2: Above you can see the fully colorized 3D point cloud that is generated and used as the basis for all precision measurements. Figure 3: Above you can see how easy it is to check the dimensions of this pump pad to ensure that a new pump would still fit on the pad without modifications. Using the imagery for visualization allows for a easier more informed model for engineers to extract from. This data can be shared with contractors or other project engineers to allow them to have a virtual site walk of a facility at the click of a button. Allowing a design team, the ability to quickly recheck on a clearance or even confirm the diameter of a pipe is correct in the existing facility drawings without having to schedule another site visit. The data is also valuable in retrofitting and cost proposals to help reduce the unknowns. From ensuring clearances for removal of old equipment, to clash detection in Navisworks point cloud data can help to ensure the success of the project. Figure 4: Above you can see the level of detail that is captured in the 3D point could. From the individual hoses on the generators to the overhead hangar rods for the cabling racks. When there is a need to merge a new design with the existing facility, this data can be imported into AutoCAD software's such as Revit and individual features can be digitized in real time to be maintained or replaced instead of generating a complete model all at once with a large initial cost. Findings and Significance By using 3D scanning and selective modeling, a facility can be more dynamic in their project planning and facility management plan. Having a virtual plant model allows facility managers to look the whole picture when reviewing facility upgrades and modernization projects. These 3D point clouds can be continuously updated as modernization projects are completed, and the existing data can be archived for historical data analysis. With the use if a web hosted viewing software the facility can help to reduce the need for field visits as well as use the data for emergency training drills and SOP documents along with allowing new personal a way to get familiar with the facility.