Case Study
As-built documentation of large scale Ammonia Plant
Sector
- Fertilizer Manufacturing
Service
- 3D Laser Scanning & As Built Model & Drawing
Location
- Gujarat, Hazira
Client Profile
Process Industry
Tools & Technologies Used
- FARO FOCUS
- Handheld Lidar Scanner (SLAM)
- FARO SCENE
Project Impact
High-fidelity process plant point cloud
Engineering-ready digital documentation
Reduced rework, streamlined retrofit planning
Business Requirement
The client planned a strategic conversion of their existing ammonia production plant to a green hydrogen facility requiring complete structural and process documentation. They needed comprehensive as-built models and technical drawings to facilitate the redesign and modification planning for this major plant conversion. Accurate baseline documentation was critical for engineering teams to design new modifications and ensure seamless integration with existing infrastructure.
Proposed Solution
We executed extensive 3D laser scanning of the entire fertilizer plant complex within 40 days using dual FARO Focus scanners to expedite data collection while maintaining precision. We established GNSS positioning to accurately map the current location and geospatial reference of all building structures and equipment. The comprehensive point cloud data was processed through FARO SCENE to generate isometric drawings and primitive models suitable for modification planning and design integration.
Challenges Faced
Initial theodolite survey closed traverse showed 100 cm error, requiring complete resurvey work to achieve acceptable accuracy standards for the complex plant layout. We successfully registered 5,500 individual laser scans into a unified model achieving 2.5 mm accuracy—a significant technical achievement requiring advanced data processing and verification protocols. Operational challenges included scanning 10-meter-high pipe racks using 12-meter scissor lifts and managing adverse weather conditions including heavy rain throughout the project duration.
Outcome
Comprehensive as-built 3D models with sub-centimeter accuracy enabling precise engineering for successful ammonia-to-green hydrogen plant conversion.