across the entire plant lifecycle

Lethabo Power Station – 3D Laser Scanning Project

South Africa

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A Proof of Concept Project demonstrating how Laser Scanning Technology, MicroStation, Bentley PlantSpace and visualisation/ simulation technology can

be leveraged to maximise the value of point cloud data across the O&M plant lifecycle on Eskom brownfields power stations.

Organisation: Eskom Holdings (Pty) Ltd

Project Name: Lethabo Power Station Laser Scanning PoC Project

Category: Innovation in Point Cloud Processing and Management

Bentley Software Used: Bentley MicroStation, Bentley CloudWorx, Bentley PlantSpace 3D, Bentley PlantSpace P&ID, Bentley Navigator, Bentley ProjectWise

Other Software Used: Leica TruView, uSMART MicroStation Pointcloud enhancement, 3D-Pact and Flownex Simulation Software

Project Phase: Proof of Concept (Operational)

Completion Date: 30/06/2012

Project Location: Viljoensdrift, Free State, South Africa

Capital Cost of Laser Scanning Project: $665,000.00

Lethabo Laser Scanning: The Project

Eskom has a fleet of 28 operational power stations, with a large portion of the high capacity stations in the middle of their O&M asset lifecycle. As such, many of these power stations are due to undergo major refurbishment and plant system upgrades in the next few years to maintain the asset or extend their useful remaining life. Such projects requires access to accurate, reliable and relevant engineering information which includes accurate 3D spatial data and lay-out information of the plant. Due to the age of these plants, access to the design base information and content are many times problematic as it was generated over 40-60 years ago. Accuracy of current drawings and engineering design base content are also an issue as changes and plant modifications were not always documented fully or correctly. Increased regulatory compliance around design base management also requires better management of the plant information asset. The goal of the Lethabo project was to utilise 3D laser scanning technology on a brownfields plant to determine to what extent it can be used to enhance O&M and major modification/refurbishment activities. This PoC also had to identify the most viable laser scanning technologies and standards for application in Eskom and specifically Generation plants. A further requirement was to evaluate the end-product deliverables from the scan process to see what other applications and laser scan-data re-use opportunities can be identified. A specific challenge was to determine to what extent the pointcloud information and data can be used as a baseline to develop interactive visualisation and simulation capabilities that can support the O&M production, operating and maintenance environment.

Lethabo Power Station exist of 6 x 600MW power generation units, with the last unit commissioned in 1986. The design of the power station was done using conventional draughting techniques and at the time of construction/commissioning, CADD systems and 3D models were not used extensively.

In 2006, a project was undertaken to perform 3D Laser scanning on Unit 1 Boiler plant as a prototype to determine the benefit of using 3D Laser Scanning technology for design base re-establishment from a 3D perspective. This meant a “3D Scanning cube” on the boiler plant area of 72m high x 150m wide x 150m deep.

346 pointcloud scans were performed with a Leica Scanner (black & white, high resolution) with 3D colour photography overlaid on top of the B&W scan. Scan accuracy was ensured with a tightly controlled Laser Scan Control Survey Network and survey markers. The pointcloud data was merged into a combined 3D Pointcloud using uSMART technology enabled on Bentley MicroStation; and a Truview Integrated Spherical Pointcloud in a web-portal format was created and enabled for O&M use.

The Goal

Project Data

Project Challenges

SCAN ACCURACY A decision was made that the highest possible scan accuracy should be achieved as there would not have been an opportunity to return to site for re-scanning. A requirement was to scan to an accuracy of 5 mm (or less) between points in the cloud, as well as for the merged pointcloud.

NUMBER AND SIZE OF 3D LASER SCAN DATA-SETS The boiler plant is large and complex in nature and the layout of the plant required 346 laser scans to be performed at various plant levels, which had to be accurately merged without compromising data accuracy.

The merged pointcloud contained more than 10+ billion data points, close to 1 TB in file size which in 2006 posed significant problems when it came to IT/IM infrastructure that could support such large data-sets. Navigation speed and viewing of such large data sets also became a major issue, significantly impacting the perceived benefit of having this data, especially from an O&M perspective.

