Laser Scanning. Providing Value, Delivering Results. SPAR 2005 Houston, Texas May 23-24, 2005

Transcription

1 Laser Scanning Providing Value, Delivering Results Houston, Texas May 23-24, 2005

2 Presenters Tad Fry Manager of Engineering Brewing, Operations & Technology Anheuser-Busch, Inc. Greg Lawes Manager Laser Scanning Services Washington Group International Note: Greg Lawes presentation is a separate PDF file

3 Agenda The Top 10 Questions About Laser Scanning An Owner s View Providing Value, Delivering Results An Engineering Supplier s View Summary Q&A

4 About Anheuser-Busch Anheuser-Busch's operations and resources are focused on beer, adventure park entertainment and packaging. Anheuser-Busch also has interests in aluminum beverage container recycling, malt production, rice milling, real estate development, turf farming, metalized paper label printing and transportation services.

5 Project Execution Core Competencies Project Management Engineering Management Construction Management Design Services Engineering Suppliers (major) In-house (full service)

6 On Going Challenges Continued Focus on Reducing Cost

7 On Going Challenges Managing Diverse Capital Plan A-B Engineering $600 MM annual average Brewing, Packaging, Utility & Facilities Meeting project objectives ROI driven Executing Projects Breweries operate 24x7x365 Mostly brown field projects Outages must be minimized well executed Capital Efficiency & Asset Utilization Focus on interoperability improvements Migration to collaborative data centric Improving contractor productivity Lower (optimize) engineering & construction costs

8 And New Challenges Maximizing The Value Laser scanning High level - versus hands on Immediate Benefits make it work Workflows ensure highest quality and optimized cost Engineering & Construction data management and design efficiency Lifecycle data and asset management

9 Agenda The Top 10 Questions An Owner s View Providing Value, Delivering Results An Engineering Supplier s View Summary Q&A

10 The Top 10 Questions 1. What is laser scanning all about? 2. Why do laser scanning? 3. What are the business drivers? 4. How can we apply this technology? 5. How do we know it s really working? 6. What does it cost? 7. Is the technology stable? 8. Are there any heartburn issues? 9. What are some lessons learned? 10. Where do we go from here?

11 Salutes

12 Definitions Real Men of Genius Point Cloud meteorologist describing advancing low pressure storm system Registration something you do at the airport hotel after missing your flight to Newark Survey something the Gallup Organization engages in Target an upscale discount retailer Pre-Project Planning something you do before taking your family of 5 to Sea World High Density has to do with physics weighs more than low density

13 The Top 10 Questions 1. What is laser scanning all about? 2. Why do laser scanning? 3. What are the business drivers? 4. How can we apply this technology? 5. What does it cost? 6. Is the technology stable? 7. How do we know it s really working? 8. Are there any heartburn issues? 9. What are some lessons learned? 10. Where do we go from here?

14 Adoption & Value Add The Sales Pitch Highly accurate field data gathering tool Extremely portable Fast schedule improvement Registered to site grid Field safety greatly improved Data compatibility with software Enables new design to be inference free Saves money engineering & TIC!!!

15 Adoption & Value Add Primary Driver Reduce growth in construction due to field interferences Brewery process operations - heavy piping focus; majority of projects in existing operating facilities

16 Adoption & Value Add Additional Drivers Speed to market Improved contractor productivity

17 Since Merrimack, NH Baldwinsville, NY Fairfield, CA Fort Collins, CO Columbus, OH St. Louis, MO Newark, NJ Williamsburg, VA Los Angeles, CA Cartersville, GA 3D Design Laser Scan GPR Houston, TX Jacksonville, FL

18 Adoption & Value Add It s working well well, most of the time! Value understood & supported Scanning is in place for all major brown field brewing work and now also in packaging

19 Increasing Value 3D Design Application Data Centric SAP IDF transfer SpoolGen Standards Library Visualization Scan Integration w/3d Smart Plant Review & LaserGen

