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Piping Isometrics: The Most Overlooked Safety Document in Process Plants

Wed, 01 Apr 2026 07:41:45 GMT

The Most Overlooked Safety Document in Process Plants

Date: 1st April 2026

There are certain documents that rarely get much attention until something goes wrong. Piping isometrics are one of them.

They’re not particularly exciting, and they rarely get mentioned in project summaries or progress meetings. Most of the time they sit quietly in project folders or document management systems.

But when an audit arrives, a modification is planned, or a safety review starts asking questions, those drawings suddenly become very important.

That’s because piping isometrics are far more than fabrication drawings. They show how a piping system has actually been built. They capture details about materials, welds, routing, valves, pressure ratings and testing requirements. In other words, they provide the technical record of what exists on site.

In industries where small mistakes can lead to serious safety incidents, that level of clarity matters.

Over the past few years, however, I’ve noticed more projects trying to reduce the amount of work put into piping isometrics. It’s usually driven by budget pressure or tight delivery schedules. Pipework gets “run on site” and the drawings are treated as something that can be finished later.

On the surface that can seem efficient. In practice it often creates risk.

Piping isometrics are not just a paperwork exercise. They are a key part of safe plant design, regulatory compliance and long-term asset management. When they’re skipped or poorly produced, the consequences can be expensive and occasionally much worse.

Why Piping Isometrics Are Not Optional

On many projects, piping isometrics fade into the background once construction is complete. They might not be looked at again until maintenance work is planned or a modification is proposed.

But when those situations arise, they quickly become one of the most important sources of information available.

Unfortunately, it’s becoming more common to see projects where the production of isometrics is reduced or delayed in an attempt to cut costs. In some cases, pipework is installed using general arrangement drawings and site sketches instead.

The short-term savings can look attractive. The problem is that this approach removes an important layer of engineering control.

Without detailed isometrics, there’s less opportunity to identify issues before installation. There’s also far less documentation available to demonstrate that the system meets the relevant codes and standards.

In a highly regulated industry, that can become a serious problem later on.

What Piping Isometrics Actually Represent

It’s easy to think of piping isometrics as drawings used mainly by pipefitters during fabrication. In reality, they serve a much wider purpose throughout the life of a plant.

A properly prepared isometric provides a clear representation of the piping system. It shows pipe sizes, routing, fittings, valves, weld locations and connection points. It also includes information on materials, pressure ratings, slopes and testing requirements.

That level of detail supports several critical activities.

Construction teams rely on it to install systems correctly. Maintenance teams use it to understand how systems are configured. Operations teams depend on it when managing and troubleshooting plant equipment.

In high-hazard environments such as chemical processing facilities, accurate information about pipework isn’t optional. Something as simple as an incorrectly rated fitting or an undocumented bypass can create operational or safety risks.

Isometrics provide the clarity needed to avoid those situations.

Standards and Codes

Industrial piping systems must comply with established engineering codes and standards. These standards exist to ensure systems are designed, built and maintained safely.

Piping isometrics play an important role in demonstrating that compliance.

Depending on the type of facility and the regulatory environment, piping systems may need to align with standards such as:

ASME B31.3 for process plant piping
ASME B31.1 for power generation systems
EN 13480 for metallic industrial piping

The specific standards vary depending on the plant and jurisdiction, but the underlying principle is consistent: systems must be properly documented and traceable. Isometrics form a key part of that technical record.

Piping Isometrics as Safety Documentation

Another important role of piping isometrics is within plant safety documentation.

When incidents occur, or when systems are reviewed as part of safety studies, engineers need an accurate picture of how the piping is configured. Isometrics provide the “as-built” representation of the system: what actually exists on site rather than what was originally intended in design drawings.

This information supports a range of safety activities, including:

Process safety management
Hazard and operability studies (HAZOPs)
Pressure system assessments
Isolation planning and maintenance procedures
Emergency response planning

If accurate documentation doesn’t exist, it becomes very difficult to verify that a system meets safety requirements.

In regulated industries, being able to demonstrate compliance is essential.

The Cost of Cutting Corners

The risks associated with poor documentation are not theoretical.

I worked with a client several years ago who had installed a large skid with a complex piping system. To speed up delivery, the installation relied on basic construction drawings and informal site sketches rather than full isometrics.

The issue only became apparent during an inspection.

Regulators identified that the piping did not fully meet code requirements, and the client lacked the documentation needed to demonstrate compliance. Without proper isometrics, there was no clear record of materials, weld traceability, pressure ratings or design intent.

The result was significant rework. The entire skid piping system had to be stripped out and rebuilt to meet the required standards.

What might have been a relatively small investment in engineering documentation ended up becoming a much larger cost in rework, delays and operational disruption.

A Critical Investment in Risk Management

Piping isometrics may not be the most visible part of an engineering project, but they are one of the most important.

They provide a clear record of how piping systems are designed and built. They support safe installation, effective maintenance and regulatory compliance throughout the life of a plant.

In industries where the cost of failure can be high, good engineering documentation isn’t an administrative burden, it’s risk management.

And in many cases, the cost of doing it properly at the start is far lower than the cost of fixing it later.

Get in touch to start your project off on the right foot.

How Energy Price Surges Are Shaping Petrochemical Plant Engineering

Thu, 26 Feb 2026 08:45:19 GMT

How Energy Price Surges Are Shaping Petrochemical Plant Engineering

Date: 26th February 2026

Working across chemical and petrochemical plants in the UK, we’ve seen firsthand how dramatically the landscape of the UK petrochemical industry has shifted over the past few years. Projects that once focused on expansion, efficiency improvements and long-term capital investment are increasingly being replaced by plant consolidation, life-extension and “patch and keep running” solutions.

The reality is uncomfortable but clear… UK petrochemicals are under serious pressure. Net zero targets, rising industrial energy costs and global competition are combining to create conditions that are forcing some sites to scale back, and in some cases, shut down altogether.

Net Zero: The Right Goal, the Wrong Pace?

Decarbonisation and environmental responsibility are essential. Most operators we work with fully accept that change is necessary. The issue isn’t the destination. It’s the speed, cost and wider economic context in which we’re trying to get there.

The UK has set some of the most ambitious net zero targets in the world. At the same time, we face some of the highest industrial electricity and gas prices in Europe. For energy-intensive sectors like petrochemicals, that combination is extremely difficult to absorb.

Meeting modern emissions standards often requires significant capital investment, such as fuel switching, carbon capture readiness, plant modifications, upgraded monitoring systems and compliance-driven redesign. But when margins are tight and long-term policy signals feel uncertain, businesses are understandably cautious about committing to major redevelopment.

As a result, we’re seeing fewer full-scale engineering design projects and more short-term interventions. Instead of replacing ageing assets, clients are asking: Can we safely extend this another five years? Instead of reconfiguring entire process areas, the focus becomes: What’s the minimum required to remain compliant and operational?

From an engineering design and 3D laser scanning perspective, the work is still there, but its nature has changed.

Stripping Back Rather Than Building Up

Another noticeable trend across UK chemical and petrochemical sites is consolidation. Assets are being stripped out rather than expanded. Redundant units are decommissioned. Parts of sites may as well have tumble weeds rolling through them. And engineering budgets are directed toward safe removal, structural integrity assessments and brownfield modifications rather than growth.

But this isn’t a failure of ambition. It’s a survival strategy.

When energy prices remain volatile and raw material supply costs are high, it is often cheaper to manufacture petrochemical products abroad and import them into the UK. That’s the economic reality many operators are facing.

But this shift raises important questions about the long-term future of domestic production.

Are We Cutting Emissions or Just Exporting Them?

One of the more uncomfortable conversations within the UK petrochemical industry is whether we are genuinely reducing global emissions or simply exporting them.

If domestic production becomes economically unviable due to high energy prices and increasing regulatory burden, demand doesn’t disappear. The UK still depends on petrochemical-derived products for packaging, construction materials, medical equipment, insulation, automotive components and countless everyday essentials. What changes is where those products are made.

Instead of manufacturing them here under UK environmental standards, we import them, often from regions with lower energy costs and, in some cases, higher carbon intensity. On paper, territorial emissions fall. In reality, global emissions may simply shift location.

From a climate perspective, the benefit is therefore questionable. From an energy security and industrial resilience perspective, the risk is far clearer.

We remain heavily reliant on oil and gas, not just as fuels, but as the raw materials underpinning modern life. Yet despite having domestic capability, we are becoming increasingly dependent on external supply chains. The recent energy crisis exposed just how vulnerable energy-intensive industries are to global market volatility. When gas prices surged, UK petrochemical plants felt the impact immediately. And for some operators, that proved to be the tipping point between continued operation and closure.

The question is not whether demand exists. It clearly does. The question is whether the UK chooses to meet that demand domestically or rely more heavily on imports.

Supply Reduction as a Survival Mechanism

Reduced UK capacity may, in the short term, help remaining plants maintain stronger utilisation rates. Tightened supply can support margins. But that is hardly a long-term industrial strategy.

Continued contraction risks hollowing out more than just production. It affects the wider engineering ecosystem including design consultancies, specialist contractors, fabricators, inspection teams and digital surveying professionals who support complex chemical sites..

Once that capability disappears, it is extremely difficult to rebuild.

What This Means for Engineering and Asset Management

From our perspective on site, the impact is clear. Priorities have shifted toward:

Asset life extension
Detailed condition and as-built surveys
Brownfield engineering design
Safe demolition and plant reconfiguration
Tighter capital control and risk reduction

In this environment, accurate site data is more important than ever. Brownfield petrochemical plants are inherently complex with undocumented modifications, legacy pipework and congested layouts increase project risk.

High-accuracy 3D laser scanning and as-built modelling allow operators to make informed decisions about whether to modify, maintain or remove assets. When budgets are constrained, there is little room for error. Reliable digital site data reduces clashes, shortens design cycles and supports safer project delivery.

The broader question still remains: what kind of industrial base does the UK want in 10 or 20 years’ time?

If we want resilient supply chains, high-skilled engineering jobs and genuine emissions reduction (rather than displacement), then policy ambition must align with industrial competitiveness, particularly around energy strategy.

Responding to Industry Pressures

The UK petrochemical sector is undoubtedly facing one of its most challenging periods in decades. Like it or not, petrochemicals still sit at the heart of modern manufacturing. From medical equipment and insulation to food packaging and infrastructure materials, demand is not disappearing.

For now though, many operators are focused on survival by running leaner, investing carefully and managing ageing assets intelligently. As engineers and technical specialists, our role is to support those decisions with accurate data and practical design solutions.

If you operate a chemical or petrochemical plant in the UK and are planning asset life extension, plant modifications, decommissioning works or require high-accuracy 3D laser scanning and modelling, feel free to get in touch.

Having the right information at the outset makes all the difference when navigating uncertainty.

The Gap Between Consumer 3D Scanners and Scanners for Professional Engineering Design

Thu, 22 Jan 2026 17:47:32 GMT

The Gap Between Consumer 3D Scanners and Scanners for Professional Engineering Design

Date: 22th January 2026

Not long ago, owning a 3D laser scanner was something limited to surveyors, large engineering consultancies, or specialist service providers. Today, consumer-grade scanners are increasingly appearing under Christmas trees (or birthdays, Eid, Diwali, Hanukkah – choose your favorite!). Falling hardware costs, improved ease of use, and the growth of 3D printing, VR, and digital content creation have made laser scanning feel accessible in a way it never was before.

But just how big is the jump between a hobbyist scanner and professional 3D laser scanning used for engineering design? And can consumer scanners realistically produce professional results?

Why Laser Scanners Are Becoming Popular Gifts

The consumer 3D scanning market has expanded rapidly over the past few years. By 2025, compact handheld scanners such as the Creality CR-Scan Otter, Revopoint MIRACO, and Shining 3D Einstar are estimated to account for tens of thousands of units sold annually. These devices promise fast results, colourful textured models, and minimal setup, making them particularly attractive to makers, designers, and digital creatives.

For many new users, a scanner represents a shortcut into 3D. The idea that you can scan an object, generate a model, and immediately use it for visualisation, 3D printing, or virtual environments is a powerful draw.

At Home vs Professional Scanners

At a glance, consumer and professional scanners appear to produce similar outputs. Both generate point clouds or meshes, apply textures, and export data into common formats. The differences become clear when you look beyond the visuals.

At-home scanners such as the Revopoint POP 3, Creality CR-Scan Ferret, or Einstar typically rely on structured light or low-power LiDAR. They are designed for short-range capture and perform well when scanning small objects or interiors under controlled conditions. Accuracy can be impressive at close range, but it degrades quickly as scale increases or environmental conditions become more challenging.

Industry-grade scanners such as the Leica RTC360, Leica BLK360, FARO Focus Premium, or Trimble X7 use high-precision time-of-flight or phase-based LiDAR. These systems are capable of scanning entire process plants, pipe racks, and steel structures from tens or even hundreds of metres away while maintaining consistent, verifiable accuracy. In industrial environments, that reliability is critical.

Hardware, Price Bands, and What You’re Paying For

Consumer scanners generally sit in the £300 to £2,000 range. Professional laser scanners typically start around £25,000 and can exceed £70,000 once software and accessories are included. The difference in cost is not simply about “better hardware”.

Professional systems are engineered for repeatability, long-range accuracy, environmental robustness, and calibration control. Just as importantly, they integrate directly into engineering workflows. Platforms such as Leica Cyclone, FARO Scene, and downstream CAD and BIM tools allow scan data to be used confidently for design, verification, and construction planning.

What You Can Actually Do With Each

Consumer scanners are extremely capable when used within their intended scope. They work well for scanning small components, capturing interiors for VR or AR, supporting basic reverse engineering, and producing models suitable for 3D printing or visual presentation. For early-stage concepts and communication, they can be highly effective.

Professional scanners are built for an entirely different purpose. They are designed to capture large, complex environments such as chemical plants, where dense pipework, steelwork, and equipment must be measured accurately and reliably. The resulting point clouds can be used directly within CAD and BIM environments to produce layouts, routing studies, clash detection models, and verified as-built information.

Can You Get “Professional Results” from a Consumer Scanner?

The answer depends on what you mean by “professional”. Consumer scanners have clear technical limitations. Accuracy drops rapidly over distance, reflective stainless steel can introduce noise, and environmental factors such as bright sunlight, dust, steam, or vibration can significantly affect results. Calibration options and validation methods are also limited.

There are also significant workflow differences. Professional laser scanning involves planned scan strategies, control networks, robust registration, and verification processes. Data is cleaned, validated, and modelled to engineering standards before it is trusted for design. Consumer workflows, by contrast, prioritise speed and visual impact.

That said, consumer scanners often exceed expectations in areas such as textured visualisations, rapid capture, portability, and creative applications. They can play a valuable role in concept design, stakeholder communication, and visualisation.

Bridging the Gap Between Hobby and Industry

The leap from hobby scanning to professional engineering design is not defined by hardware alone. It is defined by process, experience, and responsibility. In chemical plants and other high-risk environments, scan data must be accurate, traceable, and trusted without question.

Consumer scanners are powerful creative tools. Industry scanners are engineering instruments. Knowing the difference (and when each is appropriate) is what turns scanning from an interesting gadget into a professional service.

Early, accurate site data reduces risk later in the programme. If you’d like to understand how professional laser scanning can de-risk your project before detailed design begins, get in touch.

Reverse Engineering One Gingerbread House At A Time

Tue, 09 Dec 2025 18:54:24 GMT

Reverse Engineering One Gingerbread House At A Time

Date: 09th December 2025

Ever wondered how to make a gingerbread house that actually stays up under the weight of all that icing and chocolate? At O’Hare Engineering, we spend our days reverse engineering complex pipework and vessels in chemical plants across the UK. It’s all about precision, planning, and making sure everything fits perfectly with no leaks and no surprises, just smooth operations.

This Christmas, we thought, why not take the same engineering skills we use in chemical plants and put them to a tastier use? A gingerbread house.

Turns out, the same principles that keep industrial plants running smoothly can also stop your festive creations from collapsing… and make them look pretty impressive too.

What is Reverse Engineering?

In the industrial world, reverse engineering is basically taking something that already exists, like a tank, a network of pipes, or a pressure vessel, and turning it into a precise digital model. With 3D laser scanning, we can capture every curve, bend, and flange, which then lets us refurbish, retrofit, or redesign with confidence. It’s all about turning a physical structure into a virtual one that you can analyse, tweak, and replicate.

Now imagine doing the same thing with a gingerbread house. Every icing pipe becomes a bit like a pipe in a plant, each candy cane a structural support, and that chocolate roof? A vessel that’s got to hold all the festive cheer inside. The rules are exactly the same: measure, model, optimise, test. And just like in a chemical plant, one badly placed candy cane can bring the whole thing tumbling down. Gravity doesn’t care if it’s chocolate or steel.

Challenges in Reverse Engineering

Chemical plants aren’t exactly Lego sets. Pipework runs in every direction, access is tricky, and safety regulations never take a holiday. Even the smallest misalignment can cause costly downtime, operational issues and additional work down the line. 3D scanning helps us overcome these challenges by creating highly accurate models we can trust by capturing every curve, every bend, and every corner that is otherwise difficult to reach.

And, although they may seem totally unrelated, gingerbread houses have their own challenges that design engineers can learn from…

Icing walls can sag, especially when you pile too many sweets on top.
Matchmaker supports can slip or slide, sending jelly beans tumbling.
Roof panels might collapse under the weight of chocolate shingles or marshmallow snow.

In both cases, careful measurement, planning, and a little engineering magic save the day. You can think of icing as your “pipework material” and chocolate as the “vessel integrity” test. Too much or too little, and the whole structure is at risk.

Reverse Engineering a Gingerbread House

Here’s how we’d take our industrial engineering approach and apply it to gingerbread:

Scanning: Grab your elf-sized laser (or just a tape measure) and capture every angle, wall, and roof panel. Keep an eye out for uneven surfaces. One crooked drainpipe could spell disaster!
Modelling: Next, create a CAD version (or a “ginger-CAD” version) of your house. This lets you plan exactly where each sweet goes, how thick the icing walls should be, and whether that chocolate roof can actually hold its own weight.
Optimisation: Adjust icing thickness, reposition candy canes, and strengthen any weak walls to tweak, reinforce and make it as strong as possible. Think of it like retrofitting a plant. You’re strengthening up the weak points before the full load is applied.
Testing: Finally, make sure your roof can handle the weight of chocolate snow.

It turns out, industrial engineers and gingerbread architects have a lot in common!

Just like a crooked candy cane can bring down a gingerbread roof, a misaligned pipe or poorly fitted flange in a chemical plant can cause serious problems, although thankfully, the consequences are usually less sticky. The same principles apply for both gingerbread and design engineering. You’ve got to measure carefully, plan thoughtfully, reinforce where needed, and test before you finish. Whether it’s chocolate or steel, attention to detail keeps everything standing tall and running smoothly.

What Gingerbread Teaches Us About Engineering

Whether you’re scanning a reactor vessel or a gingerbread roof, the same lessons apply:

Accuracy matters. Don’t guess your measurements. One crooked candy cane can cause as much trouble as a misaligned flange.
Planning saves time (and sugar). Knowing exactly where each piece goes before you start means fewer rebuilds (and fewer grumpy elves).
Small details make a big difference. In both chemical plants and festive creations, it’s the little things. A thicker icing wall here, a reinforced corner there that keeps everything standing tall.

And, of course, it’s always more fun when you sprinkle in a little chocolate.

Fun Takeaways

This holiday season, why not try a bit of reverse engineering at home? Whether it’s Lego, a gingerbread house, or even a snow fort, a little careful measurement and planning can make all the difference. Scan your favourite decorations, sketch a model, or test your design before committing to the full build.

