Creating a 3D Design Legacy - Part 2

In PART 1 of this series we discussed how many food manufacturers are creating a 3D Design Legacy by starting new construction projects with 3D design. While the construction never exactly matches the design, that 3D model is often a reasonable virtual space for future expansion and retrofit planning. Depending on the level of accuracy needed, a new tank, pump, and pipe can be planned with just some field verification.

But what if:

• The construction was not close to the original 3D design. (it happens!)
• You are planning a significant change to the process and need accurate 3D as-built of the space.
• You are working in an old plant that has never used 3D, but you need to start reaping the many benefits of 3D design.

This is where 3D laser scanning and point clouds come into play. 3D scanning allows for the creation of accurate, as-built, three-dimensional models of your existing space, reducing downtime and decreasing design schedules on future retrofit and expansion projects.

In this article, we will show the work flow for using 3D scanning. The example project is to facilitate a very accurate valve matrix retrofit design in a food manufacturing plant.

3D Laser Scanning

The scanner is mounted on a tripod and uses a gyroscopic stabilizer for accuracy. The scanner moves the laser precisely through a range of motions. As the Class 1 “eye safe” laser beam contacts each surface along the path, millions of accurate, 3D point locations are saved to a file. This process is repeated from various locations until the entire area is scanned.

Point Cloud

Using special software, all the scan data files are aligned forming a set of points on a three-dimensional coordinate system, known as a point cloud.

While the point cloud may look like a grainy picture, each point is an accurate measurement of real-life conditions. These points allow exact placement of 3D modelled elements later in the process.

Any unwanted data, such as fork trucks, people walking through the space, or even equipment being removed can be cleaned from the point cloud.

The final, clean point cloud gives an accurate virtual space where 3D planning can begin.

3D Modelling

Now that the point cloud has been created, this space can be used as an external reference or “background” for 3D modeling when a new project needs to be planned. In this example, the existing pipes and valves for the target valve matrix were modelled precisely using the point cloud.

?3D Planning

After modeling of any needed existing components, the focus of the project can be planned. In this case, a new ingredient addition required a mix proof valve to be added to an existing matrix. The space was very tight and it was critical to reduce production downtime with an exact plan. Existing valves and pipes were moved in the modelled space and the new valves inserted.

Once reviewed and accepted by all the stakeholders, the design was released for bid and the contractor selected. The bid costs were reduced because the design was clear and an exact equipment list and bill-of-material was provided along with isometrics piping drawings.

The installation was completed with minimal production downtime and cost.

Design Advantages

There are numerous advantages when you start designing in 3D:

·      Multiple design groups can work from the same coordinate system. Process, mechanical, HVAC, electrical, etc. and all the interferences or clashes can be found in advance of construction.

·      A hybrid work space of point-cloud and CAD can be used by using layers and external references. All or just a portion of the point cloud can be converted to 3D CAD objects.

·      Precise 3D design allows for prefabricated segments or skids to be designed and built off-site at a lower cost and with minimal down time.

·      Another significant feature of 3D scanners is the associated 360-degree pictures taken from each scan location. This tool is especially valuable for remote engineers who can look at process areas without a trip to the plant.

Long Lead Planning 

Many food production facilities continue to have renovations of their processes as technology and food trends change. And the ability to go to market quickly with a new concept has great value. Some plants will proactively laser scan their production areas to develop a point cloud of the entire facility well in advance of the next retrofit projects, thus creating a 3D design legacy for the future.

Example Projects

The more complicated your production space is, the more value there will be in 3D scanning and developing a point cloud for the design work. These are just a few example projects where 3D design is used:

• Packaging equipment
• Tank farms
• Production kitchens
• Distribution piping
• HVAC
• Platforms and walkways
• Control panels and wire ways
• Safety reviews

Contact me today to discuss your project! [email protected]