NDT in Canada 2015 Conference, June 15-17, 2015, Edmonton, AB (Canada) - www.ndt.net/app.

NDTCanada2015
Solving Real World Integrity Problems
Using 3D-Laser Scanning
Three Case Studies
Jessica Donaldson
Canadian Engineering and Inspection Ltd.
Edmonton, Alberta, Canada
www.caneil.ca
 Agenda
3D Laser Scanning: What Can It Do?
Applications
Case Study 1: 3D Laser Scanning of Visually
deformed newly fabricated pipe bends
Case Study 2: Scanning to Perform Fitness For
Service Assessment of Y-Piping Spool
Case Study 3: Engineering assessment of a
large diameter storage tank and roof rafters
Conclusions
Questions
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 3D Laser Scanning
• Capture 3D documentation
• Can record complex structures and systems
with (depending on manufacturer):
– Distance accuracy up to ±2mm
– Range from 0.6m up to 130m
– Measurement speed: 40 million points/6 minute
scan
– Adjustable resolution

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 3D Laser Scanning
• Constant waves of
varying length
• Upon contact with an
object they are
reflected back to the
scanner
(triangulation)

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 Scanning Equipment
• Similar to survey
equipment in size
• 200mm spheres
• 150mm spheres
• 6ft CF tripod
• 15ft elevator tripod

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 Applications
• As-built
• Alteration
• Documentation
• 3D Virtualization
• Inspection
• Flaw/Deviation Analysis
• Accuracy for Fitness for Service
Assessments

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 Methods of Geometric
Measurement
• Traditional Methods and Limitations
– Tape measure, level, plum bob, sweep board, etc
– Surveying
– Time consuming and difficult to get many geometric data points
– Several approximations must be made
– Where is the worst spot when looking at damage?

• Different approach – 3D Laser Scanning as a tool

– Involves creating virtual models of real world objects
– Models are created from a point cloud (40 million points generated in a 6
minute scan)
– Each point gives the exact location from a detected surface

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 Processing Data
• Modeling software combines point cloud data into an
accurate model

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Example: Tank External Scan

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Example: Tank Internal Scan

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Example: Facility (as-built) Mapping

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Limitations

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Case Study 1 :
3D Laser Scanning of visually deformed newly fabricated
pipe bends
• Background Information
– Three newly fabricated pipe bends
– O.D. of 914 mm; the three bends had angles of 42°, 21°,
and 41°
– Out of roundness identified as a concern by visual
inspection
– Ends of bends have an out-of-roundness tolerance of 1%,
and the rest of the bend can have an out-of-roundness
tolerance between 1% to 3% (ASME B16.49 paragraph
12.1).
Pipe Bends and 3D Laser
Scanning Setup

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Ideal 3D Model of Bends

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 End Deviation
• Maximum Out of Roundness: 8.6mm (0.94%)

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 Front Face Deviation
• Max Deviation: 8.6mm (0.94%)

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 Arc Bend Deviation
• Maximum Deviation: 9.5mm (1.04%)

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 Conclusion
• All three bends meet the tolerance
requirements for out-of-roundness as per
ASME B16.49, for the areas that were
scanned.
• Bends Fit for Service

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Case Study 2:
Scanning to Perform Fitness For Service Assessment of
Y-Piping Spool
• Y-spool was permanently distorted when an expansion joint
attached to an associated pump failed. The expansion joint
was replaced but the client wanted to ensure the Y-spool was
still fit for service.
• No cracking or crack like indications found with NDE.
• Replaced the failed expansion joint.
• Requested to perform 3D laser scan of the Y-spool and then
perform an API 579-1/ASME FFS-1 Fitness-For-Service
assessment.

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Y-Spool Point Cloud image from 3D Scan

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Y-Cross Section Mapping

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 Analysis
• The Y-section was modelled for a Level 3 assessment
• Deformation data was taken from 3D laser scanning
results and the worst areas were modelled. Five
deformed areas with a deviation greater than 0.4”
were considered in the analysis
• Straight segments of the Y-spool deviations were
within the permissible 1% out-of-roundness
tolerance and therefore not modeled for Level 3
analysis

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Y-Section Model

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Fixed Geometry restraints, internal pressure and fluid
density loading was applied to the model for the Level
3 assessment

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Stress Analysis
Maximum of 7500psi

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Increasing Pressure Simulations
Approach yield at 120psi

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 Conclusion
• Based on the results of the assessment, it was
determined that the Y-spool was fit-for-service
provided:
– Visual monitoring of the Y-spool and attached piping for crack
appearance, increased deformation, and any other changes
– Repeat 3D laser scanning assessment to monitor deformation
– no cracks or crack-like flaws exist or develop on the welds of
the Y-spool by performing periodic NDE examination
– Cause of expansion joint failure investigated to ensure there
is no repeat occurrence of failure

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Case Study 3:
Tank Deformation and FFS
• Internal inspection of a large diameter storage tank
to API 653 requirements
• Geometric evaluation of tank shell
• Baseline shell evaluation for future inspection
• Tank
– Diameter: 85ft
– Height: 40ft
– Nominal Capacity: 40395 BBL

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Tank Overview

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 Point Cloud Model
Total of 8 scans with tolerance of ±3mm

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Cleaned 3D Point Cloud for Shell
Geometric Evaluation

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Ideal 3D Model

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Tank Scanned Model

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Maximum Bulge: 1.65in.
Maximum Dent: 2.05in.

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 API 653 Criteria
• The maximum radii tolerance for this tank, as per
API-653 for reconstructed tanks and the API 650
construction code, is ¾ in. (19 mm) measured at 1 ft.
above the shell to bottom weld.
• API 653 also states that the tolerances above the 1 ft.
level are not to exceed 3 times the tolerance at the 1
foot level. This restricts the out of roundness above
the 1 ft. mark to 2 ¼ in.

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Comparison of Tank with Tolerances

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 Conclusion – Shell Evaluation

• Deformations found to be acceptable based

on the code requirements.
• Recent edge settlement survey showed tank
to be in good condition.
• API 653 internal and external inspection
performed at the time of scanning.
• Recommended the tank as fit for service.

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 Rafter Evaluation
• Tank has 43 rafters and one central column
• Visual inspection of the rafters revealed
deformations that required further
investigation
• 8 scans were done to model rafters and tank
internals

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Rafter Point Cloud Model

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Cleaned up Rafters

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Rafter Point Cloud to 3D Model

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Analysis of Worst Case Rafter
Maximum Deviation: 1.20 in.

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 Conclusion
• There are no tolerance limits specified in API 653 for
bending of roof rafters.
• Analyzing the worst case condition, with full snow
load and vacuum applied, the rafters had an average
maximum stress of about 19000 psi. This is still well
below the yield strength and did not signify any
integrity concerns.
• Tank and roof rafters fit for service.

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 Conclusions
• Laser scanning has proven to be a valuable tool for
dealing with several asset integrity challenges that
involve dimensional analysis
• Improved accuracy of Engineering Assessments API-
579 Fitness-for-Service (Model what’s actually there
instead of guessing and approximating)
• Especially useful in the following areas:
– Records management
– Alterations/modifications
– Inspection / QC
– Fitness-for-Service and integrity engineering
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Questions

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