And if nothing else, it’s the perfect excuse to enjoy some hot chocolate while doing a little precision work. Even if your gingerbread house isn’t picture perfect, you’ll end up with a structure that actually stands… and tastes fantastic!

So, whether you’re inspecting a chemical plant, retrofitting a network of pipes, or building the ultimate gingerbread masterpiece, the principles are the same… measure carefully, plan thoughtfully, and reinforce where needed.

From all of us at O’Hare Engineering Design Ltd, Merry Christmas!

How Accurate Is Accurate Enough With Laser Scanning Tolerances?

Mon, 01 Dec 2025 17:10:28 GMT

How Accurate Is Accurate Enough With Laser Scanning Tolerances?

Date: 01th December 2025

When you’re investing time and budget into a 3D laser scan or model of your complex chemical plant layout, it’s natural to ask the question: how accurate do we really need it to be? In practice, “perfect” accuracy is rarely achievable, and, just as importantly, it’s not always necessary. The key is to determine what level of accuracy is right for the job and finding the balance between cost, schedule and risk.

Why Accuracy Matters

It’s tempting to assume that more accuracy is always better. A higher accuracy point cloud or model gives you a closer representation of the real environment, which should, in theory, reduce rework and minimise surprises during design or installation. Yet every increase in accuracy comes at a price with longer scanning times, larger data sets, heavier processing, and more complex modelling. Beyond a certain point, the extra precision can add cost and time without offering any additional benefit.

In a chemical plant, laser scanning may be used to capture pipe racks, vessels, platforms and supports to check what’s really there. The data might feed into new 3D models, help verify existing geometry before a modification, support prefab work, or simply guide future maintenance. But if the scan isn’t accurate enough, the new pipework might not fit amongst the existing infrastructure, clashes get missed, and you end up cutting and adjusting on site which is the last thing anyone wants. Go too far the other way, though, and you’ll burn time and budget processing data that’s far more detailed than the project actually needs. The aim is to always achieve a level of accuracy that’s genuinely fit for purpose.

Understanding Laser Scanning and Modelling Tolerances

In laser scanning and modelling, tolerance defines the maximum allowable deviation between the captured or modelled data and the true geometry. Several things influence this including scan resolution (the spacing between points in the cloud), registration error (how accurately multiple scans are stitched together), modelling deviation (how closely the 3D model follows the point cloud) and environmental conditions such as vibration or temperature.

For example, if a scan has a tolerance of ±5 mm, that means the data is aligned to within five millimetres of the real position. When this data feeds into a model, that same degree of uncertainty flows downstream. Knowing these tolerances is helpful when deciding whether the data is suitable for detailed design, fabrication or construction.

Typical Accuracy Levels and Their Use

As a general guide, a tolerance of ±10–15 mm usually supports early-stage work such as feasibility studies or general layout modelling, where approximate measurements are sufficient to plan routes and clearances. A tighter tolerance of ±5 mm is often more appropriate for detailed design, clash detection and prefabrication of pipes where moderate precision is needed. For highly critical applications, such as retrofitting new equipment with minimal clearance, tolerances as tight as ±1–3 mm may be justified, though these are not always practical across an entire facility.

Importantly, the scan is only one part of a much longer chain. Downstream fabrication, welding, installation and even site conditions all introduce their own tolerances. There’s little sense in commissioning a ±1 mm scan if the installation tolerances on site are ten times larger. Matching the scan’s precision to the realities of the project avoids unnecessary cost and data complexity.

Deciding What’s “Good Enough”

The right level of accuracy depends entirely on how the data will be used. If you’re producing a conceptual study or checking general layout feasibility, a moderate tolerance may be all that’s required. For detailed design and prefabrication, the accuracy needs to tighten accordingly. Site conditions also matter: complex, congested areas with poor access may limit achievable tolerances, so realistic expectations should be set from the start.

The final step is quality assurance. Someone on your team or within the scanning provider’s team should confirm that the delivered data meets the defined “fit-for-purpose” criteria before it’s accepted.

Finding the Balance

In laser scanning and modelling, the question isn’t “what’s the highest accuracy we can achieve?” but “what level of accuracy do we need to make good decisions?”. By defining the use, understanding the working environment, aligning scan tolerance with fabrication and installation realities, and embedding QA processes early, you can ensure that your deliverables are both reliable and efficient.

At O’Hare Engineering Design Ltd, we work closely with engineers and project managers to define the right level of accuracy before scanning begins, ensuring that every dataset is genuinely fit for purpose. If you’d like to discuss how to set tolerances effectively for your next project, we’d be happy to help.

Clashes in the Night! How To Avoid Design Nightmares Before They Hit Site

Fri, 24 Oct 2025 21:07:05 GMT

Clashes in the Night! How To Avoid Design Nightmares Before They Hit Site

Date: 24th October 2025

You know that moment when everything seems fine in a design review… until someone spots two pipes occupying the same space? Or a structural beam cutting through your carefully routed run? That sudden jolt of “uh-oh” that leaves you cursing under your breath.

It sounds dramatic, and it kind of is. Because these aren’t just little hiccups, they’re the kind of issues that creep into projects late, blow up costs, cause rework, and delay everything. And worse, they’re usually avoidable.

Let’s talk about how they happen, why they matter, and how we stop them before they haunt your project.

Why Do Design Clashes Happen?

Clashes usually come down to one of a few things:

Everyone’s working in silos: Structural, HVAC, piping, electrical… all doing their thing, but not really talking to each other.
Late changes: Specs change, layouts shift, someone swaps a piece of kit and forgets to flag it to the rest of the team.
Old or inaccurate site data: Especially on brownfield sites, the "as-built" drawings don’t always match reality.
Not enough space: A classic one. Pipe runs get crammed into tight areas, and suddenly insulation is overlapping or access is blocked.

These issues pop up all the time, especially in retrofit and live site work.

Space Matters More Than You Think

A big part of avoiding clashes is simply understanding how much space everything actually needs and not just the pipe itself. Think insulation thickness, support brackets, valve access, flange clearance, and the space needed for people to get in and maintain things.

Some quick examples:

Insulated pipes need more clearance than you’d think, especially if you’re using mineral wool or cladding.
Valves and flanges need space around them, not just to fit, but so someone can actually undo them.
Supports and brackets can’t just float, they need structure, and that takes space too.
Thermal movement adds another twist. Your pipes expand and contract, and if there's no room for that, things start to bend or break.

Ignoring any of that, even accidentally, can lead to big problems. And unfortunately, you often don’t spot it until it’s too late.

So… How Do We Catch Clashes Early?

Here’s how we approach it:

1. Start with laser scanning. We use 3D laser scanning to capture the actual site conditions down to the millimetre. No guesswork, no relying on drawings from 1996. Just cold, hard reality in a point cloud.

2. Model everything in 3D. Once we’ve got the scan, we model your piping, structure, and any surrounding services in a shared 3D space. This gives us a live, up-to-date digital twin of what’s happening on site and in the design.

3. Run proper clash checks. This is where it gets good. We use rule-based clash detection tools to catch things like:

Pipe vs. pipe
Pipe vs. structure
HVAC ducting vs. everything else
Clearance violations based on insulation, access, etc.

And because it’s all digital, we can fix it before it becomes a real-world problem.

4. Get everyone talking. No more working in isolation. We bring all the disciplines together early and often. Design coordination meetings, shared models, version tracking, the whole lot. It saves time, money, and headaches.

5. Keep control of the changes. This one’s easy to forget but so important. Every change is tracked and documented. Everyone knows what’s changing, when, and why and what knock-on effects it might have.

PFAS Project with No Room to Breathe

We recently worked on a PFAS removal project where the available space was literally cut down to 25% of the original footprint. Tight doesn’t even cover it.

The only reason it worked? We scanned early, modelled everything in 3D, and coordinated across every discipline involved - civil, structural, process, electrical, you name it. Every pipe, valve, and skid was placed with care and verified against the real site geometry. You can read the full case study here .

And the result? No major surprises on site. No angry calls. Just a clean, buildable solution delivered in a space no one thought would work.

Clashes are normal, but they don’t have to be inevitable. With the right process and the right tools you can catch them before they become your next project nightmare.

So if you're working on a live site, a retrofit, or just a tight layout that’s keeping you up at night, let’s have a chat. We can scan it, model it, and help you avoid the horrors of clashes in the dark.

Because no one wants to be managing that horror story project.

BIM & 3D Piping Design: What Mechanical Designers Really Need to Know

Fri, 03 Oct 2025 14:42:01 GMT

BIM & 3D Piping Design: What Mechanical Designers Really Need to Know

Date: 03rd October 2025

Most people think they know BIM.

But when you scratch beneath the surface, especially in mechanical and piping design, it seems like a lot of people are still using the word without actually understanding what it means.

So, let’s break down…

What BIM really is (and isn’t)
Why Revit doesn’t always do the job
What software and standards actually work for piping design in real-world plant environments

A guideline, not a rulebook…

You’ve probably heard someone say, “We’re doing BIM.” More often than not though, what they really mean is, “We’re using Revit.”

BIM isn’t a piece of software. It’s a way of working. It’s a framework for how different disciplines work together, share information, and keep everything coordinated. It’s about building smarter, not harder. It’s focused on things like:

Coordinated 3D models
Consistent, structured data (like the metadata)
Making sure different software and teams can talk to each other
Thinking about the full lifecycle of a project, from design to maintenance

But BIM doesn’t tell you how to design your piping system, or which flange spec to pick. That’s still down to your own engineering expertise and whatever software suits the job.

In short? BIM sets the standard. You choose the tools.

Why Revit Struggles with Process Piping

Revit is a powerful BIM tool but it’s just one of many. It’s not the full story.

Revit works brilliantly when you're designing building systems like HVAC, plumbing, or electrical. It allows for intelligent, parametric modelling and makes it easy to generate coordinated drawings and schedules; all great stuff in a building-focused environment.

But when it comes to piping design for chemical or process plants, Revit often struggles. That’s because it was originally developed with buildings in mind, not the highly specific and technical requirements of industrial facilities. Process plants are a different beast entirely. They’re filled with skids, racks, pressure ratings, slope requirements, and strict, spec-driven design rules.

Revit’s architectural foundations don’t always align with that complexity. So while it can still play a role in your workflow, especially for coordination, it’s not always the right tool for the full job, particularly when the process side of the design takes centre stage.

The advantages of BIM

One of the biggest advantages of BIM is its clash detection capabilities, spotting conflicts between pipes, ducts, and structural elements before they turn into costly headaches on site.

But BIM goes far beyond just avoiding clashes. Every component in the model, whether it’s a pipe, valve, pump, or hanger, carries detailed information, or metadata, about its specifications. This means your digital model isn’t just a collection of shapes; it’s a database packed with useful data.

Even better, you can extract all this information into schedules or spreadsheets, eliminating tedious manual tracking of things like nozzle sizes or material specs.

In short, BIM models are much more than just “pretty pictures.” They’re intelligent, data-driven digital twins of your plant that can be queried, validated, and managed throughout the project lifecycle.

Picking the right tools

When it comes to tools, mechanical designers need to pick the right ones for the job. Revit works well for MEP coordination in building projects, especially when dealing with plant rooms in commercial or healthcare settings or when your models need to align closely with architectural layouts. Using Revit MEP alongside Fabrication Parts (which are lighter and smarter than traditional families) can improve control and performance, but beyond that, Revit starts to struggle.

Tools built for process plants

For plant designs like chemical plants, food, or pharmaceutical facilities, you’ll want dedicated tools built for the complexity of industrial piping. Platforms like Autodesk Plant 3D, AVEVA PDMS/E3D, MPDS⁴, CadWorx, and OptiPlant understand the intricacies of pipe specs, pressure classes, insulation, slopes, supports, and P&ID integration. These are designed to handle the technical demands that complex piping design demands.

The real power of BIM lies in its ability to integrate across disciplines allowing structural, mechanical, civil, and electrical teams to all work from one model to stay on the same page. Done well, this means fewer clashes onsite, smoother project handovers, and a digital twin that’s useful long after construction ends. But achieving this level of coordination takes the right software, communication, and effort.

Why Site Awareness Is Critical for Reliable Design

Sat, 23 Aug 2025 19:14:51 GMT

Why Site Awareness Is Critical for Reliable Design

Date: 23rd August 2025

There’s a challenge in engineering design that doesn’t always get the attention it deserves and it’s not down to technology, software, or lack of effort. It usually comes from working without a full understanding of the site itself.

It’s not uncommon to see models that look well organised and clash-free on screen, but once you get to site, things don’t always line up as expected. Fire suppression ends up being squeezed in late, process pipework needs re-routing, or access points are harder to reach than planned.

In many cases, it comes down to limited site awareness during the design stage. When design decisions are made without clear, accurate context from the physical environment, things can get complicated further down the line.

By focusing more on early-stage site understanding, whether through better survey data, clearer communication, or more integrated workflows, we can avoid a lot of these issues before they even start.

Designing without the full picture…

This issue often starts early in a project. The design team might receive a handful of site photos, a basic floor plan, or maybe an older scan from months ago. From that, they’re expected to produce a coordinated model without having all the details they need.

Design decisions then end up relying on assumptions. And while some assumptions are unavoidable, too many can lead to problems later down the line, especially when they turn out to be wrong.

It’s not just about getting the measurements right. It’s about understanding how things fit together, how they’ll be accessed, and how the real-world conditions of a site influence the way a system should be designed.

Site awareness is more than a quick visit

A single site visit doesn’t always provide the full picture either. Good design is built on clear, reliable, and up-to-date information that is ideally delivered in a format that the design team can easily use and trust.

Knowing where existing services run, where space is tight, or where equipment is likely to be installed isn’t something that can be guessed from an old PDF or a few reference photos. That insight comes from high-quality survey data as well as from the people who understand the environment, not just the drawings.

Ideally, the survey team and the design team are in sync. The best results come when surveyors aren’t just capturing everything by default, but asking:

“What information does the design team actually need here?”

A point cloud full of unnecessary detail, poor registration, or misalignment isn’t just unhelpful, it can slow things down and create confusion later in the project.

Common pitfalls

We’ve been brought into projects where clients had already invested in scanning or photogrammetry work only to find the data wasn’t usable.

Some of the common issues we’ve seen are:

A lack of control points
Poor registration or misalignment
Data delivered in the wrong format
No clear scope or understanding of what needed to be captured in the first place

Having the right equipment is one thing, but knowing how to use it effectively and how to deliver data that integrates smoothly into the design process is what really makes the difference.

What good site surveying looks like for piping design

A reliable survey for engineering design usually combines tools. Total stations provide precision and control. 3D laser scanning gives you spatial detail. Used together, they give you confidence in the accuracy of the data, early visibility of potential issues and a dependable base to design from. Good survey work isn’t about collecting as much data as possible. It’s about collecting the right data in the right places with the end user in mind, whether that’s the modeller, drafter, engineer, or fabricator.

Coordination needs to start sooner.

This all ties into a broader issue with coordination. In most projects, process pipework tends to take the lead by either driving the equipment layout or responding to it. That’s fine. But other systems like fire suppression, containment, and ventilation still need space to work properly. If those systems aren’t considered early on, they end up getting squeezed in later, and that’s when problems start. We've seen it time and again; clashes, last-minute redesigns, and on-site teams having to work around things that could’ve been avoided.

Effective coordination doesn’t mean a visually clean model. It means early communication, shared understanding, and real-world understanding before decisions are locked in.

Technology like laser scanning and photogrammetry has made it easier to capture site data, but good design still depends on understanding the environment you’re working with. If the design doesn’t reflect what’s actually on site, things will go wrong and by then, it’s often too late to fix without cost or delay. Getting the survey right from the start, using the right methods, and sharing information early makes all the difference. It’s not about being perfect, it’s about being prepared. If you want support getting your survey data right and design-ready, get in touch, we’re happy to help.

The Value Is in the Detail: Project Design, Plant 3D, and Where AI Fits In

Wed, 30 Jul 2025 16:12:31 GMT

The Value Is in the Detail: Project Design, Plant 3D, and Where AI Fits In

Date: 30th July 2025

When it comes to Plant 3D design, the final quality of a model isn't about the software. It’s about what you choose to put into it.

We use Autodesk Plant 3D alongside Navisworks for detailed piping layouts on complex sites like chemical plants, and over time, one thing has become clear: the accuracy and usefulness of the final design all come down to the level of care, detail, and experience you invest into the project.

The image below is taken directly from Navisworks using Plant 3D, where clash detection was carried out alongside point cloud data with (what we’d consider as a business) no additional software cost. This isn’t a flashy render for marketing; it’s part of a working design that’s ready to be built. That’s the difference between a model that just looks good and one that works well in the real world.

Design Quality Is a Choice

Many people assume that the software dictates the outcome, but tools like Plant 3D and Navisworks are only as good as the workflows behind them. We make a conscious effort to build the model in a way that supports the rendering and review process from the very beginning.

That includes:

The use of point cloud data for as-built accuracy
Smart use of sub-models to keep files lightweight and manageable
Regular clash detection reviews to ensure construction is feasible
Built-in rendering time, planned into project workflows so that it doesn't add any cost or delay.

With our current hardware setup, rendering high-quality outputs typically takes between 20 and 30 minutes. This amount of time doesn’t create a bottleneck in our workflow. Instead, it is a key part of the overall process that is carefully planned and managed to maintain progress.

Where Does AI Fit In?

There’s no denying AI is transforming the way that most people work and it's a tool we’ve experimented with across a range of tasks. But when it comes to Plant 3D and real-world engineering design, I don’t see AI offering meaningful cost savings within our current work. We already use Navisworks for tasks like:

Clash detection
Project collaboration
Design review

These are core parts of every job, and we’re not paying extra to run them. Any suggestion that AI reduces costs here overlooks how refined and cost-effective these existing tools already are, especially for smaller or mid-sized businesses that are hands-on with their workflows.

The IP Trade-Off…

One of the biggest concerns we have with AI in design is intellectual property. Many AI tools (especially image or model generators) operate under terms that allow them to retain or reuse your input. That might seem minor but it’s a major red flag in a field where your design is your product.

Imagine spending weeks creating a detailed model for a client, only to find that the AI you used has rights to reuse your work for someone else’s project. That undermines not just the value of your work, but the trust your clients place in you to deliver original, secure, and private designs.

Don’t get me wrong, I think AI is a valuable tool. It’s great for idea generation, automating repetitive tasks, or helping structure documentation. I’ve used it in ways that save time and improve clarity. But, it’s not a replacement for thoughtful, professional design, especially in high-stakes environments like industrial piping systems.

We’ve worked hard to build an approach where our models remain our IP. Everything stays in-house or with software providers who respect those boundaries. That principle is a dealbreaker and one that other businesses should take seriously too.

A Process That Works

We’ve found a balance that works:

We use Plant 3D and Navisworks to create high-quality, build-ready models.
We plan rendering and review time into the project, so it adds value, not cost.
We maintain ownership of our IP at every stage.
And we use AI with care where it helps, not where it compromises.

There’s no silver bullet when it comes to great design. It’s about choosing to put in the effort, setting up solid systems, and knowing when to trust your tools,and when to question them.

We believe this approach benefits not only our company, but also our clients. It’s not always the flashiest process, but it’s consistent, accurate, and respectful of the work that goes into every detail.

If you're looking for a design approach that prioritises accuracy, efficiency, and real-world results without cutting corners, let’s have a conversation. Whether it's piping layouts, clash detection, or integrating point cloud data, we’re always happy to explore how it could benefit your next project.

