1) Alezi Teodolini Consultoria 3D used laser scanning to create as-built models for a large Brazilian oil refinery, collecting over 500 million data points over 361 stations. 2) They used the point cloud data to build a detailed 3D model of the refinery in PDMS, including piping, equipment, structures, and other assets. 3) The accurate as-built model allowed the client to reduce costs and risks for future projects by providing up-to-date engineering drawings and facilitating clash detection and work planning.

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EXPERIENCE DURING “AS-BUILT” SERVICES IN INDUSTRIAL
PROJECTS USING LASER 3D TECHNOLOGY
by Eng° Marcos Guandalini
Alezi Teodolini Consultoria3D

2. 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

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Alezi Teodolini Consultoria3D is a
HEZOLINEM Group´s company,
located in São Paulo, Brazil.
Hezolinem was the pionner of survey
equipment deal and it is a well-known
company in all Brazilian market since
1975.
The Alezi Teodolini Consultoria3D new
business area has 5 years and already
have committed team with 25
professionals for the AS-BUILT projects.
Alezi Teodolini headquarters in São Paulo

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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.

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Offered Products
CLOUD POINTS FOR
CLASH DETECTION
CAE/CAD MODELS
DIMENSIONAL
CONTROL

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Project experience during As-Built services
in a Brazilian refinery followed by PDMS modeling.
The Project

8. 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.

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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

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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.

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Planning/Execution:
– The estimative was:
• A total of 1,5 hours per 360 degrees
station;
• The use of 7 stations per day during
the site surveying based on
photography's,
• Plants and technical visits in the
project 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 problems
occurred with the batteries and
equipment temperature;
• It was finished in 3 months using 2
equipment.
Field Crew – working in the Refinery
Survey Direction

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Field Crew
• 1 Leader Enginering – 8 months
• 2 Surveyors – 3 months
• 2 Assistants – 3 months
• 1 Driver/Assistant – 3 months
• 1 Senior Piping – 8 months
Field Crew – working in the Refinery

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Survey Direction
Survey
– Flat and spherical targets
were used in order to help
during the consolidation
process;
– Total Station: Conventional
surveying in order to put
cloud points in the correct
coordinate system of site
surveying plant;
– Consolidation or register.
Field Crew– working in the refinery

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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 scanned
to obtain cloud points in
real color.
Field Crew – working in the Refinery

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Collected cloud points making easy
the scanned data interpretation
Photo taken using the
scanner in the same position
of the cloud point surveying.
Cloud Points
Collection

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

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

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Field Advantage Points
Field Advantage Points
using 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

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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

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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

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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

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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.

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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 months
Alezi Teodolini´s office – São Paulo, Brazil

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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.

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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

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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

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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

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Cloud points
STEP 4: Cloud point segmentation;
Raw Data of the Cloud Points
Cloud Points divided up on
separated groups for modeling.

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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

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Modeling with the SPECS
for PDMS
Associating a segmented
structure with a reconized
semi- automatic spec
If the pipe is isolated by the
temperature, it will be possible
to model using only the pipe
dimensions.
Creating Branches
associated with catalogs
(SPEC).

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PDMS interface
STEP 6:
PDMS modeling;
3Dipsos software / PDC (Point
Cloud Data Center) use with
PDMS direct interface;

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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.

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

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PDMS Model
STEP 8: Delivery of 3D model in PDMS
•Equipment
•Pipes
•Electrical
•Civil
•Metallic structures

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We have to up-date the model every month to the customer
Modeling Progress

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

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

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3D Laser Scanner used and its
importance during an 3D AS-Built
project
Cloud Points
X
Project
PDS Picture – We will need to delivery the solution
for PDMS.

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Cloud Points
X
As-built model
PDS Picture – We need to delivery the solution for PDMS.

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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.

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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 Material
list.

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Pipe Isometric

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Piping Plan

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PI&D

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Conclusion
• The new 3D Laser Scanner technology allows a CAE
model that shows the real situation in the field, offering
a lot of benefits in the industrial plant management's
day by day ;
• The use of 3Dipsos/PDC software allows to reduce the
modeling time that causes a direct impact in the
project cost ;
• The service cost is irrelevant if compared on its cost-
benefit vantages.

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Eng. Marcos Guandalini
São Paulo/SP, Brazil
Phone: (55 11) 3868-0825
www.hezolinem.com/consultoria3D
consultoria3D@hezolinem.com