21 Applications (not all inclusive) Site & engineering surveys As-builts of plants & facilities Profiles, volumes, area calculations Topo and detail surveys Fabrication & construction inspection Quantity surveys Conceptual design & interference checking Construction & forensic engineering Manufacturing & reverse engineering Historical & legal archive Asset management

22 Current Applications Site & engineering surveys As-builts of plants & facilities Profiles, volumes, area calculations Topo and detail surveys Fabrication & construction inspection Quantity surveys Conceptual design & interference checking Construction and forensic engineering Manufacturing & reverse engineering Historical & legal archive Asset management

23 Future Applications Site & engineering surveys As-builts of plants & facilities Profiles, volumes, area calculations Topo and detail surveys Fabrication & construction inspection Quantity surveys Conceptual design & interference checking Construction and forensic engineering Manufacturing & reverse engineering Historical & legal archive Asset management

24 Application Example Fabrication & Construction Inspection Beer Release Manifold Demo existing FBRM & associated piping Install a new FBRM nearly twice in size 16 total sections Fabricate new manifold offsite, final assembled at the brewery, and installed during a 96- hour outage window. 1.5 total tolerance between existing columns lead us to scanning the shop fabrication

25 Application Example Fabrication & Construction Inspection Quantapoint contracted to perform laser scans & survey Intergraph PDS 3D LASERGen software Registration Engineering Approach Design validation Automatic clash detection Fabrication validation

26 Application Example Fabrication & Construction Inspection Beer Release Manifold Scan of existing manifold

27 Application Example Fabrication & Construction Inspection Beer Release Manifold Combined scans of existing area

28 Application Example Fabrication & Construction Inspection Beer Release Manifold Masking tool for demolition

29 Application Example Fabrication & Construction Inspection Beer Release Manifold 3D model of new manifold

30 Application Example Fabrication & Construction Inspection Beer Release Manifold 1.5 column width limit 3D model of new manifold

31 Application Example Fabrication & Construction Inspection Beer Release Manifold Scan Targets In the fab shop

32 Application Example Fabrication & Construction Inspection Beer Release Manifold Scan Targets Scan of manifold in the shop

33 Application Example Fabrication & Construction Inspection Beer Release Manifold Field piping through floor Shop scan + existing columns modeled

34 Application Example Fabrication & Construction Inspection Beer Release Manifold Field piping through floor Manifold scan at site

35 Application Example Fabrication & Construction Inspection Beer Release Manifold Shutdown! Demo time!

36 Application Example Fabrication & Construction Inspection Beer Release Manifold Old manifold removed

37 Application Example Fabrication & Construction Inspection Beer Release Manifold Installing new manifold

38 Application Example Fabrication & Construction Inspection Beer Release Manifold column Installing new manifold

39 Application Example Fabrication & Construction Inspection Beer Release Manifold column Installing new manifold

40 Application Example Fabrication & Construction Inspection Beer Release Manifold Installing new manifold

41 Application Example Fabrication & Construction Inspection Beer Release Manifold Job complete!

43 Metrics Currently we track Project location, type, etc. Service provider Deliverables, approach # of scans Scanner type (make, model, etc.) Scan costs - as function of engineering cost Construction growth focus on interference avoidance Lessons learned expanding applications

44 Metrics - Costs Historically, the percentage of detailed engineering costs falls within the following ranges of direct costs: Utilities work 8-12% Packaging work 4-8% Brewing work 10-15% Historically, we find laser scanning costs range between 1 8% of engineering with an average of 3.5%

45 Metrics Success! Continue to see favorable reductions in construction growth due to reduced or eliminated design interferences 1% - 3% range Design cost impact neutral with further savings expected over time Project schedule improvements Constructability & fabrication validation success applying method to LA project in 2005