Is ISO 9001 Certification Worth It in Engineering? What Clients Actually Care About

Wed, 11 Jun 2025 13:17:42 GMT

Is ISO 9001 Certification Worth It in Engineering? What Clients Actually Care About

ISO 9001: 2015 is often seen as a gold standard for quality assurance, but does it really matter in engineering design?

If you’re managing a chemical or energy site, you’re under pressure to deliver safe, accurate, and cost-efficient projects. So it’s fair to ask: when is ISO 9001 certification truly necessary - and when might it not be?

Let’s explore the value it brings, when to prioritise it, and what else you should look for in an engineering partner.

What ISO 9001 Certification Means

ISO 9001 is a globally recognised quality management standard. Certification shows that a company has:

Documented, repeatable systems for managing projects and delivering results
A proactive approach to risk identification and mitigation
A culture of continuous improvement
A focus on delivering consistent value to clients

In high-stakes environments (like chemical plants, pharmaceutical facilities, and energy infrastructure), these qualities are essential.

Certification offers assurance that your partner has a structured, reliable way of working that’s designed to minimise risk and maximise accuracy.

When Certification Really Matters

ISO 9001 certification becomes especially important when you’re delivering safety-critical projects or working with hazardous materials. In these environments, errors aren’t just costly - they can pose serious risks to people, property, and compliance. Certification is also essential when regulatory bodies or internal QA teams require formal alignment with recognised standards. If your project involves coordinating multiple contractors, detailed documentation and strong cross-team communication become essential. And in scenarios where there’s little room for error due to tight timelines, congested sites, or operational pressures, working with a certified partner adds an extra layer of confidence.

What Scenarios are ISO 9001 Not Required

For smaller or lower-risk projects, particularly those with a well-defined scope and shorter timelines, ISO 9001 certification may not be a must-have. In these instances, how your engineering partner actually works can be more telling than their formal credentials. Transparent, well-documented processes, clear communication, and a strong history of delivering accurate work with minimal revisions are often more valuable indicators. Certification is one way to confirm capability. Ultimately, it’s the partner’s mindset, workflow, and attention to detail that determine project success.

What To Look For When It Comes To Quality

Whether ISO 9001 is a requirement or not, it’s always worth asking potential partners how they manage quality. Do they have built-in review and approval steps throughout their design process? How do they handle document control and track revisions? Are their systems robust enough to catch issues before they become costly problems? And perhaps most importantly, can they explain their process clearly and confidently, giving you visibility into how they’ll support your project? These are the real markers of a quality-focused team, certification or not.

Final Thoughts

ISO 9001 certification is an excellent indicator of a company’s commitment to quality, but it’s not the only one. What matters most is whether your partner delivers accurate, reliable, and timely work that supports your project goals.

Use certification as a starting point, but dig deeper into how a team operates. Because in engineering, the risks of getting it wrong are too high to leave to chance.

If you’re planning a project and wondering whether ISO 9001 should be a requirement, we’d be happy to talk it through. No pressure - just practical advice based on your needs.

Case Study: Compact Effluent Treatment System for a Chemical Manufacturing Site

Tue, 20 May 2025 17:56:01 GMT

Case Study: Compact Effluent Treatment System for a Chemical Manufacturing Site

Date: 20th May 2025

Environmental regulations across the chemicals industry are becoming increasingly stringent, particularly around wastewater treatment. For manufacturers, staying compliant isn’t just a regulatory requirement. It’s fundamental to business continuity, site safety, and long-term sustainability.

In mid-2024, a major UK chemical manufacturer needed to implement an updated effluent treatment system to remove suspended solids and PFAS from wastewater. The challenge was not just technical, it was also logistical. The available footprint for installation had been drastically reduced due to budgetary pressures, and the original design team had fallen behind schedule. At a critical point in the project, O’Hare Engineering Design was asked to step in and help bring the design to completion.

The Challenge

At the time of engagement, only a rough site layout had been developed, and key design milestones were at risk of slipping. The client faced two major hurdles: time and space. Originally, a much larger area had been allocated for the system. But, following a review of capital budgets and wider site plans, the space was cut by approximately 75%.

The system still had to meet high performance and regulatory requirements, particularly around PFAS removal, but now had to fit within a fraction of the original footprint. Adding further complexity, the revised design needed to work around existing infrastructure and tie in with multiple disciplines, including structural, civil, and electrical engineering.

From an operational perspective, the stakes were high. The treatment system was part of a wider programme of environmental improvements at the site. Any delay in its installation risked operational disruption, potential regulatory consequences, and uncertainty for the workforce of over 200 people.

The Solution

O’Hare Engineering Design began by carrying out a laser scan of the site to establish accurate base data and eliminate assumptions. The team used 3D modelling tools to explore multiple layout options, optimise the use of space, and identify potential design clashes early in the process.

A core part of the solution was collaboration. The team worked closely with our Civil Design North West Partners, our equipment suppliers, skid fabricators, civil and structural engineers, and electrical designers to coordinate the system design across disciplines. Weekly reviews helped ensure everyone remained aligned and that design decisions were grounded in practical, buildable outcomes.

To manage quality and reduce risk, O’Hare Engineering Design followed internal processes developed in line with ISO 9001, working to a high standard of documentation control and project traceability. This structured approach helped ensure that changes were recorded, drawings remained consistent across disciplines, and the client had full visibility throughout the project.

Design accuracy and buildability were prioritised throughout. Even minor issues could have had a disproportionate impact on the already operational site. The layout was refined to ensure sufficient space for access, installation, and future maintenance without needing to relocate existing infrastructure.

The Result

The final design delivered a complete, fully integrated effluent treatment system within just 25% of the space originally allocated. Despite the reduction in footprint, the solution met all environmental compliance requirements and maintained operational flexibility.

The client was able to move forward with the installation without disrupting ongoing production. That continuity was essential in maintaining workforce stability and delivering broader site improvement plans on schedule.

By capturing accurate data early and integrating input across all stakeholders, the project avoided costly rework and maintained confidence in delivery timelines. The outcome was a system that worked (in terms of layout, compliance, and practical implementation) from day one.

Conclusion

This project demonstrates how a focused, collaborative design approach can deliver strong outcomes under pressure. With a reduced footprint, tight deadlines, and complex stakeholder requirements, the challenge required more than just technical skills. It demanded careful coordination, clarity of communication, and a structured design process.

O’Hare Engineering Design’s ability to deliver a compact, compliant, and coordinated solution allowed the client to meet their environmental commitments while avoiding disruption on site. By applying ISO 9001-aligned processes and prioritising stakeholder engagement, the project remained efficient, transparent, and low-risk from start to finish.

For site and project managers working in similarly constrained environments, this case shows how high-quality design and accurate planning can unlock solutions, even when space and time are limited.

At O’Hare Engineering Design, we don’t just deliver drawings. We solve problems, reduce risk, and make it easier for our clients to meet their goals with confidence. Need support with a space-constrained or time-sensitive project? Let’s talk .

Follow the (Digital) Bunny Trail: How Smart Engineering Drawings Help You Navigate Complex Sites

Wed, 16 Apr 2025 12:16:51 GMT

Follow the (Digital) Bunny Trail: How Smart Engineering Drawings Help You Navigate Complex Sites

Date: 16th April 2025

It’s Easter season – and while the kids are out hunting for chocolate, many engineers are facing their own version of an egg hunt.

Because when something goes wrong on-site, tracking down the latest P&ID or figuring out where a specific valve is located often feels like following a trail of half-eaten clues. And in high-risk environments like chemical plants, there’s no time to waste.

So how do you turn that confusing paper trail into a clear, accurate path from problem to solution?

Let’s talk about how smart engineering drawings and 3D models can help.

The classic egg hunt… Why traditional documentation falls short

A lot of teams are still relying on outdated, inconsistent, or incomplete documentation. Drawings live in different folders (or filing cabinets), updates don’t always get shared, and what’s on paper doesn’t match what’s on site. When it comes to maintenance or incident response, you’re stuck relying on local knowledge – and hoping the person who “just knows where everything is” isn’t off sick that day.

If you’re managing a complex facility, you need more than intuition. You need information you can trust.

Why accurate site data matters

It’s at this point that smart documentation shifts from ‘nice-to-have’ to ‘critical’.

By laser scanning your site and creating a digital twin, you get more than just a snapshot of your facility – you get a detailed, interactive map of your plant as it really exists today. Not as it was built. Not as someone remembers it. But as it physically stands, right now. Every valve. Every access platform. Every pipe.

This data is captured quickly and safely, without needing to shut the plant down. And once it’s scanned, it can be turned into accurate GA drawings, updated P&IDs, and 3D models that show every connection and interaction across the system. It’s especially useful for complex sites where years of small changes have added up to a confusing mess of undocumented tweaks.

Even better, once these drawings and models are in place, they’re easy to update. So when modifications happen in the future, you’re not starting from scratch - you’re working from a reliable baseline that’s already doing half the heavy lifting.

This isn’t about flashy visuals or pretty pictures. It’s about creating a single source of truth your team can rely on, whether you’re reviewing a design, planning maintenance, or prepping for a shutdown.

How better drawings improve decision-making

Think of your updated drawings and models like a digital easter egg trail – leading your engineers, fabricators, and HSE teams straight to the answers they need.

Let’s say you’re trying to isolate a pipework section for maintenance. Instead of checking three different drawings, walking the site twice, and calling someone who might remember how it was rerouted during that job three years ago, you can:

Open the model.
See exactly how that section connects to the rest of the plant.
Check which valves need to be closed.
Identify the safest and fastest access points.

It cuts down the time it takes to make decisions. It reduces the risk of error. And it means you can plan interventions with confidence – not crossed fingers.

We’ve seen it save clients tens of thousands in reduced downtime, smoother shutdowns, and faster approvals. It’s also a game-changer for training and onboarding. Instead of trying to memorise outdated drawings, new staff can walk through the plant virtually, understand the layout, and see how everything links together.

In an industry where time really is money – and mistakes can cost even more – having instant access to reliable site data isn’t just helpful. It’s essential.

Engineering clarity is not just for Easter

In a perfect world, everything on your site would be labelled, logged, and digitised. But most facilities evolve. Equipment gets moved. Pipework gets tweaked. And those little changes often don’t make it back to the drawings.

That’s why we start every project by asking the right questions and scanning what’s actually there - not what someone thinks is there. It’s a simple shift that saves time, money, and a lot of headaches later on.

Want to stop hunting for the right drawing?

Let’s make your site easier to navigate with models that reflect reality and give your team the confidence to act fast. Book a call with us today to get started.

How 3D Laser Scanning Helps Achieve Faster Project Approvals

Thu, 27 Mar 2025 13:54:58 GMT

How 3D Laser Scanning Helps Achieve Faster Project Approvals

Date: 27rd March 2025

Anyone who’s managed an engineering or construction project knows that approvals can be one of the biggest bottlenecks. Whether it’s planning permission, regulatory compliance, or stakeholder sign-off, delays at this stage can push back entire timelines, increase costs, and frustrate everyone involved. When approvals stall, so does the project, leading to wasted time, unnecessary expenses, and a mountain of scheduling headaches.

Decision-makers (regulators, investors, or clients) need confidence that the proposed plans align with site conditions, safety requirements, and long-term feasibility. However, incomplete or inaccurate documentation raises red flags that require further review.

By capturing accurate site data, laser scanning eliminates guesswork, provides verifiable documentation, and gives stakeholders the clarity they need to approve projects quickly. Here’s how it streamlines the process and helps projects move forward with confidence…

Providing accurate, up-to-date as-built data

One of the most common issues in project approvals is working with outdated or inaccurate site drawings. Relying on old measurements or assumptions can lead to discrepancies, which can mean the design is rejected or force multiple rounds of revisions. 3D laser scanning eliminates this problem by capturing an exact digital replica of the site, ensuring all data is current and highly accurate. With millimetre-level precision, engineers can confidently present as-built conditions to planning authorities, reducing the likelihood of pushback or rework.

Improving stakeholder confidence

Approvals also often get held up because decision-makers struggle to visualise the project in its real-world environment. Misunderstandings and uncertainty can lead to prolonged back-and-forth discussions, slowing everything down.

With 3D laser scanning, complex site data is transformed into detailed, interactive 3D models. This makes it much easier for stakeholders to understand spatial constraints, planned modifications, and potential impacts. Instead of working from 2D drawings or technical reports, they can see exactly how the project fits into the existing environment, leading to quicker, more confident decision-making.

Reducing revisions and compliance issues

Regulatory bodies require precise documentation to ensure projects meet safety and environmental standards. If plans are based on inaccurate measurements, errors can be flagged late in the process, causing costly delays.

Since 3D laser scanning provides comprehensive, verifiable data, it helps engineers and designers produce highly detailed, regulation-compliant documentation from the start. This reduces the risk of approval setbacks due to missing or incorrect information, streamlining the compliance process.

Clash detection and early issue resolution

Discovery of unexpected site conflicts also has the potential to put a halt on projects. Whether it’s new infrastructure clashing with existing structures, accessibility issues, or compliance concerns.

By integrating 3D laser scanning data into BIM (Building Information Modelling) workflows, engineers can identify and resolve these clashes before project kickoff. This means potential issues are flagged and fixed in the design phase, rather than being caught during the approval stage when changes are more time-consuming and expensive.

Speeding up modifications and resubmissions

Even with the best planning, some projects will require modifications before receiving full approval. Traditional site surveys can slow this process down: waiting for new measurements, verifying dimensions, and updating designs all add unnecessary time to the project timeline.

With 3D laser scanning, all site data is already captured in a highly detailed digital format. If modifications are needed, engineers can quickly update the existing 3D model rather than returning to the site for new measurements. This means changes can be submitted faster, reducing downtime and keeping projects moving forward.

Project approvals don’t have to be a painful process. If you’re tired of slow approval processes and unnecessary setbacks, let’s talk about how 3D laser scanning can help you get projects signed off faster and with fewer complications.

How to Calculate the ROI of 3D Laser Scanning for Your Next Project

Mon, 03 Mar 2025 18:38:42 GMT

How to Calculate the ROI of 3D Laser Scanning for Your Next Project

Date: 03rd March 2025

Is 3D laser scanning worth the investment?

Balancing cost, time, and quality is always a challenge when planning an engineering project. While choosing the cheapest option might seem like a smart move initially, if it leads to inaccuracies, delays, or costly rework, those savings quickly disappear.

So, one of the biggest questions when investing in new technology for your project is whether the return on investment (ROI) justifies the upfront cost. Or is it just going to be additional cost and time?

The benefits of 3D laser scanning aren’t always immediately obvious, but they can be substantial. So, how can you calculate the ROI of 3D laser scanning and determine if it’s the right choice for your next project?

Understanding 3D laser scanning’s role in development projects

Before jumping into ROI calculations, it’s worth brushing up on how 3D laser scanning actually fits into design projects, especially in chemical plants.

This technology makes it easy to capture highly accurate site data, producing detailed digital models of existing structures. These models become a solid foundation for engineering design, modifications, and compliance documentation. Unlike traditional measurement techniques which often rely on manual effort and come with a risk of human error, 3D laser scanning is a faster, more precise, and non-intrusive way to gather reliable data. It removes the guesswork, speeds up the process, and ensures everyone involved has access to accurate, up-to-date site information.

Why choose 3D laser scanning over traditional methods?

One of the biggest advantages of 3D laser scanning is its ability to capture data from hard-to-reach areas. This is particularly useful in chemical plants where safety risks are an important concern. Engineers can use the generated 3D models to analyse existing conditions, identify potential design clashes, and make sure new installations or modifications fit seamlessly into the current site set up. This significantly reduces the likelihood of errors or delays during the execution phase of a project and means that teams can collaborate and move from phase to phase on a project without friction.

Scan data is also essential for asset management and maintenance planning. Its highly detailed as-built models allow facility managers to track structural changes over time, making it easier to plan renovations, upgrades, and inspections. Maintaining accurate digital records also helps meet regulatory compliance requirements, reducing the risk of fines or project delays.

This is all great, but can you actually calculate the ROI of 3D laser scanning?

Yes! When looking at the cost-benefit side of things, it’s all about comparing what you invest upfront versus the savings you’ll gain. Some of the biggest cost reductions come from cutting down on labour for manual measurements, reducing errors that lead to rework, and speeding up project completion times, which means lower overheads. Plus, there are long-term savings from better maintenance planning.

The direct and indirect cost benefits of 3D laser scanning

One of the biggest ways 3D laser scanning saves money is by reducing the need for manual measurements. With fewer people required on-site, labour costs go down. Accurate data is captured from the very start, helping avoid costly rework, design changes, and delays. Projects also move faster thanks to the streamlined data collection process, which means less money is spent on overhead costs.

Beyond the direct savings, there are plenty of other financial benefits over the long run. Safety is a big one: Fewer site visits means there’s less potential for accidents, lowering insurance and liability costs. More accurate designs also help optimise material use and reduce waste.

Regulatory compliance is another aspect of the project that benefits since precise documentation ensures projects meet industry standards, preventing costly penalties. Having these detailed as-built models also makes long-term maintenance planning much easier, leading to better asset management. Ultimately, this means teams become more productive because they can focus on design improvements instead of fixing measurement errors.

Calculating the ROI of your laser scanning project

To figure out the ROI of 3D laser scanning, project managers should take a few key factors into account:

Initial Investment/The cost of using the 3D scanning service.
How much time is saved by quicker data collection and design adjustments?
The money is saved by avoiding rework and material waste.
The project efficiency and how faster completion times mean lower overall costs.
The long-term benefits of laser scan data such as safer operations, better compliance, and improved maintenance planning.

Using this data, here’s how you calculate ROI:

Total Savings - Initial Investment / Initial Investment x 100%

So, let’s say a chemical plant invests £50,000 in 3D laser scanning services. By using the technology, they save £30,000 in reduced labour costs, £25,000 in minimised rework, and £20,000 in improved project efficiency, totalling £75,000 in savings.

This would mean that:

ROI = 75,000 - 50,000 / 50,000 x 100 = 50%

This means the company gets a 50% return on its investment, making 3D laser scanning a financially smart choice.

Next steps

If you’re managing projects at a chemical plant and looking for a way to cut costs while improving accuracy, 3D laser scanning is a smart investment. Not only will it save time and money, but it’ll also boost safety and make compliance a lot easier.

Curious about how 3D laser scanning could work for your next project? Let’s chat! Book a call with our team today and see the benefits for yourself.

FEED studies: What are they and why are they important?

Tue, 04 Feb 2025 08:37:30 GMT

FEED studies: What are they and why are they important?

Date: 04th February 2025

In any engineering project, especially in complex environments like chemical plants, proper planning is everything. It’s what separates smooth, successful execution from unexpected delays, costly mistakes, and potential safety hazards. Front-End Engineering Design (FEED) studies are one of the best ways to ensure these are the case.

But what exactly happens during a FEED study, and why is it so essential in industries like chemical engineering?

What Are FEED Studies in 3D Laser Scanning?

A FEED study is an important planning phase in engineering projects that defines all design aspects before construction begins. Chemical plants are increasingly using 3D laser scanning within FEED studies to capture precise as-built layouts of the existing site, creating a digital twin of the plant. This makes it much easier to design new piping systems, spot any potential clashes, and fine-tune layouts before anything is built. By tackling these issues early, FEED studies save time, money, and headaches down the line.

When it comes to piping design, using 3D laser scanning within your FEED study gives everyone involved (such as designers, fabricators, and contractors) a clear picture of what’s going on. This makes communication smoother and helps to avoid missteps. Plus, it ensures safety standards are met and reduces surprises during construction. With fewer delays and more accurate cost estimates, a FEED study helps keep the project on track and gives everyone peace of mind.

