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Optimizing Plant Expansion: 3D Laser Scanning and Modeling for the Gas Industry

PMI > Blog draft > Case Study > Optimizing Plant Expansion: 3D Laser Scanning and Modeling for the Gas Industry

Introduction & Project Overview

A prominent Public Sector Undertaking (PSU) in India's gas sector embarked on an ambitious project to increase and retrofit one of its main demineralization plants. The 36,401 sq. ft. plant has a pivotal position in the larger energy infrastructure. With expansion on the cards, the client looked for an efficient, accurate, and non-intrusive solution to record existing infrastructure and plan for future modifications. Production Modeling India (PMI) was hired as a partner with trust, utilizing 3D laser scanning and smart modeling software to deliver a digital basis for plant redesign, visualization, and planning.

Business Needs & Objectives

The most important goal of the client was to digitally record the as-is state of the plant through high-accuracy 3D laser scanning and utilize that information to create accurate and smart 3D models. These models would serve as the basis for:

• Expansion and modification planning.
• Removing dependency on old or incomplete 2D drawings.
• Creating detailed ISO and Spool drawings.
• Enhancing the collaboration and coordination between different stakeholders of the projects.
• Improving planning for long-term maintenance and life-cycle with facility management.

With the size of the plant and the importance of the gas infrastructure, accuracy, coordination, and speed were paramount.

Key Challenges

The project was accompanied by its share of technical and operational challenges:

• Large Area and Data Volume: Scanning a facility of more than 36,000 sq. ft. necessitated 565 scanning positions. Achieving total coverage without gaps or overlaps was only possible through careful planning.

• Scan Registration and Processing: Registration and integration of scan data from many positions needed to be smooth so that misalignment of the final point cloud model was not done.

• Modeling Complexity: Proper modeling of piping systems—from pipe diameters, flanges, and valves to bends, and fittings—involved specialized domain knowledge as well as skills in CAD products such as Revit, Plant 3D, and Inventor.

• Draw Generation: Generation of ISO and Spool drawings needed to convey every engineering element derived from the 3D model, meaning accurate dimensioning, annotations, and adherence to industry standards.

• Stakeholder Coordination: Continuous communication with project managers, designers, and engineers was needed to validate model accuracy, approve design interpretations, and incorporate evolving project needs.

• Timeline Management: Delivering high-quality outputs while adhering to project deadlines posed a critical balancing act.

Optimizing Plant Expansion: 3D Laser Scanning and Modeling for the Gas Industry

PMI’s Approach & Solutions

PMI deployed a structured and phased approach to ensure accuracy, efficiency, and client satisfaction.

Scanning Strategy

A scanning plan was developed in order to delineate milestones for every section of the facility. 3D high-resolution laser scanners were employed to record millions of data points with great accuracy. Blind spots were avoided, and whole spatial coverage was ensured.

Quality Control in Registration

Every one of the 565 scans was separately verified and precisely registered into a common point cloud with sophisticated registration algorithms. Error tolerances were reduced to provide a trustworthy base model.

Expert Modeling Team

PMI tasked experienced CAD experts with expertise in Revit, AutoCAD Plant 3D, and Inventor. These engineers developed each detail—ranging from intricate pipe systems to structural support—from scanned inputs. Piping components were developed with precision to conform to actual dimensions and specifications.

Drawing Generation

Using Plant 3D and Navisworks, ISO and Spool Drawings were directly picked up from the 3D model. These precise engineering documents contained dimensions, annotations, symbols, material specifications, and welding details, ready for fabrication or on-site installation.

Clash Detection & Quality Assurance

Prior to final delivery, the models were subjected to thorough clash detection, dimensional checks, and walkthrough simulations using Navisworks and Web Share (Reel View) for stakeholder review and validation.

Project Coordination

Weekly sync-ups and collaborative progress dashboards fostered transparency and responsiveness. Frequent interaction with cross-functional teams maintained the model connected to ground realities.

Workflow & Methodology

PMI utilized a 7-stage workflow to organize project implementation:

Preparation Phase

Planning the scanning sequence, establishing area boundaries, and assigning teams.

Scanning Phase

Conducting 3D scans through laser scanners throughout the facility.

Data Processing Phase

Registration, cleaning, and optimization of point cloud data.

Modeling Phase

Creating precise 3D models with Revit, Inventor, and Plant 3D.

ISO Drawing Generation

Deriving technical drawings of pipes and mechanical parts.

Documentation & Reporting

Sharing NWC, DWG, PDF, ISO, and Spool outputs.

Post-Project Evaluation

Performing reviews, lessons learned, and providing the final Web Share link for stakeholder consumption.

Business Impact & Benefits

Through the adoption of an end-to-end 3D laser scanning and modeling solution, the client achieved considerable operational enhancements:

• Improved Planning Accuracy: With accurate models and current drawings, the client reduced errors in redesign and expansion.

• Lower Construction Costs: Accurate models greatly reduced rework and site rectification.

• Easier Maintenance: The 3D model served as a digital twin to facilitate easier preventive maintenance, training, and upgrade planning.

• Enhanced Decision Making: Plant locations could be visualized by project stakeholders and feasibility determined before implementation.

• Documentation Consistency: The stakeholders used standardized and verified data, which enhanced coordination and eliminated ambiguity.

Optimizing Plant Expansion: 3D Laser Scanning and Modeling for the Gas Industry

Conclusion & Key Takeaways

PMI’s involvement in the demineralization plant expansion project reaffirms the critical role of 3D laser scanning and intelligent modeling in modern industrial projects. By delivering a fully coordinated, clash-free, and dimensionally accurate digital model, PMI empowered the client to plan confidently, reduce waste, and streamline expansion efforts. For gas and process industries undergoing upgrades or retrofits, such digital interventions are not just innovations, they are necessities for staying efficient, safe, and future-ready.

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