The Challenge
AsBuilt was contracted to capture the head chute and drive of a coal conveying system responsible for delivering fuel to a coal-fired power plant unit. The existing drive required replacement, and the plant elected to upgrade the system to match the drives installed on three other units for consistency and maintainability.
Complicating the effort, the plant lacked accurate drawings of the existing arrangement. Without reliable documentation, verifying fitment, planning installation, and aligning the new drive with existing infrastructure posed significant risk.
The Solution
AsBuilt utilized 3D laser scanning to capture the full as-is condition of the conveyor head chute and drive assembly. The scan data was processed into a detailed 3D model, providing accurate geometry of the existing equipment and surrounding structures.
The new drive assembly was then placed directly into the model and point cloud environment to validate fitment, alignment, and clearances prior to procurement and installation. This ensured the upgraded drive would integrate seamlessly with the existing system and match the configuration of the other plant units.
Key Outcomes
- Defined Project Scope
Scan-based models enabled the drive to be fully specified, allowing contractors to bid confidently using accurate 3D information. - Rigging and Installation Planning
Installation teams planned rigging paths, clearances, and sequencing using point cloud measurements and 3D models. - Precise Equipment Replacement
Scanning captured equipment in its exact installed position, supporting like-for-like replacement without field guesswork. - Management of Change
Following installation and owner acceptance, the model was updated to reflect the final configuration for future reference.
Deliverables
- Registered 3D Point Cloud
- 3D As-Built Model
- Clash Detection Support
Why It Matters
Conveyor drive replacements directly impact fuel delivery and plant reliability. By establishing accurate as-built conditions and validating upgrades digitally, AsBuilt reduced installation risk, improved coordination, and supported long-term configuration control for critical material handling systems.