The Importance of FEED Studies

To understand the importance of FEED studies, imagine trying to renovate a century-old house. You want to add a new bathroom, but you have no idea where the pipes are, where the wiring runs, or which walls are load-bearing. Without accurate blueprints, you risk drilling into essential systems, causing damage, and wasting time and money.

Now, scale up this problem to a chemical plant. Instead of a burst water pipe, a miscalculation could lead to costly downtime, environmental hazards, or even safety risks for your workers. In the same way that renovating a house without a blueprint is a recipe for disaster, skipping a FEED study in a chemical plant sets the stage for preventable problems.

How 3D Laser Scanning Supports FEED Studies

Let’s break down the process:

1. Scanning the Plant: Laser scanners can be used to capture the precise dimensions and layout of the plant, including pipework, equipment, and structural elements. These scanners can access hard-to-reach areas, ensuring no detail is missed.

2. Processing the Data: The captured data is transformed into a detailed point cloud, which is then used to create a 3D model of the plant. This digital twin reflects the as-built conditions with remarkable accuracy.

3. Design and Analysis: Engineers use the 3D model to design modifications, simulate workflows, and check for potential clashes or conflicts. This ensures new installations will fit seamlessly into the existing environment.

Why FEED Studies Are Non-Negotiable

Skipping a FEED study might feel like a way to save time, but it’s almost always a costly decision in the long run. Here’s why it’s so important… In a chemical plant, even small errors can lead to big safety risks, and addressing those issues after the fact can be expensive and time-consuming. A FEED study also ensures your designs meet all the necessary industry and safety standards, so you’re not caught off guard later. Most importantly, it gives engineers and stakeholders confidence that the project is built on solid, accurate data.

Starting a project without a FEED study is like heading out on a road trip without a map - you might make it to your destination, but you’re more likely to hit some unexpected bumps along the way. By using 3D laser scanning as part of your FEED study, you get a clear, detailed understanding of your plant’s current layout, setting your project up for success from day one.

So, when you’re planning your next upgrade or retrofit, ask yourself: Do you want to rely on guesswork or have a detailed plan to guide you? If you’re ready to take an informed approach, contact our team today at enquiries@ohare-eng.co.uk.

Ensuring Santa’s Workshop Meets Modern Elf And Safety Standards

Thu, 12 Dec 2024 20:07:07 GMT

Ensuring Santa’s Workshop Meets Modern Elf And Safety Standards

Date: 12th December 2024

As Christmas draws nearer, Santa’s workshop is a hive of activity, with each elf diligently crafting, wrapping, and sorting presents to ensure everything is ready for the big night. Behind the scenes, the elves play a crucial role in bringing the holiday magic to life, but in a workshop as bustling as the one at the North Pole, there’s no room for complacency. Health and safety are just as important as holiday cheer.

With the workshop so full of activity - sharp tools, heavy packages, moving parts, and even flying reindeer - it’s clear that maintaining a safe environment is critical to keeping spirits high and accidents low. But, in a building as iconic as Santa’s workshop, how do you balance tradition with the need for up-to-date protocols?

Let’s take a closer look at how the North Pole can embrace modern health and safety practices through innovative engineering design to maintain both efficiency and the joy that defines Christmas…

Sitewide Snowstorm Sprinkler Systems

Designing and making presents for nearly 2.2 billion children across the world is no mean feat. But, when it comes to last-minute wrapping of these presents, it's on everyone in the workshop to chip in. Elves line every workbench, elbow-to-elbow, surrounded by mountains of highly flammable wrapping paper. It’s a festive scene, but also a potential fire hazard. To keep everyone safe, state-of-the-art snowstorm sprinkler systems should be installed in every room of Santa’s workshop to douse any flames before they spread and put a stop to all festive operations.

Meeting Emissions Standards

The workshop's ancient coal furnace, with its billowing smoke, is not only a relic of the past but also a clear violation of North Pole emission standards. It’s time for a modern upgrade. By installing energy-efficient heating and cooling systems, Santa can create a more comfortable and environmentally friendly workspace for the elves. Embracing renewable energy sources, such as harnessing the Arctic’s powerful winds or the midnight sunlight in the summer, would further transform the workshop into the definition of sustainability making Santa’s operations a shining example of green energy innovation.

PPE For Glitter and Glue

Elves often find themselves working with glitter, glue, and sharp tools, all without the proper protective equipment, putting them at risk of injury. To ensure their safety, it’s crucial to provide them with appropriate PPE kits. These could include festive yet functional items like candy-cane-striped gloves, reindeer antler ear protectors, and cheerful hard hats. Additionally, goggles and masks are essential to prevent glitter from causing eye irritation and to protect against inhaling potentially harmful glue fumes. With the right gear, elves can work safely while still embracing the holiday spirit!

Proper Ventilation That Embraces The Arctic Chill

Even in the frosty North Pole, overheated workshops can leave hardworking elves feeling sleepy and unfocused. The solution is a clever system that taps into the North Pole’s natural chill to keep things cool and breezy. This setup ensures fresh, clean air circulates through the workshop, whisking away fumes from paints and adhesives while maintaining a pleasant and safe temperature. With a perfectly balanced environment, the elves can stay energised and focused, creating holiday magic without breaking a sweat.

Quality Control and Elf Training

With new elves joining Santa’s Workshop each year to keep up with increasing demand, a few hiccups are bound to happen - like the occasional mix-up that sends a teddy bear to a teenager and a gaming console to a toddler. To keep the holiday magic on track, it’s time to step up the training game. A well-structured onboarding program can ensure every rookie elf understands the workshop’s processes and safety protocols from day one. And, of course, quality control checkpoints are a must to double-check that each gift is perfectly labelled and on track to the right child. After all, even Santa’s team can’t rely solely on magic to make everything run smoothly…

Sleigh Maintenance and Aviation Standards

The sleigh might be powered by Christmas magic, but even Santa's ride needs a little TLC to stay in top form. Regular maintenance checks are a must to ensure the sleigh's structure can withstand turbulence and the breakneck speeds of a globe-trotting journey. While Rudolph's nose is a reliable beacon, a modern GPS system would give Santa pinpoint precision, ensuring every house is reached without a single wrong turn. After all, even the most magical sleigh deserves a high-tech upgrade.

Heated Reindeer Runways

Santa’s reindeer deserve only the best, especially when preparing for their epic Christmas Eve journey. Imagine a runway so advanced that it stays completely ice-free, no matter how frosty the North Pole gets. With clever pipework running beneath the surface to provide steady warmth and powerful heat cannons above ground to blast away snow, the reindeer can enjoy smooth, slip-free takeoffs and landings. Dasher, Dancer, and the crew will feel like they’re soaring from a luxury launch pad rather than an ice rink ready to deliver magic to the world!

Machine Safety in Toy Production

Elves are hard at work operating vintage machinery, but the exposed gears and lack of emergency stop buttons are more of a holiday hazard than a helper. Adding safety guards and installing emergency stop buttons would bring Santa’s toy-making machines into the modern era, keeping accidents at bay. To top it off, brightly coloured signage can make hazardous areas stand out like Rudolph’s nose, ensuring every elf stays alert and safe.

Santa’s Workshop may be magical, but it can also be a model of modern safety and efficiency. With a few upgrades, Santa can ensure his hardworking elves stay safe, happy, and ready to spread holiday cheer for generations to come!

The different types of engineering design drawings and what they’re used for…

Wed, 27 Nov 2024 08:50:51 GMT

The different types of engineering design drawings and what they’re used for…

Date: 27th November 2024

Engineering design projects, especially in chemical plants, often involve multiple teams and many moving parts. In such complex environments, ensuring everyone is aligned is critical. When miscommunication occurs, it’s often due to one culprit: inaccurate or mismatched drawings.

From high-level layouts to detailed system schematics, each type of drawing plays a unique and vital role. This blog delves into the essential engineering drawings used in chemical plant design, highlighting how they promote safety, efficiency, and effective collaboration among teams.

1. General Arrangement (GA) Drawings

General Arrangement (GA) drawings give an accurate overview of a plant’s physical layout, including the placement of all major equipment, pipes, and structural elements. They are typically created in plan (top-down) and elevation (side) views, offering a comprehensive overview of equipment and piping arrangements. They also use sections and elevations to show multiple angles and layouts, making it easy to visualise how each component fits together within the plant.

For a piping engineer, GA drawings are invaluable for coordinating designs with other engineering teams, such as civil, structural, and electrical. This ensures that piping systems fit precisely within the plant’s layout. GAs also help identify potential spatial issues early, so adjustments can be made to avoid issues during construction. This is important for efficient planning, ensuring that all elements are accessible for maintenance and meet space and safety requirements.

In the UK, GAs are commonly designed to adhere to BS EN ISO standards, ensuring uniformity and compliance with national safety regulations. Following these standards helps maintain consistency and is essential in heavily regulated environments like chemical plants, where safety is a top priority.

2. Piping and Instrumentation Diagrams (P&IDs)

P&IDs are detailed diagrams of how your system will work in relation to the rest of the plant. These drawings are functional rather than scaled, focusing on the relationships between different system elements rather than exact dimensions.

Design engineers use this to source materials and map out the route for the proposed pipework to enable accurate and efficient manufacturing of the system. A P&ID will typically show the types and locations of valves, instruments, sensors, and control devices, with details about their function within the process. During the design phase, these diagrams clarify how each process component interacts, and they serve as a reference throughout the plant’s lifecycle, from construction and commissioning to operation, maintenance, and troubleshooting.

P&IDs act as a bridge between the broader plant layout in GA drawings and the specific details in isometric drawings. They define how each component functions, informing layout and installation decisions.

3. Process Flow Diagrams (PFDs)

Process Flow Diagrams (PFDs) are vital in chemical plant design, offering a high-level overview of the entire process. They detail major equipment, process lines, and flow directions while highlighting operational parameters like pressure and temperature. Unlike P&IDs, PFDs focus on the overall process rather than intricate control systems, making them indispensable for initial planning and communication across teams. By simplifying complex systems, PFDs help engineers and stakeholders understand key workflows, identify inefficiencies, and guide more detailed design phases.

4. Isometric Drawings (Isos)

Isometric drawings, or isos, present a three-dimensional view of piping layouts in a 2D format. These drawings focus on specific pipe runs, showing their exact length, angles, fittings, and dimensions. Isometric drawings are among the most detailed engineering drawings and are essential for piping fabrication and installation.

Isos contain key information about each pipe, such as lengths, angles, weld points, valve positions, and materials. These drawings also include notes on construction requirements, such as weld types, and flange specifications. Each component is labelled with precise measurements to guide fabricators and installers.

Isometric drawings provide a detailed blueprint for constructing piping sections. This accuracy ensures that all piping components are manufactured to the correct specifications, reducing errors and rework during installation. They are also useful for performing stress analysis, as they allow engineers to predict how pipes will behave under different conditions, such as high pressure or temperature.

5. Site Layouts

Site layouts offer a high-level view of the entire plant’s layout, showing the location of key areas, roads, boundaries, and major plant elements. They are typically created in the early planning stages to ensure that all necessary components fit within the plant’s physical space and that the site complies with zoning, environmental, and safety regulations. This drawing is often used by both the client and the regulatory bodies to confirm that the plant’s design meets all regulatory and logistical requirements.

For piping engineers, site layout plans provide a basis for laying out piping systems while ensuring compatibility with the site’s physical constraints. They’re also essential for emergency planning and ensuring safe access to critical areas.

Conclusion

Engineering design drawings are indispensable tools in piping design, guiding engineers from planning through to construction and maintenance. Each drawing type supports the others, forming a network of detailed information that is essential for safe and efficient plant operations. As a piping engineer, mastering these drawings and adhering to UK standards will ensure that your designs contribute to a reliable, safe, and compliant chemical plant.

If you’re missing any of these key drawings for your site, get in touch today.

Why bother with visualisations in pipework design for chemical plants?

Tue, 29 Oct 2024 07:24:03 GMT

Why bother with visualisations in pipework design for chemical plants?

Date: 29th October 2024

When designing pipework systems that transport hazardous chemicals under high pressure and varying temperatures, safety, efficiency, and cost control are non-negotiables. Mistakes in this critical phase can lead to costly rework, operational inefficiencies, or even dangerous safety incidents.

Traditionally, piping design relied on 2D drawings and manual calculations, but as systems become more complex, so does the need for more advanced tools like 3D modelling, and interactive layouts. These tools allow engineers to create detailed, accurate representations of entire pipework systems, anticipating risks, streamlining installation, and ensuring the system operates correctly from day one.

So, with so many design tools at our disposal, why use visualisations in piping design for chemical plants? And how can they help optimise safety, efficiency, and cost?

Improved understanding of complex systems

Chemical plants often have intricate pipework systems that transport various chemicals under different temperatures and pressures. Visualisations provide a clear, detailed view of these complex systems, making it easier for engineers to understand how different components interact. Instead of relying solely on technical drawings, visual tools give engineers and stakeholders a clearer understanding of the entire network. This clarity ensures everyone is aligned on the project's scope and functionality.

Early detection of design issues

One of the biggest advantages of using visualisations is the ability to spot potential design flaws before they become real-world problems. By using 3D modelling software, design engineers can simulate how a piping system will function under various operating conditions. This allows issues to be picked up early, like pressure drops, inadequate spacing, or material weaknesses. Catching these problems early, before physical construction begins, reduces the likelihood of costly rework and delays later in the project.

Improved communication between teams

Chemical plant design involves collaboration between multiple disciplines - process, mechanical, civil, structural, and safety engineers, to name a few. Miscommunication between these teams can lead to costly errors. Visualisations, such as CAD models or piping and instrumentation diagrams (P&IDs), serve as a universal language that all stakeholders can understand. By providing a visual representation of the system, these tools ensure that everyone involved is on the same page, reducing the risk of misunderstandings.

Using space more efficiently

Maximising space efficiency is essential in chemical plants, where equipment, piping, and safety zones often compete for limited space. Visual models help engineers optimise pipe layouts to ensure smooth operation while avoiding congestion. By visualising the entire system in 3D, designers can identify areas where space is underutilised or overcrowded, leading to more efficient and practical layouts. These optimised designs also ensure that maintenance access is preserved and that the system complies with regulatory and safety standards.

Simulation of real-world conditions

One of the most powerful features of visualisation tools is their ability to simulate real-world operating conditions. Engineers can use these tools to model factors like temperature, pressure, and fluid flow within the pipework. This allows them to predict how the system will perform under various scenarios, helping them to optimise designs for safety and efficiency. By stress-testing designs in a virtual environment, engineers can make data-driven decisions that improve the reliability of the system.

Faster decision-making

The ability to quickly visualise and evaluate design options speeds up the decision-making process. Visual representations enable engineers and stakeholders to assess different scenarios and alternatives in real-time, rather than relying on lengthy technical reports or abstract data. This streamlined approach allows for faster problem-solving and quicker project milestones, which is essential in today’s fast-paced industrial environments.

Cost savings

Perhaps one of the biggest benefits of using visualisations is the cost savings they can provide. Identifying and addressing design flaws before construction begins leads to fewer on-site changes, reducing labour costs and material waste. Additionally, optimised designs can lead to more efficient use of resources, further lowering project expenses. By minimising errors and maximising efficiency, visualisations help companies stick to their budgets while delivering high-quality results.

Incorporating visualisations into the pipework design process for chemical plants is no longer an option but a necessity. From enhancing understanding and communication to optimising layouts and reducing costs, the benefits are clear. By leveraging tools like 3D modelling, and real-world condition testing, engineers can create safer, more efficient, and more reliable systems.

At the end of the day, visualisations help bridge the gap between design concepts and practical implementation, ensuring that chemical plants operate smoothly and efficiently. As technology continues to evolve, we can expect visualisations to play an even more central role in the future of pipework engineering.

To find out more about our visualisation and 3D modelling services, download our free brochure .

A PROACTIVE APPROACH TO PIPE INTEGRITY IN CHEMICAL PLANTS

Wed, 02 Oct 2024 13:25:50 GMT

A PROACTIVE APPROACH TO PIPE INTEGRITY IN CHEMICAL PLANTS

Date: 02th October 2024

Chemical plants are complex industrial facilities that rely heavily on piping infrastructure to transport often hazardous materials around the site. Over time though, this infrastructure can deteriorate due to factors like age, corrosion, and general wear and tear.

Let's say this pipework is carrying something like water. If it were to fail, you not only risk flooding the site but also shutting down production until the internal problem has been resolved. Now, if you replace that with one of the more dangerous chemicals found in chemical plants, this deterioration poses significant safety and environmental risks.

To mitigate these risks, it’s important to assess the condition of ageing piping systems and implement effective mitigation measures.

The role of laser scanning in plant maintenance

Laser scanning technology has emerged as a powerful tool for assessing the condition of ageing piping infrastructure. This technology uses lasers to create highly accurate 3D models of existing structures and environments. By capturing these images, laser scanning provides valuable insight into the physical condition of piping systems. And, the data can be used to create intelligent P&IDs to act as a maintenance log for your entire site. Here’s a link to our blog on ‘Why more chemical plants are now opting for intelligent P&IDs’ .

What are the key benefits of using laser scanning for piping assessment?

It delivers highly accurate and precise measurements, allowing you to identify even the subtle signs of deterioration.
It’s a non-destructive and efficient method for data collection. Work doesn’t need to stop for the data to be collected, reducing downtime and minimising disruptions to plant operations.
Laser scanning captures the entire piping system, including its complex geometry and connections, providing a comprehensive understanding of its condition.
It generates detailed documentation that can be used for future reference, facilitating maintenance and repair planning.

Engineering Design Considerations

Once the condition of the piping system has been assessed using laser scanning, engineers can develop appropriate mitigation strategies. These strategies may involve repairs, replacing sections of piping that have deteriorated beyond repair, strengthening existing piping to improve its capacity, and implementing regular inspections and maintenance procedures to prevent further deterioration.

Integrating Laser Scanning and Engineering Design

To effectively harness the advantages of laser scanning and engineering design, it is important to integrate these two disciplines. This involves analysing laser scan data to pinpoint areas of concern and evaluate the extent of deterioration. Additionally, creating 3D models of the piping system and simulating its behaviour under various loading conditions allows for the assessment of the proposed mitigation strategies' effectiveness. By quantifying the risks associated with the ageing piping system and prioritising mitigation efforts accordingly, a risk assessment can be conducted. Encouraging collaboration between laser scanning experts and engineers ensures that the collected data is utilised effectively to inform design decisions.

Laser scanning and engineering design are powerful tools for assessing and addressing the risks of ageing piping infrastructure in chemical plants. By combining these technologies, it is possible to identify potential hazards, develop effective mitigation strategies, and ensure the safe and reliable operation of these critical facilities.

Mechanical vs. Design Engineers: Which Do You Need for Your Next Large-Scale Project?

Tue, 20 Aug 2024 07:31:25 GMT

Mechanical vs. Design Engineers: Which Do You Need for Your Next Large-Scale Project?

Date: 20th August 2024

Engineering expertise is vast and varied, making it challenging to determine the right specialist for a complex project. From software to structures, there's an engineer for almost every task. But when it comes to project managing large-scale installations like carbon capture equipment, you've likely asked yourself “Do I need a Mechanical Engineer or a Design Engineer?”

Let's clear up the confusion. While these roles might seem interchangeable, their responsibilities and skill sets are distinct. In this post, we'll break down the key differences to help you make an informed decision for your project.

The Mechanical Engineer

A Mechanical Engineer is the architect of a chemical plant’s mechanical infrastructure. Their role goes beyond the design table, looking at the entire lifecycle of equipment and systems. They conceive, design, and refine equipment such as pumps, compressors, heat exchangers, and reactors, ensuring they are optimal and safe to operate within the chemical process.

