The Challenge
AsBuilt was contracted to perform comprehensive laser scanning, 3D modeling, design validation, and Management of Change (MOC) documentation for an Auxiliary Cooling Water (ACW) vent system and associated equipment replacement within an operating industrial facility.
The project involved replacing aging vent components and critical cooling water equipment within a dense, congested mechanical environment. Existing documentation was incomplete and outdated, creating significant risk for clashes, installation delays, and rework. The facility required:
- Accurate field verification of existing conditions
- Identification of spatial conflicts and constructability risks
- Precise dimensional data for retrofit design
- Support for formal MOC compliance and review
- Minimal disruption to ongoing plant operations
Traditional measurement methods would have introduced safety risks, schedule delays, and potential inaccuracies. A highly detailed digital capture of existing conditions was required to ensure design integrity and seamless integration of the new vent system.
The Solution
AsBuilt deployed high-resolution terrestrial laser scanning (LiDAR) technology to capture a complete digital representation of the project area. The scan incorporated all surrounding structural elements, mechanical systems, piping, utilities, and equipment to provide a comprehensive as-found condition dataset.
Field Data Acquisition
- Full 3D laser scan of the Auxiliary Cooling Water system area
- Capture of structural steel, pipe racks, cable trays, conduit, HVAC, and adjacent process lines
- High-density scan coverage to ensure millimeter-level accuracy
- Colorized point cloud generation for enhanced visualization
This approach eliminated manual measurement errors and provided a complete digital twin of the space.
Engineering & Modeling
Using the scan data, AsBuilt generated a precise 3D as-built model to support vent system redesign and equipment replacement planning.
Key modeling components included:
- Accurate modeling of existing piping and vent configurations
- Integration of structural steel and support framing
- Modeling of utility systems and spatial constraints
- Clash detection and interference analysis
- Verification of tie-in points and connection elevations
The model enabled engineers and stakeholders to evaluate constructability, confirm clearances, and optimize routing before fabrication or installation began.
Management of Change (MOC) Support
To support plant governance and compliance requirements, AsBuilt provided digital documentation and modeling outputs aligned with the facility’s Management of Change (MOC) process.
Deliverables supported:
- Risk assessment reviews
- Design validation and approval workflows
- Stakeholder coordination
- Construction planning and sequencing
- Regulatory and internal compliance documentation
The digital model provided a visual, data-driven foundation for faster MOC approvals and reduced engineering uncertainty.
Deliverables
AsBuilt delivered a comprehensive digital dataset to support engineering, operations, and long-term asset management:
- Raw laser scan data
- Post-processed, registered point cloud
- Colorized photorealistic 3D site visualization
- Parametric 3D as-built model (LOD appropriate for retrofit design)
- MOC-ready documentation and model files
Results & Impact
By leveraging 3D laser scanning and intelligent modeling, AsBuilt enabled:
- Reduced rework and field conflicts
- Improved installation accuracy
- Accelerated design and MOC approval timelines
- Enhanced safety through reduced manual field measurements
- Reliable digital documentation of existing conditions
The project demonstrates how reality capture and 3D modeling mitigate risk in complex retrofit environments, particularly for cooling water systems and critical process infrastructure upgrades.
