The Challenge
AsBuilt was contracted by a power generation facility to support a Hydrocyclone replacement project intended to improve the reliability and performance of the plant’s dewatering system.
The existing hydrocyclone and support structure required replacement to accommodate a new unit with updated loading requirements, revised piping connections, and modified elevations. The project required:
- Accurate existing-condition documentation
- Structural analysis for new equipment loading
- Proper alignment of supply and discharge piping
- Seamless integration with the active dewatering system
- Reduced installation risk within an operating plant
Incomplete legacy drawings and undocumented field changes increased the risk of misalignment, structural conflicts, and installation delays.
The Solution
Laser Scanning & Data Validation
AsBuilt conducted a high-resolution terrestrial laser scan (LiDAR) of the hydrocyclone and surrounding mechanical area. The scan captured:
- Existing hydrocyclone geometry
- Structural steel supports and framing
- Adjacent piping and tie-in points
- Utilities and nearby equipment
- Elevation relationships and spatial constraints
The scan data was registered, post-processed, and quality-checked to ensure engineering-grade accuracy before being prepared for modeling.
3D Modeling & Structural Redesign
Using the verified point cloud data, AsBuilt developed a precise 3D as-built model (DWG format) of the existing structure and piping systems. Based on the model:
- A new support structure was engineered to accommodate the updated hydrocyclone
- Structural members were sized and positioned to meet revised loading requirements
- Elevations were adjusted to align with the new equipment footprint
- Clash detection was performed to prevent interferences
The redesigned structure ensured proper support, access, and long-term operational stability.
Piping Design & Integration
To integrate the new hydrocyclone into the dewatering system, AsBuilt developed detailed supply and discharge piping drawings, including:
- Tie-in locations to existing piping
- Revised routing and elevations
- Connection details for fabrication and installation
This ensured accurate fitment and minimized field modifications during installation.
Deliverables
- Raw laser scan data (Recap format)
- Post-processed, registered point cloud
- Photorealistic 3D visualization
- 3D as-built model (DWG)
- Structural design for new hydrocyclone support
- Supply and discharge piping drawings
Results & Impact
The project delivered a fully engineered hydrocyclone replacement solution grounded in accurate as-built data. By combining laser scanning, structural design, and piping integration, AsBuilt reduced installation risk, improved dewatering system reliability, and ensured seamless integration within the existing power plant infrastructure.