A comprehensive grasp of chemical processes is essential for Mechanical Engineers to seamlessly integrate mechanical systems, enhance performance and prevent bottlenecks.

Prolonging equipment lifespan and minimising downtime is also a key focus. Mechanical Engineers create maintenance schedules, predict potential failures, and strategies to optimise overall plant operations.

The Design Engineer

While Design Engineers have an understanding of all these components and lifecycles, their specialism lies in transforming these concepts into tangible blueprints. Their precision and attention to detail are essential for bringing a project to life.

Design Engineers are highly skilled in using computer-aided design (CAD) software to create detailed 2D and 3D models of mechanical components. Alongside accurate and comprehensive technical drawings, these models act as the foundation for manufacturing and assembly. These drawings include dimensions, tolerances, and material specifications, ensuring precision and consistency.

Their role also involves creating comprehensive design documentation that's vital for manufacturing, assembly, and future reference.

The Perfect Partnership

While Mechanical and Design Engineers bring unique skill sets to the table, their roles are interconnected. So, the success of large-scale projects relies on a seamless collaboration between the two.

In the early stages of a project, Mechanical Engineers are pivotal in defining the overall mechanical system. But then as the project progresses, Design Engineers take over, creating detailed drawings for manufacturing. During plant operations, both roles remain essential, with mechanical engineers focused on optimisation and troubleshooting, and design engineers handling modifications and upgrades.

By understanding the distinct strengths of each role, project managers can build a high-performing team capable of delivering exceptional results.

If you’re unsure which would be the best fit for your next project, get in touch with a member of our team today. If we’re not the right fit for your project, we’ll help point you in the right direction.

What role are 3D laser scanning and mechanical design playing in the carbon capture movement?

Fri, 19 Jul 2024 08:37:23 GMT

What role are 3D laser scanning and mechanical design playing in the carbon capture movement?

Date: 19th July 2024

The UK has set ambitious goals for reducing its carbon footprint by 2050, and the chemical industry plays a crucial role in achieving these targets.

In 2021 the chemical industry was responsible for around 5% of total net GHG emissions in the EU ( ref ). But getting this number down can’t just be done with the flick of a switch - it takes a huge amount of engineering, and is seeing lots of chemical plants in the UK adapting their sites to install Carbon Capture and Storage (CCS) systems.

Carbon capture is essentially a giant filtration for the site that traps CO2 emissions, preventing them from contributing to climate change. It’s believed that these filters can capture between 60% to 95% of the CO2 produced by a site (like a power plant) before entering the atmosphere. This captured CO2 can then be permanently stored underground or reused in other industrial processes.

So, how are 3D laser scanning and mechanical design being used in sustainability projects across the UK to transform chemical plants into more carbon-neutral operations?

The challenge of retrofitting existing plants

Integrating carbon capture (CCS) into existing chemical plants is crucial for a low-carbon future, but these facilities pose unique challenges. Their complex layouts, unlike modern plants designed for carbon neutrality, make adding bulky CCS equipment difficult. Traditional measurement methods, reliant on manual processes, are time-consuming and error-prone, further complicated by extensive surveying that disrupts production.

Solving retrofitting challenges with 3D laser scanning

Advanced 3D laser scanning offers a solution for integrating carbon capture systems into existing chemical plants. This technology can be used to create highly accurate digital twins of the space. By scanning a plant, engineers obtain a precise point cloud representation of all its components, including pipes, vessels, and machinery. It also allows the virtual placement of CCS equipment to identify potential space constraints before any physical modifications begin. Real-time simulations can also be run on the digital twin to optimise CCS integration while minimising disruption to ongoing plant operations.

Planning for seamless integration

By having this 3D scan data and using it to develop accurate 3D models of the site, mechanical design engineers can design and integrate the new equipment into and around the existing site. In the case of CCS integration, this meticulous planning involves tasks like designing custom brackets and supports to ensure the capture equipment is securely mounted, and modifying existing piping and ductwork to seamlessly accommodate the capture process. Sometimes it can involve creating entirely new connections for optimal efficiency. By using 3D models within the planning phase of a CCS project, engineers can optimise the placement and layout of the capture equipment, ensuring it integrates seamlessly with the existing plant infrastructure.

Advanced design software empowers mechanical design engineers with a powerful technique called ‘clash detection’. In this process, the 3D model of the capture equipment is virtually placed within a digital twin of the site. This virtual environment acts as a powerful testing ground, allowing engineers to identify any potential spatial conflicts with existing structures or equipment before any physical construction begins. This minimises the risk of unforeseen complications during on-site installation, saving valuable time and resources. Additionally, clash detection helps to identify potential safety hazards that could arise during physical installation, promoting a safer work environment for construction crews.

Furthermore, the iterative design process within the virtual environment allows for continuous refinement and optimisation of the capture equipment integration plan. Engineers can test different configurations and layouts, ensuring the chosen design offers the most efficient use of space, minimises disruption to existing plant operations, and facilitates a smooth and efficient installation process. This translates to reduced project timelines, lower costs, and a minimised risk of delays or complications during the physical integration phase.

The Future of Sustainable Chemical Plants

By combining 3D laser scanning with advanced mechanical design, companies are transforming their operations into more sustainable and environmentally friendly facilities. These advancements not only benefit the environment but also ensure the competitiveness of the UK's chemical sector in the global market. As these technologies continue to develop, we can expect even more efficient and effective methods for capturing carbon emissions and creating a greener future for the chemical industry.

If you found this article interesting, be sure to take a look at our blog about ‘Why are lots of chemical plants in the UK converting to hydrogen?’

How 3D models and laser scanning can be used in all phases of chemical plant piping design and construction…

Fri, 24 May 2024 06:20:55 GMT

How 3D models and laser scanning can be used in all phases of chemical plant piping design and construction…

Date: 24th May 2024

It's a common misconception that 3D scan data is only valuable during the design phase of a chemical plant piping project.

While it undoubtedly provides a great deal of insight at this stage, the efficiency and precision of 3D laser scanning offer a valuable asset throughout the entire project lifecycle – from feasibility studies to construction, quality control, and maintenance to ongoing team training.

So, just how can 3D laser scanning be used in all phases of chemical plant piping design and construction?

Feasibility Studies: From Greenfield to Detailed Design

Before a single pipe is laid, 3D laser scanning can play an important role in setting your project up for success. By meticulously mapping existing site conditions, down to the finest detail, engineers can plan pipework layouts that seamlessly integrate with the space and any existing infrastructure or equipment. Visualising the precise location of utilities and potential obstacles allows for proactive problem-solving, reducing the risk of costly clashes during construction. This can mean significant time and resource savings and a smooth and efficient build process.

By having these models available early on in the project development, they can also be a valuable asset for getting your stakeholders on board with the project as it allows your vision to be understood by people who are less technically minded.

Procurement and Construction

The benefits of 3D laser scanning extend far beyond the planning phase. During construction, scan data can act as a digital reference point for the installation of pipework and new equipment. It can be used to generate detailed 3D models and visualisations of the space and any newly designed pieces of equipment. This then allows engineers and construction crews to decide and test the best materials for each specific job, enabling easier procurement of parts the first time around. Adhering to these design specifications not only enables an aspect of quality control to be implemented and checked throughout the project as you bring different contractors on board, but it also promotes a safer, more efficient construction environment.

Operations and maintenance

The "as-built" 3D models generated from laser scans are an invaluable asset for plant operations and maintenance. This digital record provides a clear and accurate depiction of the actual piping configuration as it has been constructed. With this information readily available, maintenance crews can pinpoint specific pipe sections for repairs or upgrades, minimising downtime and optimising maintenance activities.

Ongoing Training

Beyond its construction and operational benefits, 3D laser scanning data can be used for ongoing personnel training. By generating immersive 3D models of the plant piping system, companies can create realistic training scenarios for new employees or refresher courses for existing staff. This allows for a safe and controlled learning environment, encouraging a deeper understanding of the plant's intricate piping network.

3D laser scanning is no longer just a design tool; it empowers efficiency and precision throughout all phases of chemical plant piping design and construction. From initial planning to ongoing operations, 3D scanning offers a comprehensive solution for optimising workflows, ensuring safety, and maximising the lifespan of the equipment and chemical plant. As this technology continues to evolve, we can expect even greater benefits and innovative applications to emerge, shaping the future of chemical plant construction in the UK.

What role can automated scan data registration play in the time-quality-cost trade-off?

Fri, 26 Apr 2024 06:27:48 GMT

What role can automated scan data registration play in the time-quality-cost trade-off?

Date: 26th April 2024

While 3D laser scanning captures this complex maze of pipes, vessels and ever-shifting machinery in incredible detail, it's not until that data has been processed that it becomes actually useful in a business. This seemingly simple task unlocks the full potential of your laser scan data, transforming it from a point cloud into an actionable 3D model.

So what is scan registration? How does automated scan registration work? And what role is it playing in the time-quality-cost trade off a lot of design engineers encounter on a daily basis?

What is scan registration (or post-processing)?

Think of it like putting together a giant jigsaw puzzle. Each scan you collect represents a different angle, view, or piece of information about your site. Scan registration takes these individual scans, with their slightly different viewpoints and orientations, and aligns them precisely into a unified coordinate system to create a complete picture.

Traditionally, this process has relied on engineers manually identifying overlapping areas or distinctive features within each scan to achieve precise alignment. This manual approach, while effective, can be incredibly time-consuming, especially for expansive and intricate chemical plants. This is why a lot of softwares are using AI to automate this process.

How does it work?

These programs leverage cutting-edge algorithms to automate the alignment process. This software works by intelligently identifying natural features within the scans, such as common pipe segments or strategically placed targets, to achieve precise alignment between individual scans.

What role does automated registration play in the time-quality-cost trade-off?

Automated registration disrupts the traditional time-quality-cost trade-off in 3D laser scanning. Traditionally, achieving high quality meant spending more time on manual registration. However, automated registration software achieves this task efficiently, saving time without compromising quality. Since most software comes with built-in automation, this can also save on costs too.

Are there any situations where you might manually process scan data?

In many cases, a hybrid approach is best; where automation handles most of the alignment, and then manual adjustments are made for specific areas. That way you can be sure that your models and scans are of the highest quality possible.

There is occasionally a project where completely manual registration is required. For example, when…

You’re working in a unique or challenging environment that has unusual features or contains reflective surfaces that disrupt automated algorithms.
You’re using low-quality scan data. Scans with limited detail or significant noise might not offer enough "natural features" for automated software to work effectively. Manual registration allows for a more targeted approach using specific control points.
The project you’re working on requires exceptionally high accuracy or needing to focus on specific areas with unique features. Manual registration offers more granular control over the alignment process.
You’re using older or less capable registration software, automation might not be as reliable.

Whether you’re using an automated system or not, manually reviewing any point cloud data before converting it to your chosen format is an essential step in post-processing. This ensures that the quality of your final product isn't affected by your change in process.

Ready to unlock the time-saving intelligence of automated scan registration for your next chemical plant project? Contact us today to discuss how our expertise and technology can streamline your workflow and deliver exceptional results.

Using Redundancy In Engineering Design To Avoid Cracking Under Pressure

Thu, 21 Mar 2024 16:36:12 GMT

Using Redundancy In Engineering Design To Avoid Cracking Under Pressure

Date: 22nd March 2024

We've all heard the saying ‘Don't put all your eggs in one basket.’ It's a simple reminder to diversify and avoid relying on a single source for something important. This principle is just as crucial in the world of chemical plants, where safety and efficiency are essential.

It’s like trying to balance a tray of 36 eggs along with 6 bags of shopping to avoid doing a second trip to the car. Once you get the right set-up, it works fine, until you trip over the doorway, fall over the dog or (depending on how long the drive is) your arm gets tired and starts to shake. In the best-case scenario, you might save a few eggs with a quick catch. However, if all your eggs were in that one basket, the outcome wouldn't be pretty.

Chemical plants face similar risks, but they handle potentially hazardous materials and complex processes instead of fragile eggs. That's where redundancy comes in – it's the engineering equivalent of carrying a sturdy basket for your eggs, a safety net that ensures smooth operations even if a component fails.

Redundancy in action

In a chemical plant, redundancy means having backup systems in place for critical functions. These could be:

Backup pumps: If a pump malfunctions, a secondary one kicks in to keep the flow of chemicals uninterrupted.
Secondary containment: In case of a leak, a secondary wall or structure prevents environmental contamination.
Dual control panels: Having two control panels allows operators to maintain control even if one system fails.

Redundancy isn't just about safety, it's about efficiency too. A single equipment failure can halt production, costing time and money. Redundant systems minimise downtime, keeping your plant running smoothly.

However, just like our overflowing basket of eggs, redundancy isn't without its challenges. Building and maintaining these extra systems adds to the initial investment in the plant and increases ongoing operational costs. Additionally, managing multiple systems requires careful planning and skilled personnel to ensure everything functions seamlessly.

The key lies in finding the right balance. Critical processes might require extensive redundancy, while less vital functions could benefit from a simpler approach. This is where a design engineer can be worth their weight in gold on a project. An experienced engineer will be able to carefully evaluate risks and costs to determine the optimal level of redundancy for each system.

If you're interested in finding out more about specific redundancy systems used in chemical plants or best practices for implementing redundancy, feel free to get in touch with one of our engineers today at enquiries@ohare-eng.co.uk.

What does generative AI mean for the future of piping design?

Wed, 28 Feb 2024 17:41:44 GMT

What does generative AI mean for the future of piping design?

Date: 28th February 2024

The UK chemical industry is facing a lot of pressure from a lot of different angles at the moment. From growing concerns about making greener and more sustainable practices a business essential, to stricter safety regulations tightening the reins on operations, it's becoming clear that those who can't adapt will have to be left behind.

And those adaptive practices don’t just have to be internal.

At times, like this, when changed on the horizon, innovation becomes more than just a company value. It becomes a necessity.

The trouble is that applying new technologies to existing sites, operations and industries can be a bit of a minefield. It can be difficult to know what’s just a fad and what's actually going to bring real value to your site.

And, at the moment, one of the biggest buzz words in engineering design is ‘generative AI’. But what actually is generative AI? And what does it mean for the chemical industry?

What is generative AI?

Generative AI is a form of artificial intelligence that focuses on creating new content, like text, images, or code, instead of just analysing the existing data. Think of it like a highly creative problem solver. Trained on massive datasets, it can generate new designs based on specific criteria and constraints.

In the piping design specifically, this can be used for:

Automating pipe routing and layout: Generative AI can be used to create different options for pipe routing, considering factors like shortest distance, minimal bends, and avoiding obstacles. This can significantly reduce design time and improve layout efficiency.

Material selection and specification: AI can analyse various processes and recommend the most suitable piping materials based on factors like pressure, temperature, and compatibility with the chemicals being transported.

Pipe stress analysis: Generative AI can be used to perform complex stress analysis on piping systems, considering factors like thermal expansion, pressure fluctuations, and support locations. This can help identify potential weak points and ensure the safety and reliability of the piping system.

Create basic 3D models based upon existing point cloud data. Given existing data or point clouds from 3D scans, generative AI can automatically create 3D models of the piping systems in your plant which can then be built on.

As with every emerging technology though, it comes with both its benefits and its considerations.

What are the benefits of generative AI for UK chemical plants?

By automating repetitive tasks and generating optimised layouts and materials selection, generative AI can reduce design time, minimise material usage, and lead to cost savings and faster project completion. Additionally, the creation of accurate 3D models and visualisations allows for a deeper understanding of complex systems, so that safer maintenance and operation can take place in compliance with UK Health and Safety Executive (HSE) regulations.

Generative AI can also optimise piping systems for optimal flow, pressure distribution, and heat transfer, leading to improved plant performance and reduced energy consumption. This allows for more innovation and customisation by generating multiple design options that can be tailored to specific needs while adhering to UK regulations, ensuring both compliance and optimal performance.

Key considerations when using generative AI (or AI in general)

While generative AI holds a lot of potential for piping design, it's important to bear in mind a couple of key considerations when using this technology.

For starters, relying on AI without any human input can create some ethical concerns, as crucial decisions regarding safety and regulatory compliance ultimately require the expertise of skilled engineers. Using this technology as a starting point is fine (if not sometimes encouraged), but no designs should be finalised without being thoroughly checked by an expert. The problem is that, if things go wrong, it's hard to hold a system accountable. Without transparency, it's difficult to pinpoint where an error occurred, whether it was due to the data, the model's design, or its implementation. This lack of accountability can have serious consequences in safety-critical domains.

This is why data quality also plays a crucial role and should not be overlooked in the design process. The quality of generated designs hinges on the quality of the training data used. Any biases in the data (no matter how minor) can translate to biased designs, meaning that careful selection and curation of training data is essential.

While still in its early stages, generative AI is rapidly evolving. By embracing this technology responsibly, UK chemical plants can unlock a future of safer, more efficient, and sustainable operations. Remember, AI is a tool, not a replacement for human expertise. The key lies in harnessing its power responsibly and collaboratively, paving the way for a brighter future for the UK chemical industry.

If you’d like to explore your engineering design options further, get in touch with us today at enquiries@ohare-eng.co.uk .

Plant 3D vs. E3D: Choosing the Right Piping Design Software for Your Project

Mon, 29 Jan 2024 08:00:00 GMT

Plant 3D vs. E3D: Choosing the Right Piping Design Software for Your Project

Date: 29th January 2024

Precision, efficiency, collaboration – they’re arguably the engineering trifecta of piping design.

Whether you're tackling a maze of pipework within a nuclear power or chemical plant, or are working on a smaller scale maintenance project in oil & gas, choosing the right software can be the difference between success and the whole project being a total headache. And currently, there are two key players in the piping software game: AutoCAD Plant 3D and AVEVA E3D design (previously AVEVA PDMS).

So, when it comes to choosing between these powerhouses, what are the benefits that might sway you one way or the other?

E3D: The Industry Titan

Think nuclear reactors and sprawling refineries – that's where E3D is in its element, leading the industry standard for large-scale projects. Its strengths lie in its unmatched ability to handle vast, intricate layouts, seamlessly accommodating collaboration between large teams. However, its hefty price tag, not to mention the additional "bolt-on" costs – means that it is considered more of a niche software. This has also led to a decline in popularity in the oil and gas sector, where more agile alternatives are seeming to be more in favour.

Plant 3D: The Workhorse

While a notably smaller price tag makes Plant 3D a more affordable option, its strengths extend far beyond cost. It excels in plant layout and piping design, and is one of the easier softwares to integrate with tools like laser scanners and Inventor (making it perfect for skid fabrication and vessel design). Just like E3D, Plant 3D allows multiple designers to work together on a project, however, it's essential to have a vigilant administrator ensuring its smooth operation and compliance with piping specifications.

Choosing Your Weapon

The choice between Plant 3D and E3D boils down to your project's unique needs and constraints. For example, you’ll want to consider:

Project Size and Complexity: For multi-million pound projects with large sites and large teams, E3D's technical arsenal may be worth the investment.
Budget: For smaller, cost-sensitive projects, Plant 3D's affordability and workflow efficiency shine.
Industry: This one isn’t set in stone, but generally, E3D reigns supreme in the nuclear industry due to the much larger scale of the site and budget. Previously, it was common to see this used in the oil and gas sectors too but we’re currently seeing more of a shift in these industries toward Plant 3D.
Futureproofing: There are currently a couple of other softwares creeping their way into the market. Emerging contenders like Smart Plant 3D and (strangely) Inventor are also offering a lot of features and bolt-ons to streamline the piping design process. In our opinion, they aren’t currently considered competitors of Plant 3D and E3D, but they’re definitely ones to watch for smaller projects.