PLANT ACCESS Lethabo Power Station is operational 24/7/365, so scanning work had to be performed on running plant. It was a non-negotiable requirement that scanning should not impact any operational or maintenance activities and that safety of staff, plant and equipment was not compromised in any way during the data acquisition process.

Initially, it was thought that the boiler internals could also be scanned, but due to extreme space restrictions, safety considerations and accessibility issues, an alternative method was required to establish the boiler 3D design base.

OPERATING CONDITIONS As Lethabo Power Station is a coal fired plant, and as such a high level of coal, ash and dust “fall-out” were experienced that impacted laser scanning progress and planning. Accessibility, high temperature and humid conditions in the boiler also affected scanner battery life and calibration frequency on the equipment used.

USE-ABILITY OF THE 3D LASER SCANNING OUTPUTS The large scan data set created a significant challenge in that most end-user computer equipment at the time could not deal with the size/volumes of data generated. It became imperative to find alternative methods of viewing this information and exposing O&M staff to this valuable information. Operating staff also required a user-friendly, easy and interactive platform to interrogate and use the information produced. There was also a view until recently that one had no choice but to convert pointcloud data to solid 3D models to be able to use it for O&M training and visualisation when it came to O&M training simulator technologies like 3D-Pact.

Value Add of Using Bentley Products

• After it was found that 3D Laser scanning could not be successfully used inside the boiler (space and access restrictions), the most viable method of generating a 3D design base model of the boiler was to use Bentley PlantSpace 3D and original plant drawings of the boiler internals to re-generate a 3D plant model of the boiler. Very little plant interaction and measurement was required to generate the model, and the ease with which the pipe/tube specifications could be set up to create the 3D plant model, allowed the project to produce its first deliverable in less than 3 months (it was intended to be a 24 month project, fast tracked to 18 months, and finalised in 12 months).

• At virtually the same time this PoC project was undertaken, an exercise was also nearing completion

where the Lethabo P&ID’s were draughted intelligently into the Bentley PlantSpace P&ID platform. The interaction between the 2 data-sets became extremely important as it was possible to validate plant process components identified in the 3D model/point cloud to P&ID content. This significantly increased the value-add on both of the initiatives due to the cross validation & verification of engineering design information.

• Development of the uSMART pointcloud data accelerator technology, enabled Eskom to view the

integrated pointcloud on the Bentley MicroStation platform in order to do the necessary pointcloud clean-up and plant tagging enhancements. At the time, only the MicroStation CADD software engine could deal with the integrated pointcloud data file size generated on this project.

• The ability to bring larger pointcloud datasets into MicroStation also allowed Eskom to start

leveraging numerous scan datasets to create solid 3D model objects within MicroStation. A major benefit of this was that the 3D-Pact O&M Visualisation and Simulation technology could be enabled on a brownfields plant – something not thought possible at the time 3D-Pact technology was being developed.

• MicroStation was found to be the most efficient and capable tool to build true 3D models of existing plant. It’s also the primary platform used to develop, integrate and prepare the 3D model content used for 3D-Pact visualisation and simulation.

Benefits

By leveraging the MicroStation platform, uSMART and Truview technology capabilities, it has been possible to:

• Deal with large 3D laser scan data volumes effectively and reuse the data in various applications.

• Add “Intelligence” to the pointcloud data (plant tags) - significantly enhancing its re-use and value (e.g. being able to link it via the plant tag to other design information like datasheets, documentation, drawings, etc). This intelligence could also be re-used in Truview to enhance the user experience as this information enhances the visual 3D aspects.

• By creating a 3D Spherical Viewer Portal using Truview, immediate benefit could be obtained for

O&M purposes. • It has been successfully used to plan design, outage and maintenance work around major

High Pressure Pipework refurbishment activities in the Boiler Area.

• The Truview content is readily available for operator training, significantly speeding up plant understanding and knowledge (safe, virtual and training-friendly environment where new staff can familiarise themselves with the “as built” plant).

• Improved emergency preparedness training, hazard identification and safety training of staff and contractors. Created the capability to train staff on safety issues where hazardous locations exist where it is not ideal to expose trainees to actual plant environment.

