This document discusses using laser scanning and 3D modeling software to create an accurate digital as-built model of a vacuum gas oil storage area at a Hellenic Petroleum refinery in Greece. Laser scanning was used to capture over 300 million data points, which were then converted into an intelligent 3D model using AVEVA PLANT software. The 3D model integrates piping, equipment, and structural attributes and will be connected to a data management system for accessing drawings, specifications, and other documentation.

1. 5th International Terrestrial Laser Scanning User Meeting
Plant Survey and Intelligent 3D Modeling using
Laser Scanner Technology
and Reverse Engineering Software
Pilot Application in Hellenic Petroleum refinery
(Aspropyrgos, Athens, Greece)
Michael Xinogalos, Surveying Eng. NTUA
(LaserAction / Astrolabe Engineering)
Evangelos Megalios, Chemical Eng. AUTH, M.Sc.
(Hydrus Engineering)
Prague, 8-9 June 2010

2. About us
LaserAction is an international Group of collaborating companies and specialists with
advanced experience in laser scanning technology, applications and tools.
Our mission is to provide high quality services related to laser scanning technology
worldwide:
- Full elaboration of laser scanning projects for any field of application
- Laser scanning and related surveying services
- Processing of laser scanning datasets
- Support and consulting services for companies involved in laser scanning activities
- Training on laser scanning technology and relevant hardware and software tools
- Other relevant engineering / consulting services
Hydrus Engineering specializes in industrial and marine design, modeling and
management using state of the art / industry leading technology in 3D modeling field
(AVEVA PLANT/PDMS software solutions):
2 www.csassociates.gr

3. Purpose
As built status documentation for most industrial facilities all over the
world is:
- Incomplete
- Inaccurate
- Obsolete
- In 2D drawings’ format
- Often in old hardcopy documents
Everyday tasks affected (representing significant cost):
- Operational and safety procedures
- Maintenance
- Expansion design and construction
- Management
Need for efficient industrial as-built documentation methodology:
- Complete
- Geometrically accurate
- Up-to-date
- 3-Dimensional
- Based on industry standard software solutions
- Results easy to incorporate in everyday facility’s operations
- Offering maximum expandability
3 www.csassociates.gr

4. Proposed solution
- Data capture using Laser Scanning Technology
- Intelligent 3D Modeling using AVEVA PLANT solutions
4 www.csassociates.gr

5. Proposed solution
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6. Hellenic Petroleum – VGO Storage Area
HEL.PE.
- Holds leading position in Greek
Energy sector
- 3 major refineries in Greece, 1
in FYROM
- Covers 76% of Greece’s total
refining capacity
Pilot Project
 Laser Scanning
 Other data collection
 Database generation
 3D Modeling
 Data Management
6 www.csassociates.gr

7. Laser Scanning
4 Storage Tank
19 Pumps
~300 Pipes
32 Laser Scanning Position – Total ~300 millions points
7 www.csassociates.gr

8. From 3D Laser Scanning to 3D Modeling
Data
3D Point Cloud Intelligent 3D Model
3D Point Cloud
Vacuum Gas Oil Storage Area*
*HELPE Refinery
8 www.csassociates.gr

9. Modeling Methodology
Workflow:
1. Other Data Collection
a. Photographs of area to be modeled
b. Existing drawings (Plot Plans, GAs, PID’s, Piping Layouts, ...)
c. Equipment specifications, piping specifications, instrumentation, materials,
insulation specifications, structures’ specifications...)
d. Refinery drawing abbreviation system
2. Software Database Creation
a. Equipment
b. Material
c. Piping classification
d. Column and Beam Specification
3. 3D Model creation
9 www.csassociates.gr

10. Piping Data - Attributes
Insulation – Protection
Steam Tracing
Dimension – Liquid – Area Heat Conservation 10mm
Or Personal Protection
Nominal Diameter: 2 inches
Process Line: O
Area: 880121
Liquid: Heavy Naphtha
2’’ – O – 880121 – Ax (ST) Connection Type
BW ASTM 234 Gr WPB
Piping Network Type Pipe Classification Ax ASME B16.9
Material: ASTM A106 Gr.B
Fabrication: SMLS.PE. ASME 36.10
Flanges
Welding Neck 150RF STD
ASTM A105 ASME 16.5
Gasket Valves – Instrumentation Orifice FLG 300RF WN
150RF 1.6mm thickness ASTM A105 ASME 16.5
Flexible Graphite Sheet Gate 150RF A216WCB API600
ASME B16.21 Check 150RF A216WCB Swing Blind 150RF STD
Type BC BS1868 ASTM A105 ASME 16.5
10 www.csassociates.gr

11. Equipment Data - Attributes
Dimensions
Storage Area
Nozzle Type - Dimension
Material
Vessels Design & Operation Temp – Press
Description
Custom Attributes
Dimensions
Nozzle Type - Dimension
Pumps
Discharge Pressure
Material
Power
Material
Beams Joint Type
Columns
Specification
11 www.csassociates.gr

12. Modeling Customization
HVAC
Cables
Cables Trays
Temp., Press
and flow,
Indicators,
and process
control
instruments
Auxiliary Lines
Fire Fighting System
Foam System
Stairs, ladders,
walkways, platforms
Main Equipment
Main Piping Network
Equipment Foundation
Main building facilities
12 www.csassociates.gr

13. 3D Model
Vacuum Gas Oil Storage Area
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14. 3D Model
Vacuum Gas Oil Storage Area
Photo 3D Model
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15. Piping Attributes
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16. Pipes Isometrics
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17. Drawings
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18. PIDs
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19. History and data Consistency Checker
Gray – no changes Gray – no error
Yellow – spec change Yellow – warning
Red – shape change Red – error
19 www.csassociates.gr

20. Data Management System – AVEVA NET
Operation Data
Specification Documents •Instrumentation data
•Reports
• Vendor Docs •Maintenance Schedules
• Manuals •Photos
• Specifications •Control Panels
• Spares Docs
Safety And Quality Drawings
• Staff Training
•PIDs
• ISO Docs
•3-D Model
• Legislation
•Isometrics
•2D-Drawings
•Equipments Drawings
20 www.csassociates.gr

21. Data Management System – AVEVA NET
AVEVA NET
Database
21 www.csassociates.gr

22. Data Management System – AVEVA NET
AVEVA NET
Database
22 www.csassociates.gr

23. Data Management System – AVEVA NET
Drawing
Vendor
Doc
3D Model, Photos,
Point Cloud
ERP Systems
(SAP)
Data Forms
Production Data
23 www.csassociates.gr

24. Data Management System – AVEVA NET
24 www.csassociates.gr