Remember, your software is just a tool, a powerful one yes, but ultimately, it's the designer's skill and vision that determine the success of the project.

To find out more about how we can assist with your next project, drop us an email at enquiries@ohare-eng.co.uk .

A Workshop in Need of Optimisation

Thu, 14 Dec 2023 09:34:48 GMT

A Workshop in Need of Optimisation

Date: 14th December 2023

As Christmas Day approaches, children worldwide eagerly await the arrival of Santa and his sleigh overflowing with presents. But behind Santa and his reindeer, lies a hidden world of innovation and engineering: Santa's Workshop.

Every December, the elves at Santa's Workshop enter a state of frenzied activity. With an estimated 2.2 billion children eagerly awaiting their gifts, the pressure is on to finish building and wrapping an astonishing 6,043,956 toys every single day!

To put that into perspective;

According to their LinkedIn profile, Hovis bake and deliver around 1.3 million loaves of bread per day.
Nestle produces around 4.5 million KitKats per day.
And Lego produces around 164 million bricks per day which, on average, comes to about 600,000 sets per day.

So, what Santa and his elves are doing is no mean feat! And that’s assuming that every child in the world only gets 1 present per year in their stockings.

A Workshop in Need of Optimisation

Even Santa's Workshop - the absolute hub of Christmas magic that it is - isn’t immune to the wear and tear of time. Over the years, machinery will need to be repaired and replaced, production lines will need upgrades to integrate new technologies, and the workshop itself could potentially need to expand to meet growing demand for billions of presents every year.

In recent years, 3D laser scanning and mechanical design have emerged as powerful tools for optimising industrial processes and enhancing the efficiency of manufacturing facilities. In addition to the magic, these technologies can be applied to the Santa's Workshop to transform its operations, ensuring that the spirit of Christmas continues to spread joy and wonder to children worldwide.

Capturing Santa's Workshop

By 3D laser scanning Santa's Workshop, we can create a detailed 3D model of the entire facility, including its intricate layout, machinery, and production lines. This digital representation serves as a valuable blueprint for understanding the workshop's structure, identifying potential areas for improvement, and planning for future expansion.

Optimising and Maintaining Santa's Workshop Equipment

Once we have a 3D model of Santa's Workshop, we can use mechanical design software to analyse and optimise its machinery, production lines, and logistics systems. This software allows our engineers to visualise, simulate, and test different layouts to identify and eliminate inefficiencies, minimise waste, and enhance overall production efficiency so we can get those elves some more well deserved holidays!

Expanding Santa's Workshop

As the number of children receiving Christmas gifts continues to grow, Santa's Workshop faces the challenge of expanding its production capacity while maintaining its charm. After all, a huge modern factory wouldn’t look quite as good in all the movies! 3D laser scanning and mechanical design play an important role in this process. By analysing the 3D model of the workshop, engineers can pinpoint areas for expansion, optimise floor plans, and design new machinery and production lines that seamlessly integrate with the existing infrastructure.

Making Sure the Workshop Runs Smoothly Year-Round

Regular maintenance is essential for keeping Santa's Workshop in top condition and ensuring that it can operate efficiently throughout the year. By using his 3D laser scan data to create an intelligent P&ID, Santa will have easy access to all the information he could ever need for a piece of equipment, detailed maintenance plans and visibility of potential hazards at his fingertips. This allows him to schedule maintenance and repairs before they disrupt production. This proactive approach helps to maintain the workshop's reliability and efficiency, ensuring that Santa can deliver presents to children on time, every year, without fail.

3D laser scanning and mechanical design are not just tools for optimising industrial processes; they are also tools for unlocking the magic of Santa's Workshop. By using these technologies to streamline the production process, Santa and his elves can focus on their most important task: spreading joy and wonder.

How can laser scanning and design engineering be used for site maintenance on chemical plants over the quiet season?

Tue, 28 Nov 2023 15:59:58 GMT

How can laser scanning and design engineering be used for site maintenance on chemical plants over the quiet season?

Date: 28th November 2023

Is your site getting a Christmas break too?

Chemical plants are complex facilities that require regular maintenance to ensure their safe and efficient operation - you don't need me to tell you that! But often, during quiet seasons when lots of your staff are off (like Christmas) and production is reduced or halted, is an opportune time to conduct more extensive maintenance activities.

Having this proactive approach to maintenance allows for thorough inspections, repairs, and upgrades that might not be feasible during peak production periods. By addressing potential issues during these quieter times, chemical plants can optimise their operations, minimise downtime, and enhance safety throughout the year.

But, when you think of site maintenance, laser scanning and design engineering aren’t often the first thing that springs to mind…

That’s because, when we think of maintenance, we often think of the potential risks that are already known to us. Maybe there’s a specific section of pipework that’s in need of replacement, or a machine that is essential to business that always gets the bulk of your attention and budget. It might also feel a bit like overkill if you’re just thinking about each project individually and on a short term basis.

When you’re thinking of maintenance on a site wide scale and improving the longevity and management of maintenance documentation though, laser scanning comes into its own. It provides precise and detailed 3D models of plant infrastructure, enabling comprehensive inspections and accurate assessments of potential problems. This detailed information forms the foundation for efficient maintenance planning, allowing for targeted interventions and resource allocation. Design engineering further complements this process, utilising the laser scan data to create optimised maintenance plans, tailored to the specific needs of the plant. By integrating these two tools into your maintenance strategy, chemical plants can maximise the benefits of quiet seasons, ensuring optimal performance and safety throughout the year. And here’s how…

Create accurate as-built models

Laser scanning is the ideal tool to capture detailed 3D representations of chemical plant structures, equipment, and piping systems. These as-built models give you a precise representation of the current site or an area of the shop floor which can replace outdated or inaccurate drawings to help you make more informed decisions about site improvement and development. These are particularly useful if, like a lot of chemical plants, you’re looking to expand and start taking steps towards net zero goals (read more about this here ) in the new year. With accurate 3D models of your existing facilities as a reference it will be easier to see which modifications are possible with your current set up and where further development is required so you can budget and plan ahead.

Identify potential hazards

3D laser scanning can reveal hidden or obscure areas that may pose potential safety hazards, such as structural damage, corrosion, or leaks. This information can be used to schedule preventive maintenance or repairs and reduce safety risks on site. Laser scans also provide precise measurements of structural components, which allows engineers to assess their integrity and identify areas that require reinforcement or repair. This can prevent structural collapses and ensure the overall safety of the plant.

Plan and optimise maintenance activities

Laser scanning data can be used to develop detailed maintenance plans that account for the exact locations and conditions of equipment and piping. This ensures that maintenance crews can work efficiently and effectively, reducing downtime and improving plant reliability. By analysing 3D laser scans, engineers can identify early signs of wear and tear on equipment, allowing for proactive maintenance and replacement before failures occur. This can prevent costly downtime and production disruptions.

Investigate accident or incident sites

In the event of accidents or incidents, laser scanning can accurately capture the scene, documenting the extent of damage and providing valuable information for investigations and insurance claims. They can capture intricate details that might be overlooked by traditional methods, such as photography or manual measurements as well as produce highly accurate measurements of the scene, providing investigators with precise dimensions and distances. This information is essential to look at the scene from multiple angles to determine the exact location of objects, the extent of damage, and the trajectory of events. This is especially essential on sites where hazardous chemicals and materials are present as it can be used to inform future preventative measures.

Develop virtual reality training modules

Laser scanning is an invaluable tool for creating immersive virtual reality (VR) training modules for chemical plant workers. By capturing precise 3D models of plant environments, VR trainers can simulate hazardous situations without putting trainees at risk. Additionally, interactive scenarios can be designed to enhance critical thinking and problem-solving skills. Data collected from these training modules can provide valuable feedback for improving training effectiveness. This innovative approach to training has the potential to significantly enhance safety, efficiency, and preparedness in chemical plant operations.

Support future asset management

Laser scanning data can be used to create and integrate intelligent P&IDs (piping and instrumentation diagrams) into a comprehensive asset management system, providing a centralised repository of crucial information for the entire life cycle of chemical plant assets. This includes their location, condition, and maintenance history. This information can be used to make informed decisions about maintenance, replacement, and decommissioning. Intelligent P&IDs can also be used to track changes to the plant's assets over time, which can help to identify potential problems before they occur. Additionally, they can be used to improve communication and collaboration between different departments involved in the asset management process.

Both of these methods offer a comprehensive and efficient approach to chemical plant maintenance. By providing accurate 3D models, identifying potential hazards, optimising maintenance activities, investigating accidents, developing virtual reality training modules, and supporting future asset management, these tools can significantly enhance safety, efficiency, and productivity in chemical plant operations. If you have any questions or would like to discuss your site maintenance needs further, drop us an email at enquiries@ohare-eng.co.uk .

Why are lots of chemical plants in the UK converting to hydrogen?

Mon, 23 Oct 2023 16:20:57 GMT

Why are lots of chemical plants in the UK converting to hydrogen?

Date: 23th October 2023

When you think of chemical plants, ‘sustainable’ and ‘low carbon’ aren't usually the first words that come to mind.

In 2021, the chemical industry accounted for around 10% of the UK's total greenhouse gas emissions. But, with the UK's new net zero targets coming into play, many chemical plants are having to make the move towards carbon neutrality, with many opting to make the switch to hydrogen.

There are a number of reasons why chemical plants are converting to hydrogen. The first being that hydrogen is a clean-burning fuel that produces only water vapour when combusted. This makes it an ideal replacement for fossil fuels as it’s a way to reduce their carbon footprint and meet the UK's net zero targets. It’s also more efficient fuel than fossil fuels, so can help to reduce operating costs by extracting more energy from the same quantity and can be used for a variety of purposes in chemical plants, such as generating power, producing steam, and feedstock for chemical processes.

That being said, the overall ‘greenness’ of these sites is directly impacted by the types of hydrogen they are using and in some cases producing.

What are the different types of hydrogen?

There are a number of different types of hydrogen, each with its own environmental impact. The three main types of hydrogen are:

Grey hydrogen: which is produced from fossil fuels, like natural gas or coal. This is the most common type of hydrogen produced today but it also has the highest carbon footprint.
Blue hydrogen: Blue hydrogen is also produced from fossil fuels, but the carbon dioxide emissions are captured and stored. This is a cleaner way to produce hydrogen than grey hydrogen, but it’s more expensive.
Green hydrogen: Green hydrogen is produced from water using renewable energy sources, such as solar and wind power. This is the cleanest type of hydrogen, but it’s also by far the most expensive.

As well as these, there are also a lot of emerging sources of hydrogen that are being developed or are in use in small quantities. These include:

Pink hydrogen: Pink hydrogen is produced using nuclear power. It is a low-carbon option, but it has the potential to produce radioactive waste.
Black and brown hydrogen: Black and brown hydrogen are produced from coal and biomass, respectively and have a higher carbon footprint than grey hydrogen.
Turquoise hydrogen: Turquoise hydrogen is produced from methane using a molten metal pyrolysis process. It is a low-carbon option, but it is still in the early stages of development.
White hydrogen: White hydrogen is naturally occurring geological hydrogen found in underground deposits. It is still in the early stages of development.

The categories of hydrogen used by UK chemical plants depends on a number of factors, including the availability of renewable energy sources, the cost of hydrogen production, and the specific needs of the chemical process.

Currently, the majority of hydrogen used by UK chemical plants is grey hydrogen. However, many plants are starting the movement towards lower-carbon alternatives like blue and green hydrogen.

What changes to infrastructure will be required for the switch to hydrogen in the UK?

One of the main challenges chemical plants and other industrial facilities face is the need to modify their existing equipment to use hydrogen. Hydrogen has different properties to natural gas, so it can cause problems with some materials used in the existing infrastructure. For example, hydrogen can make steel pipes brittle, making them more likely to crack.

On a larger scale, there are some specific examples of the infrastructure changes that will be required for the switch to hydrogen in the UK including the introduction of a nationwide hydrogen pipeline network, storage facilities, refuelling stations and hydrogen safety systems.

The UK government is working with industry to develop standards and regulations for the use of hydrogen. The government is also providing financial support for hydrogen projects, such as the HyNet project in the North West of England and the Acorn CCS project in Scotland.

The switch to hydrogen in the UK chemical industry is still in its early stages, but a number of major chemical companies have announced plans to convert their plants to hydrogen by 2050. The UK government is also providing financial support for lots of these projects including the development of new hydrogen production technologies, such as turquoise hydrogen.

If you’re part of a transformation project and would like to find out more about how your site could be adapted to support hydrogen usage, get in touch with us today.

Training your team vs. hiring an expert: Which is the best option for piping challenges and design?

Thu, 28 Sep 2023 07:00:00 GMT

Training your team vs. hiring an expert: Which is the best option for piping challenges and design?

Date: 28th September 2023

“Should I outsource this or is there someone internally we can train up?”

It's a question most project managers have asked themselves, especially on projects with a large team behind you. Sure, factors like…

What's the project's budget?

How long do you have to get this stage of the project done (i.e. are you planning this ahead of time or is it a last minute problem that needs solving)?

Who’s available to do the work?

… will always play a role in which option you choose. But, when you’re working on a large site like a chemical, energy or power plant, relying on these factors alone won't always give you a clear answer or direction. So what are the pros and cons of training up your team vs. bringing in the experts? And what other key considerations should you be taking into account?

The Pros & Cons of Training Your Internal Engineers in Piping Design

Every skilled engineer and project manager recognizes the value of enhancing their internal team's capabilities. While shadowing experienced team members and self-training in equipment and software are valuable, relying solely on these methods can limit your team's skills pool.

One of the major advantages of training is its cost-effectiveness compared to hiring an expert. Various training options, from online courses to in-person workshops, make it easy to find a solution that aligns with your schedule and budget. However, training does have its drawbacks. Firstly, it can be time-consuming, especially if you're working full-time. Secondly, it may not be as effective as hiring an expert, particularly when delving into unfamiliar topics.

The Pros & Cons of Outsourcing to a Piping Design Engineer

While upskilling your internal team is a valuable approach, sometimes bringing in an external expert can be a more practical solution for some engineering projects.

Bringing in an expert offers several notable benefits. First and foremost, it provides access to a high level of expertise right from the start. Experts bring specialised knowledge and experience that could potentially take years for people who are new to the field to learn. They can tackle complex tasks with precision, reducing the risk of errors and ensuring a successful outcome. Experienced professionals are also more used to the intricacies of their field, which often translates into quicker problem-solving and efficient project management. This can be particularly beneficial for time-sensitive projects.

However, there are some drawbacks to consider when opting for external expertise. One significant concern is cost. Hiring an expert, especially one with a strong track record, can be expensive. This cost may outweigh the benefits if the project is relatively straightforward and can be handled by an internal team with the right training. Also, your chosen experts may not always be readily available, and their schedules may not align with your project timeline which can create delays or require adjustments to your project plan.

Key Considerations…

There’s rarely a right or a wrong answer when trying to decide between bringing in an expert or training your team. But, there are some key considerations that will point you in the right direction and make you feel confident in the route you choose. Here are some factors to keep in mind:

Its Relevance to the Role: How relevant will this training be to your team's daily or monthly responsibilities? It's most cost-effective when the skills learned are consistently applied within the business, such as advanced software usage directly relevant to their job roles. However, if the skill is needed for a one-time task like software setup and maintenance, then it may be more cost effective to bring in an expert to set you off on the right footing.

Importance of Accuracy: Assess whether the task requires precise execution from the outset. Training can be an effective way to ensure accuracy, but it depends on the specific circumstances. Do you need it to be right the first time around? Do you have the wiggle room if something were to not go as expected? Some projects just don’t have the time, budget or flexibility to be used as a potential training exercise. There will always be opportunities down the road, but if you need a job done right, then outsourcing the tasks to an experienced expert is how you’ll most likely achieve it.

Staff Turnover: Evaluate your organisation's staff turnover rate. High turnover due to limited growth opportunities may make upskilling your team an appealing option. However, there's a risk that invested time and resources may go to waste if employees leave shortly after training, taking their acquired skills with them.

Selecting Participants: Be strategic about who you send for training. Avoid the common mistake of sending everyone or the entire team for training simply because it "would be good to know." Tailor training opportunities to employees' experience levels and job requirements. Sending a long-term employee who regularly uses specific software for an advanced training day can yield more benefits than sending an apprentice unfamiliar with the software.

By carefully considering these factors, you can make informed decisions about whether to invest in training your team or hiring an expert. If you’d like to talk more about your options though, get in touch - we’d be happy to talk through it with you.

HOW USEFUL IS AERIAL LASER SCANNING IN CHEMICAL PLANT SURVEYING?

Thu, 17 Aug 2023 10:40:56 GMT

HOW USEFUL IS AERIAL LASER SCANNING IN CHEMICAL PLANT SURVEYING?

Date: 17th August 2023

In the world of site surveying, the evolution of technology has given rise to innovative methods that redefine precision and efficiency. While handheld and tripod-mounted scanners have long been the norm, recent advances in technology have seen aerial drones and vehicle-mounted scanners altering landscapes across industries, particularly construction.

So, this beckons the question: Do aerial and vehicle-mounted scanners have a place in modern surveying of complex confines of chemical plants?

While aerial scanning may have some very niche applications on site, like surveying external aspects that stretch vast distances such as pipework connections between sites, the risks it poses on site still currently outweigh the benefits.

What are the on site limitations of drone and vehicle mounted scanners?

When undertaking a large scale site surveying project, the allure of drone and vehicle mounted scanners is undeniable. However, their adoption within industrial sites introduces a host of practical challenges that warrant careful examination.

Added complexity and limited range

Whether you’re using a drone or vehicle mounted device, you need to be able to move the scanner to specific and sometimes difficult to reach locations. In order to do this you can either have one person controlling the vehicle with a remote control, or you can have an autonomous system. This is usually carried out using GPS so that the scanner knows where it is within the environment. Both of these complex processes are made even more complicated when you’re working indoors because of the absence of GPS which means that landmarks or bespoke coordinate systems must be produced to piece together the scan images in the post processing phase of a project. These vehicles also have limited range as they must maintain a constant and stable connection with a control device which can limit the size of the site you’re able to cover autonomously.

Increased risk and regulatory compliance

Whenever you’re using a laser scanning device, there is always the risk of damaging the equipment. But the use of drone and vehicle mounted scanners introduce additional physical risks such as collisions, crashes, and navigational complexities within three-dimensional spaces. Beyond the immediate risk of physical collisions, these airborne platforms pose additional hazards that merit careful consideration. Chemical plants often contain volatile substances, and the dynamic movement of drones and vehicles can disturb these materials, potentially dispersing harmful fumes across the facility. The batteries powering these systems also create a potential threat on site. While modern battery technologies have made significant strides in safety, the dynamic and potentially turbulent flight of aerial platforms can increase the likelihood of mechanical stress or impact-induced incidents, potentially leading to sparks or even fires on chemical plants.

Chemical plants are also subject to strict regulations and safety protocols. Introducing drones into these environments might require extensive regulatory approvals and compliance measures, which can be time-consuming and complex.

Data quality and resolution

While drones offer a dynamic vantage point and the capability to capture larger areas in less time than standard methods, they often fall short in meeting the exacting demands of surveying tasks within chemical plants that require detailed images of specific areas.

The accuracy and resolution of data collected by drones can be influenced by several factors. Flight altitude, speed, and sensor specifications all play a key role in determining the level of detail and precision achievable. Chemical plant surveying often requires highly detailed and precise data, especially when assessing intricate pipework networks, equipment installations, or structural integrity. However, the limitations of drone-mounted sensors, including payload constraints and sensor technology, can result in data that doesn't meet requirements.