• Feasibility studies and modification proposals can be better evaluated for “fit” against known “as built” plant dimensional information.

• Improved maintenance planning (e.g. scaffold size requirements) and job safety analysis.

• The ability to import and use Truview pointclouds in 3D-Pact has negated the need to first create solid 3D models of the plant before it becomes possible to use the 3D-Pact Technology.

• Fast and efficient creation of solid 3D models in designated plant areas is possible as an alternative to using the native pointcloud data.

• This project has created a platform where the following becomes possible on brownfields plants:

• More effective operator regulatory competency and capability testing can be done safely in a virtual plant that closely mimics the real plant asset. The laser-scan based 3D model is the best representation of an “as built” plant due to the high level of dimensional accuracy obtained.

• Virtual Incident/emergency situation simulation during training and job safety analysis help prepare operators for such conditions; resulting in better operator response in emergencies reducing the impact of actual plant damage caused by such occurrences. Emergency scenario planning capability is also enhanced.

• Improved plant operational and start-up/shutdown efficiencies can be achieved in that the virtual plant can be used to evaluate existing operating procedures and methods and improve them.

• Enhanced plant commissioning and operating – changing plant conditions and operating parameters can be simulated in a 3D virtual environment if the flow simulation technology is also enabled.

Return on Innovation

Benefits

Time Savings

Money Saved

• The technologies deployed allowed the scanning and intelligence enhancement portion of the PoC project, which was initially planned to be a 24 month exercise, was completed in 9 months (3 months ahead of schedule).

• The ability to release and leverage the Truview spherical viewer for O&M purposes very early in the Project, allowed for a faster ROI on the Project deliverables.

• The ability (currently under development and finalisation) of enabling virtual simulation and end-user interaction within the Truview 3D point cloud, significantly save on the time-consuming requirement to convert the entire plant 3D pointcloud dataset into a solid 3D Model.

• With re-evaluation and subsequent optimisation of the Laser Scanning methodology used in 2006, it is anticipated that technology enhancements and improvements now make it possible to convert point-clouds to solids 50% faster.

• Similarly, enhanced intelligence can also be achieved between 40-60% faster compared to the original 2006 project execution timelines.

The neutrality of point cloud data makes the data-set very valuable, as the information could seamlessly be imported and used on various CADD software platforms. This provides significant cost savings as no conversion of data is required to use it on different software platforms.

Although executed as a Proof of Concept (PoC) Project, various financial benefits could be identified by actively exploring and driving this technology for use on Brownfields Plants in Eskom.

By having the plant 3D laser scanning model data available, significant reductions in draughting and surveying costs when plant modifications are required, is already possible.

Typical additional (and potential) cost savings that can be achieved are listed below:

Typical Cost Impact Cost

Lost production saved due to better outage planning (Preventing delayed Start-up of 2 days due to outage slip)

$ 250,000/year/incident

Reduced Plant load loss risk due to better operator training Load Loss, 800MW Unit/day

Unit Trip, 800 MW Unit, return in 4 hours

$ 240,000/day $40,000/incident

Improved boiler tube survey planning and work execution (Reduced unplanned outages on boiler due to tube leaks)

$720,000/incident

Better planning for HP Pipework replacements (unplanned failure can result in significant load losses)

$6,720,000/incident

Improved Plant & Worker Safety Prevention of 1 disabling injury Prevention of 1 fatality

$16,000/incident $225,000/incident

Reduced Outage Costs (better scaffold planning, less outage cost, better outage activity planning and execution)

$ 35,000/year

Alarm/abnormal condition training (Reduced load losses & trips) $4,750,000/day

Large Equipment Failure prevent (e.g. Generator failure due to breach in clean conditions during repair work)

$8,500,000/incident

How this Project created a Competitive Edge

• Partnering with the 3D Pact developers to enable bleeding edge technology capabilities in Truview Viewer (similar to that which can be obtained within conventional solid 3D CADD Models).

• Showing the extent to which the 3D Laser Scanning Data can be used (and re-used) for maximum ROI3 benefit.