46 Metrics Do we competitively bid our laser scan services?

47 Metrics Laser Scanning Services Internal External

48 Metrics Is the low bid the right price? The answer should be YES! But what about value?

50 Current State The executive summary is and, of course

51 Technology Sustaining technology Here to stay, however, you must be willing to get into the details to ensure consistent results Is not a panacea technology & software still evolving Accuracy and amount of data captured is superior to manually obtained data Improved visualization provides benefit to operations & maintenance Understand the application need Apply correct technology & workflows Reduces but does not eliminate manual field effort

52 Heartburn (potential) Lack of standards Calibration Data Workflows Definitions (Refer to Real Men of Genius) Certification Pre-qualification CSP program people versus company Education Training needed for all levels of users

53 Risk Management It is a technology with great potential It is supposed to help manage risk, but there are pitfalls Planning, approach, experience, the unknown Who and what will be impacted? Impact on overall schedule, engineering approach, budgets, project quality, contractor productivity, even technology acceptance

55 Maximizing The Value Workflows ensure highest quality and optimized cost Laser Scanning Elements Pre-qualification of Service Providers Pre-Project Planning Scope of Services & Deliverables Pre-Bid Site Visit Bid & Award Onsite EHS On Site Workflows & QA Post Site Data Processing & QA Best Practices Needs improvement! What is the goal? Critically important!!! We require it Define proposal breakdown SOP education of plant personnel Critically important!!! QA process? How will data be used?

56 Maximizing The Value What about the data? - Lots of data! - File movement - Design work station configuration How can we make the designer most efficient? Data outputs define the standards - Raw scan data - Scan maps - Registered scan models - Registered survey data - Digital photos Engineering & Construction data management and design efficiency And the data applications this can impact workflows

57 More Lessons Learned Establish a control network of benchmarks with known plant coordinates. Visibly identify key pipelines and/or tie points in the plant prior to laser scanning. The engineering personnel who are present during the laser scanning should have complete knowledge of the job scope. Every project is unique and even the best plans will require flexibility.

58 More Lessons Learned Take digital pictures corresponding to the scans. Highly reflective surfaces e.g. polished stainless steel tanks, piping, etc. can cause inaccuracies with scan data. Very dark & non-reflective surfaces, such as armaflex insulation, same issue. Plan the scan! Laser is a line-of-sight tool it can not see through or behind solid objects Target placement plan

59 More Lessons Learned Ensure proper pre-qualification of service providers CSP program issues person versus company Updating our internal program QA/QC submittals for entire workflow Deliverable samples Ensure commitment OEM hardware/software support Don t mix deliverables outside of core competencies Frameworks 3D model vs. scan services

61 The Informational Needs Lifecycle data and asset management Who owns the data? I do! So now what?

62 What Are The Informational Needs? Are they long-term, driven by system wide plans? Plant asset management, Plant asset As-built record, Maintenance and Operation for training and planning Or, are they short-term, task or project driven? Engineering, Construction, Fabrication New technology capabilities driving new potential Multi-use considerations impact direction (completeness, density) Managing huge amounts of data

63 Agenda The Top 10 Questions An Owner s View Providing Value, Delivering Results An Engineering Supplier s View Summary Q&A NOTE: PLEASE REFER TO GREG LAWES PDF FILE FOR THIS PORTION OF THE PRESENTATION

64 Laser Scanning Providing Value, Delivering Results To Projects, To The Owner NOTE: PLEASE REFER TO GREG S PDF FILE FOR THIS PORTION OF THE PRESENTATION Greg Lawes Laser Scanning Services

65 Agenda The Top 10 Questions An Owner s View Providing Value, Delivering Results An Engineering Supplier s View Summary Q&A

66 Providing Value, Delivering Results! Laser Scanning Value saving time & money! ROI saving money Reduced field rework Optimize engineering costs Risk mitigation tool Project schedule improvements Engineering Estimate 60% of field work (surveying to checking) can be eliminated with laser scanning Construction Constructability Reducing time required for field verification

67 Providing Value, Delivering Results! Education & training Planning, planning, more planning Executing the project Quality work practices Cost of services Technology and Innovation Emerging standards

68 Laser Scanning Providing Value, Delivering Results Q&A