As technologies like drone and vehicle mounted laser scanning equipment develops, it can be tempting to be swept up in all the hype it generates. But within the promises of emerging technologies often come intricate challenges for chemical plants. Niche applications hint at its potential, but current risks, from technical complexities to safety concerns, present challenges that must be considered. Balancing innovation with practicality within chemical plants requires a meticulous evaluation. If you’re not sure what the best approach to your surveying project is, get in touch with us today to explore your options.

TIME-OF-FLIGHT VS. PHASE-BASED LASER SCANNING: ARE THEY HORSES FOR COURSES?

Tue, 25 Jul 2023 09:27:56 GMT

TIME-OF-FLIGHT VS. PHASE-BASED LASER SCANNING: ARE THEY HORSES FOR COURSES?

Date: 25th July 2023

When I first started working with laser scanning technology (much longer ago than I’d like to admit), there was a really clear choice between using time-of-flight (TOF) or phase-based scanning technology. But, in the rapidly evolving field of 3D laser scanning, is the choice really still that easy? How has 3D laser scanning technology developed over the last few years? And what do you need to consider before using either of these tools?

Time-of-Flight Scanning (TOF)

Time-of-flight scanning, also known as TOF, measures the distance to a specific point by calculating the time it takes for a light signal to travel from the scanner to the object and back. To do this, the laser scanner emits a pulsed light signal and measures the time it takes for the signal to return to the sensor, enabling precise distance calculations.

Phase-Based Scanning

Unlike TOF, phase-based laser scanners produce a constant beam of light into multiple phases to capture the 3D shape of an object. Instead of measuring the time it takes for the light to return, it measures the phase shift of the returning laser's energy to calculate depth information, generating a highly detailed point cloud of the object's surface.

Phase-based scanning is most commonly used for applications like industrial metrology, reverse engineering, and quality control. This is because it’s highly accurate and can capture intricate details and complex surfaces. However, phase-based scanning can be more time-consuming compared to other methods as it requires multiple images from different angles and lots of data processing.

Key considerations when choosing a scanning method

It used to be that you had 2 key considerations that needed to be taken into account when choosing between TOF and phase-based scanning: Time and accuracy.

But, as technology has developed, time has actually become less of a limiting factor when choosing between these 2 methods than it used to be. When I first started working with laser scanners (longer ago than I’d care to admit to), phase-based scanning was most peoples' go to because it was significantly quicker than TOF. At the time, it took around 6 and a half minutes to complete a full scan using phase-based equipment where it would take you nearly 22 minutes to complete that same scan with a TOF scanner. Nowadays though, this time has been massively reduced so both methods take on average 3 minutes to produce a complete scan in one position.

So, that leaves accuracy.

Accuracy is still an important consideration when choosing your laser scanning method and this is because TOF is still notably more accurate than phase-based scanning is. It’s the same difference as you’d see using a sniper rifle compared to a shotgun. With phase-based scanners, you can aim your laser in the general direction, but you have much less control over the exact point you want to as your intended target. Because of this, the accuracy of your scans can be impacted as they tend to produce much more scatter in the final point cloud images.

TOF scanning on the other hand is like using a sniper rifle with a clear target in mind - it’s very precise. This means that the outputs produced are much more accurate and contain far less scatter that needs to be tidied up during post-processing.

In 2023, phase-based and TOF scanning continue to shape the landscape of 3D laser scanning technologies. And, while we’ve been using TOF for the last 10 years now, it has become much more of a case of personal preference rather than there being any significant differences between the technologies.

If you’re thinking of taking on a design project and would like to find out more about how 3D laser scanning could help, get in touch with us today to arrange a free demo.

WHY HAS MY LASER SCANNING EXPERT INCLUDED THESE 3 THINGS IN THEIR RISK ASSESSMENT?

Tue, 20 Jun 2023 16:13:48 GMT

WHY HAS MY LASER SCANNING EXPERT INCLUDED THESE 3 THINGS IN THEIR RISK ASSESSMENT?

Date: 20th June 2023

Is it me, or do risk assessments seem to make even the safest job look as dangerous as scaling Everest?

Laying out every potential risk, from paper cuts to fires and explosions, can feel overwhelming when they’re all laid out in 1 big document. Even just the mention of some of these risks can make them feel far more likely to happen than they are.

So, if the credibility of a risk actually happening is so low, why include certain risks in your risk assessment and method statement? And why are some that you’d expect to see on there not included?

Batteries on PetroChemical Sites

Whichever laser scanner you’re using, it will always provide a risk because the equipment is battery operated. Most laser scanning equipment will use a Lithium Ion (Li-Ion) battery which is not uncommon in households. The risk with using these on sites, like PetroChemical sites, is that they are susceptible to ‘thermal runaway’, which can cause them to overheat, leading to fires and sometimes explosions if you’re within certain environments. This mostly happens if a battery becomes overcharged, is damaged or is exposed to high temperatures which is why there’s so many regulations about transporting them or carrying them in large quantities. Although it is unlikely that this will occur on site, it’s an important risk to take into consideration, especially when working on a high risk site.

Static in ATEX rated zones

An ATEX rated site is one where potentially explosive atmospheres can occur due to the presence of flammable gases, vapours, mists, or combustible dust. They are most commonly found in petrochemical plants, oil refineries, chemical manufacturing facilities, pharmaceutical manufacturing and grain handling facilities and are important to consider when undertaking a 3D laser scanning project. This is because all the different moving parts in the 3D laser scanner can cause friction which can then cause static and a source of ignition in ATEX rated zones. Because of this, a gas sniffing device must be present when using the scanner to mitigate the risk. To put this into perspective, this rule is in place for the same reason that it’s suggested you don’t use your phone in a petrol station.

Eye and skin damage

When I first started out in 3D laser scanning, damage to the human body caused by the laser scanner was a big concern that a lot of project managers were asking about. Nowadays it’s not so commonly asked, but my answer still remains the same. The laser scanners we use are classified for safety purposes based on their potential for causing injury to eyes and skin. The laser scanners we and most laser scanning experts use are Class 1 (in accordance with IEC60825-1 2014), meaning they are safe for both eyes and skin. However, if a person's eyes or skin are exposed to higher-powered lasers (class 4 or above) or focused laser beams used in certain industrial applications, it can lead to burns or other injuries so should definitely be included in a risk assessment and precautionary actions taken.

In reality, the likelihood of a lot of these things happening is relatively low and, because you're not interacting with the thing you’re going to scan itself, you’re just plonking the machine down and letting it do its thing so there’s less risk you’re going to get injured as a result of it. That being said though, it’s important to be aware of the risk so that any precautionary measures can be taken.

If you found this article useful, take a look at our article ‘ What role does 3D laser scanning play in on site health and safety? ’

CHOOSING THE RIGHT 3D SCANNING METHOD: LIDAR OR PHOTOGRAMMETRY

Tue, 30 May 2023 07:00:00 GMT

CHOOSING THE RIGHT 3D SCANNING METHOD: LIDAR OR PHOTOGRAMMETRY

Date: 30th May 2023

No one likes getting part way through a project and realising they’ve taken the wrong approach. It’s costly. It's frustrating. And most of all, starting your project off with the wrong data collection method can feel like a huge waste of time that you just don’t want to go back and redo.

With this in mind, you want to make sure that you’re making the right choice from the start, instead of just pushing through and trying to shoehorn your data into a format that isn’t quite right.

But, is there actually a right and a wrong choice when it comes to choosing between these two scanning methods? And what factors affect their suitability to a chosen project?

Before we’re able to explore this, it’s important to understand exactly what each of these different methods involves. So here goes…

Photogrammetry

Photogrammetry is a 3D imaging technique that captures and analyses multiple 2D photographs of an object or space and layers them to create detailed three-dimensional information from these images. This in turn allows you to create accurate and realistic 3D models.

The process begins by capturing a series of overlapping photographs from different angles around the object or space. The software then analyses the images, identifying common features, patterns, and points of reference. By triangulating the positions of these points across the multiple images, the software can calculate depth and spatial relationships, generating a 3D mesh.

Photogrammetry offers a cost-effective and accessible approach to 3D modelling, as it utilises commonly available camera equipment and software solutions. The resulting models can be further processed, refined, and textured to create highly detailed and accurate real- world representations of objects or environments.

LiDAR

Light Detection and Ranging, or LiDAR, itself refers to the technology that uses laser beams to measure distances and create 3D representations. 3D laser scanning on the other hand, specifically refers to the process of utilising LiDAR to capture highly detailed and accurate 3D data of objects or environments.

In 3D laser scanning, LiDAR is used to emit pulses of light to measure the amount of time it takes for the light to return from a surface within the scanned area to calculate its distance. The system collects millions of data points by scanning the environment from different positions and angles. These data points are then used to form a dense point cloud, which represents the three dimensional spatial coordinates and characteristics of the object or environment. These models can then be used for 3D modelling, visualisations and engineering design.

So which is better?

Well, if you ask me, there's no clear winner in the battle between LiDAR and photogrammetry - it's horses for courses. But there's a number of different factors that determine which option you choose…

Accuracy: If your project requires a high level of accuracy, LiDAR tends to be the preferred option. It provides highly precise distance measurements, making it suitable for applications that demand precise spatial data.
Resolution: Photogrammetry can capture intricate surface details and textures, making it a good choice for projects that require capturing fine features - just look at this .
Range: LiDAR has the advantage of longer range capability, making it suitable for large-scale outdoor scanning or mapping. Photogrammetry is often more suitable for smaller, close-range objects or indoor environments.
Equipment and Budget: Photogrammetry can often be accomplished with standard digital cameras, making it a more accessible and cost-effective option. LiDAR systems typically require specialised equipment, which can be more expensive.
Data Processing: Photogrammetry typically requires significant computational processing power and time to generate accurate 3D models from a large number of images. LiDAR data processing is usually more streamlined, as it directly provides 3D point cloud data.

Carefully evaluating these factors will help determine the most suitable approach for a given application or project. But, if you’d like some help, get in touch.

WHAT DOES A MECHANICAL DESIGNER REQUIRE FROM AN ORGANISATION TO BEGIN A PROJECT?

Thu, 18 May 2023 07:17:48 GMT

WHAT DOES A MECHANICAL DESIGNER REQUIRE FROM AN ORGANISATION TO BEGIN A PROJECT?

Date: 18th May 2023

There’s many reasons why an organisation might be considering bringing in an external consultant on an engineering design project. They might require specialists and expertise that aren’t currently available in-house. Or expensive specialist equipment, like laser scanners, that's cheaper to outsource than buy.

Whatever your reason to outsource this work, there’s one question I hear time and again from potential clients - particularly bigger organisations in the chemical, oil, gas and power sectors. And that is ‘what information are you going to require from me?’

Often, the reason behind this is because they’re concerned that they will need to hand over lot’s of sensitive material about the site or business which can involve a lot of legal documentation and paperwork.

So, this raises the question… What is the bare minimum that a mechanical designer needs to know ahead of beginning a project?

1. Project scope

What are the project requirements, objectives, and goals? In order to provide the best outcomes, a mechanical design engineer needs to understand the solution you’re looking to achieve in order to help you achieve this. We don’t need to know all the details about your wider site, but understanding how you want it to fit into the existing infrastructure and business goals is important.

2. Budget

Hopefully this one won't be too much of a shock to you! Before a designer can start on a project, it's important that they understand the allocated budget to ensure that design decisions are aligned with financial constraints. This doesn’t necessarily need to be set in stone, but shaving a vague idea is important so that an organisation isn’t too shocked by a quote and doesn’t risk a big bill on completion.

3. Technical specifications

One of the most important pieces of information any mechanical designer will request at the start of a project is your P&ID (if you’re not sure what this is, check out this blog from February 2023 ). This document should contain detailed information about pipe size, line number, material, insulation and systems - just to name a few things - that’ll give your designer the technical specifications they need to get started.

4. Communication channels

This probably isn’t something that a designer will directly ask you for, but it's something that will need to be agreed before you get started. Who will your designer be reporting to? And will the organisation have a designated contact who they can call if they have any questions? By having these clear communication channels from the get go, it will ensure that the project progresses smoothly, information is shared as efficiently as possible and any issues are addressed promptly.

By providing these resources and information to the mechanical designer, the organisation can help ensure that the project is completed efficiently and effectively, and meets the organisation's needs and expectations.

If you’re considering starting a mechanical design project and would like to find out more about how we can help, book a free design consultation today using this link .

3 ENGINEERING DESIGN TRENDS THAT AREN’T JUST FADS OR BUZZWORDS

Fri, 28 Apr 2023 08:14:48 GMT

3 ENGINEERING DESIGN TRENDS THAT AREN’T JUST FADS OR BUZZWORDS

Date: 28th April 2023

"It’s just a fad."

"No one will be using or even thinking about that in 6 months time."

These are phrases that most engineers have heard when a new design tool or technique is introduced to the market.

As engineers, it's important to embrace new technologies that can help us work smarter, not harder. However, it's easy to become jaded when new-fangled systems and processes come and go so quickly. So, which 2023 engineering design trends are actually worth your time and energy?

1. Digital Twinning

Digital twinning has massively climbed in popularity in the last year or so. In case you’ve not come across this term yet, digital twinning is the process of creating a virtual replica of a physical asset, system, or process. This technology allows engineers to model and simulate various scenarios as well as test solutions in a virtual environment before implementing them in the physical world. It can be used to identify potential problems and design solutions before a physical prototype is built.

Recent advances in this technology have made it an essential tool for the future of engineering design by making it more accessible and user friendly. The reason that it's one to watch in 2023 is it is making huge advancements in health and safety practices on site as well as improving the efficiency of many on site design procedures and reducing scrap and wasted materials.

2. AI and Machine Learning

Artificial intelligence (AI) and machine learning are making huge waves in nearly every industry sector at the moment, and it appears that a lot of mechanical designers are looking for new innovative ways to use this software to optimise new and existing systems. Although its application isn’t as clear cut as it is in say manufacturing or R&D, 2023 has already seen an increase in uses for AI and machine learning to provide automated solutions in mechanical pipework design. Most notably, this software is being used to support tasks like layout and routing, sizing and selection of components, optimisation of systems and predictive maintenance on site.

This trend does come with a couple of huge watch outs though, especially in its current early stage development. Firstly, these systems seem intelligent (because they are) but they can only work with the data it has and the parameters it’s given. This means that the solutions they provide aren’t always the most realistic, and getting from A to B isn’t always achieved using the most simple or common sense approach.

Secondly, there is the issue of traceability when it comes to using AI within engineering design. Traceability is an important aspect of any design project because it reinforces all design decisions that were made throughout the development process to ensure all quality control, risk management, health and safety, budget and compliance requirements have been met.

Finally, AI algorithms rely on large amounts of data, which can include sensitive or confidential information about the pipework system and/or the organisation that owns it. It is important to ensure that appropriate measures are taken to protect the privacy and security of this data.

3. Sustainable Engineering Design

Sustainable design is a growing trend in engineering. Engineers are increasingly looking for ways to design products and systems that are environmentally friendly and resource-efficient in order to comply with the government's Net Zero targets. Sustainable design can be achieved through a variety of methods, such as using recycled materials, designing for energy efficiency, and reducing waste on site and is an important consideration within most design projects moving forwards.

Engineering design trends are constantly evolving, but these 3 are definitely the ones to watch. Digital twinning, AI and machine learning and sustainable design are all making great strides in improving on site efficiency and safety. By embracing these trends, engineers can future-proof their designs and stay ahead of the curve.

WHAT ROLE DOES 3D LASER SCANNING PLAY IN ON SITE HEALTH AND SAFETY

Thu, 20 Apr 2023 08:00:04 GMT

WHAT ROLE DOES 3D LASER SCANNING PLAY IN ON SITE HEALTH AND SAFETY

Date: 20th April 2023

For many, 3D laser scanning isn’t the first solution they think of when it comes to improving on-site health and safety protocols. And why would they?

On the surface, 3D laser scanning is a tool to help map environments and generate point-cloud models of spaces to plan and design new equipment or improvements to the site. All of these processes fall into the initial planning stages of any design project whereas health and safety should be an ongoing practice in any organisation to ensure that people and the surrounding area are protected from injury, hazards and environmental damage.

But, with its hyper focus on the details within any given space or process, is there a way that 3D laser scanning can be better used within more stages of an engineering design project to improve health and safety on site at each stage of the build?

The short answer is yes, and here’s how…

1. Project planning and preparation

If utilised correctly, 3D laser scanning can be used by project managers, engineering designers and contractors to plan and prepare for works to be done on site more effectively. By having an interactive 3D model of the site ‘as is’, it allows you to identify any potential problems and develop strategies to overcome them before any of the work begins. For example, if you’re planning on connecting a new piece of equipment to an existing pipework system, you can use your scan data to model how this will fit into the existing infrastructure, as well as identify any brackets, valves or pumps which may need to be replaced in order to support this change. This can help to reduce the risk of accidents and injuries on site as, if these problems aren’t addressed, it can cause the system to fail, parts to be broken (especially if it's in a high pressure system) and leaks to occur.

2. On-site maintenance and inspection

Ongoing site maintenance and inspection is something that is always important but rarely feels urgent until something breaks. But, when you don’t prioritise this, you’ll be feeling the impacts of it further down the line.

If you’re not inspecting and maintaining the plant to a certain degree, it can end up costing more money in the long run as you might need to replace more pipework or fix a pump and your inline fittings might now need replacing completely too instead of just maintaining them. By having 3D scan data available, it can be easier to compare the site ‘as is’ to how it was previously by overlaying your most up to date point cloud data over previous imagery to inspect and monitor where wear and tear is happening and maintenance may be required.

3D laser scanning data can also be used to create rendered 3D models of your site where you can embed maintenance information about each piece of equipment into the model to use as a virtual database. You can read more about this in our blog on ‘ How 3D modelling enabled essential plant maintenance on complex sites ’.

3. Training and education

Where pipework and infrastructure isn’t easily accessible, having 3D laser scans of the space or equipment can prove to be an invaluable training tool for new starters, employees and stakeholders alike. This data can not only help to educate employees about the logistics of the site, it can also be used as an immersive training tool to train them to identify potential hazards and learn how to respond to them in a safe way.

Moreover, this can be used to help map an unsafe environment before a person is sent in for maintenance by identifying potential risks and hazards in advance so that precautionary measures can be taken.

4. Quality control

Errors in fabrication can be an expansive mistake for any organisation. They can set projects back by weeks, be expensive to fix and can potentially have huge health and safety implications if something were to go wrong. 3D laser scanning can be used to ensure that any health and safety points have been identified and mitigated in advance as well as to verify that the work is being performed correctly and hasn’t deviated from the plan, meeting the required standards.

If improving your on site health and safety processes is at the top of your agenda at the moment, and you’re looking for a way to futureproof your strategy, get in touch with us today to arrange a free laser scanning demo.

DIGITAL TWINNING: IS IT JUST A NEW NAME FOR AN OLD PROCESS?

Thu, 13 Apr 2023 08:00:09 GMT

DIGITAL TWINNING: IS IT JUST A NEW NAME FOR AN OLD PROCESS?

Date: 13th April 2023

Digital twinning. It’s a term a lot of designers are throwing around at the moment like it's the next big thing. But, actually, this concept of integrating your data within a virtual environment has been around since the early 2000’s under one title or another. First it was intelligent 3D modelling, then Building Information Modelling (BIM), and now, it seems, digital twinning.

With all these new names of course comes an update in digital practices to match the requirements and expectations for modern users. But, at the end of the day, are these new processes and ways of accessing site information any different or are engineers just using this new buzzword to reignite excitement in an existing practice?

So, what exactly is digital twinning?