• The numerous 3D laser scanning data re-use options that have been identified with this PoC for Brownfields Plants - providing the Owner/Operator with a number of options on how to utilise the data, based on business drivers and goals.

• Handling the point cloud scan data as one integrated pointcloud file and adding plant tag intelligence into both the merged pointcloud as well as Truview provided a very high level of data quality and design base validation & verification capabilities.

• The ability to use 3D laser scan data in MicroStation 3D to generate a solid 3D models that can be used for conventional 3D-Pact Visualisation & Simulation software technology.

The Project Differentiators

Meeting the Engineering Challenges

The Unique Competitive Edge • Developing and productising the use of 3D Laser Scanning data in a bleeding edge pointcloud

technology application - enabling 3D visualisation and simulation within a pointcloud (negating the need to create a 3D solid model first) .

• 3D laser scanning information is no longer a survey or verification/3D data re-establishment technology only, but a key business information asset that can be leveraged to great effect in the O&M environment.

• A virtual, interactive 3D O&M training and plant information environment at the user desktop/laptop could be created with multiple options of how the data is presented (converted to a solid 3D CADD Model, or enabled in the Truview pointcloud).

• Leveraging 3D CADD Models and PC gaming technology to create a unique, easily accessible and highly valuable information asset usable and available to all plant staff.

• The numerous applications for the 3D virtual environment capability within construction, commissioning, training, operational readiness and skills development, which significantly enhances Eskom’s business operations and safety programs.

• Being able to effectively deal with the complexity and size of the plant area that had to be scanned.

• Scan accuracy of average 2 mm achieved across entire scan. • By using the Bentley product suite and other enabling supporting technologies, project

deliverables was completed 12 months early; without compromising quality and outputs of the project.

• Major re-use of point-cloud data and O&M application could be identified and enabled. • The PoC also showed how new hand-held laser scanners have an accuracy (down to 40 microns) –

which is suitable to capture equipment and component level detail for highly detailed and accurate models of plant components/equipment to be used in 3D models (and also subsequent use in Finite Element Analysis and Computational Flow Dynamic applications).

Competitive Edge – Examples

Operations Training in 3D-Pact from solid 3D modelling off a sub-station pointcloud scan

Incident Simulation using actual Truview pointcloud and enabling this in 3D Pact visualisation & simulation software

Operating and Emergency Procedure virtualisation in Truview Pointcloud with dynamic condition simulation

Environmental & Community Impact

By utilising 3D Laser scanning information, better planning of maintenance and outage activities can be done, resulting in less resources being consumed, with long-term environmental benefits. Emergency situations can be better analysed and planned for, also minimising the negative impact of environmental incidents (environmental and regulatory impacts).

The Environment

The Community All the elements of the Project was executed using local South African engineering and consulting capabilities. The 3D visualisation and simulation capability was exclusively developed in partnership with a local South African company, supporting Eskom’s corporate strategy to focus on local supplier and engineering capability development. Eskom is actively engaged with engineering skills development – the technology capabilities developed in the PoC show how 3D laser scanning data and information, visualisation and simulation technology can be used to create smarter, optimised and highly efficient power generation infrastructure.

Collaboration Technology Used

Where information had to be accessed to verify/validate existing plant design base content, the Bentley ProjectWise application , implemented at Lethabo Power Station, was used.

Acknowledgements

Jackie Herndler, Eskom CADD Office, Group Technology Engineering Waleed Moses, Eskom CADD Office, Group Technology Engineering Hester Malherbe, Lethabo Power Station CADD Office Lethabo Boiler Plant Engineering Department Lethabo Operating & Training Department

Project Partners

Eskom Team Members

Leica Truview

Scanner technology

Truview Software technology

SmartTech uSMART MDM

MDM (Mass Data Management) technology development

Pointcloud intelligence enhancement

3D Draughting

Lethabo 3D pointcloud scanning project

Boiler Internal 3D modeling

Lethabo Intelligent P&ID project

Pointcloud intelligence enhancement

Lloyd & Hill South Africa

Lethabo 3D Scanning & Photogrammetry

Creaform3D - 3D Engineering Solutions

Component FEA/CFD Scanning Prototype