If you type ‘digital twinning’ into google, the first result you’re given is a definition from Unity which explains that:

“A digital twin is a dynamic virtual copy of a physical asset, process, system or environment that looks like and behaves identically to its real-world counterpart. A digital twin ingests data and replicates processes so you can predict possible performance outcomes and issues that the real-world product might undergo.” ( Unity )

It sounds like something from a sci-fi novel right! But, in actuality, this is basically describing an interactive, virtual replica of your site. As well as detailing the design components of the shop floor and machinery, a digital twin is capable of simulating many of the functionalities of the equipment to model not only how the site fits together, but how it works as a whole and how workers will interact with it. To create a full blown digital twin of your site with all the information you need about your site or chemical plant embedded in it, you need a mix of ‘as-built’ digital modelling and BIM.

Building Information Modelling (BIM)

According to Autodesk, a leader in BIM softwares;

“Building Information Modeling (BIM) is the holistic process of creating and managing information for a built asset. Based on an intelligent model and enabled by a cloud platform, BIM integrates structured, multi-disciplinary data to produce a digital representation of an asset across its lifecycle, from planning and design to construction and operations. ” ( Autodesk )

This means that, like digital twinning, the primary focus of this process is to create a detailed virtual copy of a piece of equipment or site which contains embedded information about how the site works and functions in order to get insights for maintenance or innovation purposes. Although this particular definition of BIM doesn’t specifically detail interactivity and functionality detailing, that doesn’t mean that it’s not possible with this software and hasn’t (or can’t) been used for this purpose by designers. I remember a project I was working on back in 2009 for a chemical processing plant that required these exact specifications.

So, is digital twinning a new thing or a rebrand of an existing process?

There’s no denying that digital twinning and BIM are fundamentally very similar. But, the biggest difference between the two is their capability to simulate core functions within the site. This is most relevant when it comes to how each of these models are used. BIM, for one, focuses on the design and construction of machines and the site as a whole, whereas digital twinning gives you far more information about how the site functions, how components interact with each other and how people interact with the site.

If you’re interested in upgrading your current document management system and integrating it within a virtual model of your site, get in touch with the team today to find out how we can help.

HOW 3D MODELLING ENABLES ESSENTIAL PLANT MAINTENANCE ON COMPLEX SITES

Thu, 30 Mar 2023 08:00:01 GMT

HOW 3D MODELLING ENABLES ESSENTIAL PLANT MAINTENANCE ON COMPLEX SITES

Date: 30th March 2023

It shouldn’t be news to you that maintenance is one of the most important activities you should be investing in. Like with any well oiled machine, keeping up to date on services, inspections and general maintenance is essential to keep things ticking over nicely. And yet, when times get tough and the purse strings start to tighten, maintenance budgets are often one of the first to be impacted in favour of new projects that promise a much faster financial return.

So, with a recession looming, what are the implications of slashing your site maintenance budget first?

Are there ways that technology can help to navigate the impacts of budget changes on site?

And, is there a way to split that budget strategically?

Why aren't maintenance budgets a top priority?

When times are tough, maintenance budgets are often one of the first to be affected. After all, if the site is still functioning well and you’re maintaining business as usual, then the old ‘if it aint broke dont fix it’ rule often comes into play. Why not invest this money into generating new projects and infrastructure to increase your output capacity?

But, what many forget is that, when you cut maintenance funding back all the way to its bare bones thinking that it's not a current priority, you’ll be feeling the impact further down the line…

What’s the impact of not investing in site maintenance?

If you’re not maintaining the plant to a certain degree, small issues have this nasty habit of spiralling into much bigger problems the longer you leave them.

What was initially a dodgy valve or small section of pipework that needed general repairs can quickly escalate into a whole section of pipework, in-line fittings, or a pump that now needs replacing as a knock on effect. If you then add in any additional stresses put on this existing infrastructure through the addition of new systems or increased outputs, the timescales before essential maintenance is required can be hugely reduced.

It’s easy to see how small, seemingly insignificant maintenance tasks that can “wait until there is the time” can end up spiralling. And it’s not just timescales that can be affected. Your costs can also be massively impacted as bigger, more complex repairs and maintenance can incur additional planning, fabrication and consulting costs in a big block sum that could have been easily avoided or mitigated with incremental maintenance.

The same can be said from a health and safety perspective within the organisation. If you’re behind on maintenance and someone gets injured on site, a piece of equipment malfunctions or there's a chemical leak that has an environmental impact, you will be liable - especially if your site, equipment or documentation hasn't been properly maintained.

How can 3D modelling help you use your maintenance budget more strategically?

As you can see, maintenance is important, but it's not always as easy as just looking over the site and inspecting equipment. On complex and large scale sites like chemical and power plants for example, existing infrastructure like pipework and utilities has a tendency to;

Be difficult and/or hazardous to access and inspect

Have unclear records of when every pipe, piece of equipment, valve, etc. is due for inspection and maintenance

Have multiple versions of each piece of documentation

But, by creating an ‘as-built’ virtual database for your site using 3D scanning and modelling techniques like BIM and digital twinning, you can have all of this information and documentation stored in one place which details exactly when your maintenance needs to be done. The knock on effect of this is that, when you know that maintenance work and activities are required, you can more effectively plan your resources, budgets, costs and timescales because you have visibility of when each activity needs to take place. And, when funding is limited, being able to justify and evidence your requirements with your shareholders increases your chances of achieving this funding.

Furthermore, when you have machinery that is regularly maintained to the highest standards you minimise the risk of unforeseen issues and equipment failures which in turn reduces the risk to project schedules and costs.

If you would like to find out more about using interactive 3D modelling to streamline your internal processes, send us an email today at enquiries@ohare-eng.co.uk .

BEHIND THE RENDER: WAYS TO USE POINT CLOUD DATA

Thu, 09 Mar 2023 15:05:53 GMT

BEHIND THE RENDER: WAYS TO USE POINT CLOUD DATA

Date: 9th March 2023

Point clouds. It's not all about building 3D models. So what actually is a point cloud? And what can you do with this data?

What is a point cloud?

When building a 3D image of a site using 3D laser scanning or a photogrammetry software, a point cloud is the point on the surface of an object or environment where your laser or software hits that's captured to create a digital copy. This point is recorded using a cartesian coordinate system, recording each point on a set of X, Y and Z axes. These are then all meshed together during the ‘registration’ phase of a scan to create your 3D image.

So, once you have this data, what are you actually supposed to do with it?

3D Modelling and Visualisations

When we’re talking about point cloud data, this is the first application most engineers will think of. This is because these points create a mesh wire frame for your chosen render to be applied. For many large-scale projects like site modelling for ‘as built’ BIM projects or complex mechanical design builds, creating these models without first having point cloud data to work from can be time consuming and affect the overall accuracy of the work produced.

Site Development and Retrofitting Projects

How many asset-based mechanical design projects, a complete 3D model and visualisation isn’t always required. What is required though, is an accurate representation of the current ‘as built’ conditions of the site so that your design engineer can be sure to work or fit exacting specifications. For many projects, highly accurate point cloud data alone can form enough of a basis to guide in the development of the site, without the additional time or cost that comes with a complete 3D model or visualisation.

This is also true of reverse engineering and retrofitting as the point cloud data allows a designer to overlay project designs over the existing infrastructure to clarify that the design is feasible.

3D Asset Tagging

An integral part of mechanical design currently is the development of business information modelling (BIM) and digital twins. A very simple version of these practices, however, is to use the point cloud data collected about a site and overlaying this on photographs and imagery that is also collected by your laser scanner to embed information about your site. This way you can build up an interactive asset management system that holds all the information and documentation about how the site and equipment functions, as well as P&IDs, manufacturer information, maintenance, and health and safety logs and links them directly to the piece of equipment or point on site they refer to..

Site Verification and Project Tracking

We all know how long some projects can take. Particularly in industries like nuclear and petrochemical, it’s not unheard of that development can take years if not decades to be completed. When this is the case, details can be missed and timescales can drag if careful project management and tracking doesn’t take place. This is where point cloud data can really come into its own and add real value to a project because it can act as a record of progress when collected at key milestones in the build. When compared to previous scans of the build, this data can be used to track changes, monitor progress and highlight any parts or components that are missing by overlaying it onto your designers drawings.

In their own rights point cloud data can be considered a real asset within your business, even before any render or model has been applied. If you’re interested in finding out more about any of these applications, please get in touch with a member of our team today at enquires@ohare-eng.co.uk .

WHY MORE CHEMICAL PLANTS ARE NOW OPTING FOR INTELLIGENT P&IDS

Thu, 02 Mar 2023 12:24:37 GMT

WHY MORE CHEMICAL PLANTS ARE NOW OPTING FOR INTELLIGENT P&IDS

Date: 2nd March 2023

A piping and instrumentation diagram (P&ID) is the document of all documents within a chemical plant. It should always be kept up to date and should hold as much information as possible about the site.

Almost every chemical plant will already have one of these in place for their existing infrastructure, so why are an increasing number of chemical plants now opting for intelligent P&IDs instead of the standard ones?

Before we can answer this, it’s important to quickly clarify what a P&ID actually is…

A P&ID is a detailed 2D CAD diagram of how your existing system works. It doesn’t just look at individual parts, but details how each existing system or any new proposed systems work in relation to the rest of the plant. I go into this in a lot more detail in this blog if you’d like to find out more .

Intelligent P&IDs, on the other hand, build on this existing model to combine your CAD model with your existing database so that you can store more information about the site in the diagram without adding to its complexity. Instead of including all your information in the space around your diagram, an intelligent P&ID embeds the information about a particular part's temperatures, pressures, size, pipe number and so on in the line itself. This means that, when you click on a specific line in the P&ID, it will tell you all the information you need to know about that specific point in the system.

The reason a lot of chemical plants are now opting for these intelligent P&IDs instead of the traditional diagrams is that all the data stored in an intelligent P&ID can be trickled down into a 3D model for ease of use and accessibility throughout the site. Instead of sieving through a load of folders and documents to find a specific piece of part or pipe data from various versions and updated P&IDS of the same individual systems, everything is stored and accessed from one place. All any engineer will need to do is open the 3D model of the full chemical plant, click on the area they want to find out more information about and focus on the part. This is also great for site evaluations as well as on site training and employee inductions.

What other benefits are there to intelligent P&IDs that are causing plants to make the switch?

Although there is quite a lot of initial time and cost involved in the setup of an intelligent P&ID, an increasing number of chemical plants are opting for this option because it means that…

All changes are managed in a single database saving you the time and hassle of rummaging through files and chasing designers for updates.
You have the ability to capture and embed more information within the diagram that you do with a traditional P&ID.
It’s easier to edit and maintain so you always have the most up to date diagram available.
You can be confident that consistent site wide standards are being met and maintained.
An intelligent P&ID can be combined with a digital model of your site to create an interactive digital twin of your site.

If you’re interested in finding out how an intelligent P&ID might benefit your chemical plant, book your free design consultation with us today.

3 CONSIDERATIONS WHEN CREATING AND USING VISUALISATIONS OF COMPLEX ENVIRONMENTS

Wed, 08 Feb 2023 09:11:58 GMT

3 CONSIDERATIONS WHEN CREATING AND USING VISUALISATIONS OF COMPLEX ENVIRONMENTS

Date: 8th February 2023

What do you need to consider before signing on the dotted line?

A visualisation is a valuable tool for many of the organisations I work with - particularly if the project or site they’re working on is highly complex. But, the decision to add a visualisation to your arsenal of tools and documentations is one that often comes with a whole host of questions and considerations. The problem is often knowing where to start.

So, here are 3 things you might want to consider when starting on a large-scale visualisation of a complex environment…

1. For most retrofitting or large scale projects you’re probably going to need 3D laser scan data to work from.

If you’re looking to create the most accurate visualisation of your shop floor or complex environment, you’re going to need an accurate frame of reference to work from. Using 3D laser scan data as your base to build your visualisation from will not only help you to identify the correct layouts, sizing and render as what it was on the day, but will also make the job quicker and easier as you have a frame of reference and aren’t starting from scratch.

It’s important to consider this requirement as, depending on the size of the site you’re looking to create a visualisation of, it can require your designer to be on site for a few days to collect this information.

2. The post processing phase of any internal environment requires a specific site coordinate system rather than GPS coordinates.

Plant design using GPS coordinates just doesn't work… And this is because (as I had it described to me by an IT geek!) AutoCAD Plant 3D works on the same principle as most computers do with computer mathematics. In the same way that your RAM goes up from 2Gb to 4Gb to 8Gb to 16Gb (and so on…) the coordinate systems in AutoCAD do the same. The issue is, when these numbers start getting ridiculous and you start trying to draw a line from A to B, the distance between A and B might end up being 2 metres rather than the 200 millimetres you were trying to achieve. This is because it can't stretch the line beyond its limit and the coordinates have reached the extremes of what the software can accurately process.

So instead, projects like this usually require a site coordinate system based on what you’re trying to achieve so that you can have the most accurate and complete image when it comes to post processing.

3. The gigantic file size of your final visualisation.

It never fails to amaze me quite how big these highly detailed files can turn out. I’ve been caught out enough times to know that this is an important consideration when thinking about a project because it might be that you only actually need a visualisation of a specific area or piece of equipment and a 3D model might be enough for the rest of the site. If you’re not sure which level of detail would best suit your project, have a word with your mechanical designer who will be able to advise.

Visualisations are a useful tool for any engineer looking to relay their ideas to a board of stakeholders or for retrofitting equipment. If you’d like to find out more, drop us an email today at enquiries@ohare-eng.co.uk .

WHAT’S THE DIFFERENCE BETWEEN A P&ID AND PFD?

Wed, 01 Feb 2023 09:00:00 GMT

WHAT’S THE DIFFERENCE BETWEEN A P&ID AND PFD?

Date: 1st February 2023

Process Flow Diagrams (PFD’s) and Piping and Instrumentation Diagrams (P&ID’s) are both process engineering drawings used to explain process information at the design and manufacturing stage of any design project. At first glance, both contain relatively similar information.

So, why do you need both a PFD and a P&ID on a project? What are the differences? And when would you use each diagram within the engineering design process?

What is a Process Flow Diagram (PFD)?

A PFD is a document that is created at the start of the design process to show the equipment required, how everything in the system connects and most importantly indicate the direction of chemical flow. In a PFD, all of this information should be able to be read and understood at a glance.

What are the key components of a PFD?

Every PFD should contain the following information…

Pipe lines which explain the mass, energy balance, flows, temperatures and composition of streams.
Main Equipment

What is a Piping and Instrumentation Diagram (P&ID)?

Where a PFD provides a top level overview of your design, a P&ID will provide a much more detailed diagram of how your system will work and how it will work in relation to the rest of the plant. This is used by design engineers to source materials and map out the route for the proposed pipework to enable accurate and efficient manufacturing of the system.

What should be included in a P&ID?

As a P&ID is far more detailed than a PFD, there are many more components required within the documentation. This includes;

Pipe size, line number, material, insulation
Utility lines, drains and vents
Isolation and shut off valves
Instrumentation and its signalling
Pipe lines which explain the mass, energy balance, flows, temperatures and composition of streams.
Control loops
Isolation and shut off valves
A basic equipment list for the design, such as pumps and heat exchangers.

Why do you need both a PFD and a P&ID on the same project?

Although both of these process engineering design drawings are relatively similar, both are required on a job because they are both required by different people at different stages of the design and manufacturing process. A PFD for example shows how the system will function during operation so will usually be used during the design, proposal and ongoing maintenance phases of any project. A P&ID however shows how the equipment will function and connect within the site as a whole. This is required within the conceptualisation, procurement and manufacturing stages of a design project.

For more information about the process engineering drawing services we can offer, take a look at our mechanical design page or get in touch with us today.

THE IMPORTANCE OF COLLECTING GROUND LEVEL SCANS

Tue, 10 Jan 2023 13:52:20 GMT

THE IMPORTANCE OF COLLECTING GROUND LEVEL FLOOR DATA

Date: 10th January 2023

When was the last time you collected ground level data on a laser scanning project?

For many engineers, it’s something they try to avoid or don’t always consider doing. But, without doing this, data can be missed and the overall quality of your scan can be impacted.

Whether it’s a full site you’re scanning or a particular piece of equipment, a lot of valuable information often sits at ground level, just out of the line of sight. For example, if you’re trying to get a lot of information about the flange formation or the valve holes then you’ll need to get as low as possible as the scanner can only see what you can see in effect.

So, why are people wary of collecting ground level scan data?

Ultimately, it comes down to the engineer. But, some of the more common reasons I’ve heard for not collecting this data include;

Not wanting to put expensive equipment on the ground on a busy site and risk it being broken or damaged.
Being under tight time pressures and not being able to fit these additional scans in.
Scans taken at ground level are less efficient at building a complete image of the site.
Additional post processing time spent removing activity from live sites.
Being limited by line of sight vision so uneven terrain can impact the overall scan quality.

These are all valid concerns when you’re working with expensive and specialist equipment, so is there a way to reduce the risk that ground level scans pose to equipment and data quality?

3 tips for efficient ground level laser scanning…

Scope out the site first to identify safe, level and protected scanning positions that will still enable you to collect all the data you need.
Take ground level scans at the start or the end of the day when there are fewer people around to accidentally damage the equipment or affect the results. Sometimes it’s also worth collecting data outside of the site's working hours (if possible) to reduce traffic on site that might affect scan quality.
Make sure the laser scanner you are using has a suitable angular resolution for the job at hand. This will mean that you can be more efficient with the data you’re collecting.

For more information about our laser scanning processes and what to expect when our engineers are on site, take a look at our 3D laser scanning page or get in touch.

HOW TO PREPARE YOUR SITE FOR 3D MODELLING AND LASER SCANNING WORK

Tue, 20 Dec 2022 16:04:42 GMT

HOW TO PREPARE YOUR SITE FOR 3D MODELLING AND LASER SCANNING WORK

Date: 28th December 2022

This is one of the most common questions I’m asked by clients in initial on site visits…

“Other than a general tidy up, is there anything else we need to do to prep the site before you come in and scan it?”

And the answer to this is no, not unless you want a very specific piece of kit scanned that isn’t currently very accessible.

The reason this seems to be a common question is that, as with any great tool, it’s quite well known that 3D laser scanners have their limitations. The biggest one being their difficulty to scan certain surfaces and environments.

It’s true that dark, shiny and clear surfaces can all cause chaos and scatter within a scan.

So what can be done to minimise the risk and increase the quality of your scan data when working with these materials?

Dark spaces

Getting creative with scanning angles can often be a quick fix when it comes to dark spaces. From certain angles, you can sometimes block or hinder the light, particularly if you’re trying to scan a place with limited access. Putting your scanner on the floor or taking multiple scans of the same space but from different angles can sometimes help overcome any missing data. Adding additional lighting also works but isn’t always possible depending on the space or environment you’re scanning within.

Shiny surfaces

Again, getting creative with your scan angle can help to overcome this laser scanning hurdle. But, if you’re still struggling to reduce scatter in your scan data, other quick wins include adding talcum powder to the surface (if you can) or wrapping the surface in paper. One thing to know about this tip though is that you need to be sure that whatever you’re adding to the surface to dull the reflection does not distort the shape or diameter of the pipework you’re trying to scan.

Clear surfaces

It hopefully won’t come as any surprise to hear that it’s impossible to scan clear surfaces like glass and perspex. These surfaces will simply refract the lasers which will cause distortion and huge amounts of scatter within your scan data. The only way to overcome this is to cover the surfaces with something like paper so that it doesn’t affect the dimensions of your scan too much. We can always add in specific materials when the scan data is being rendered to reflect the correct layout of your site.

These are all very quick solutions to the major scanning limitations. If you’re undergoing a site mapping or engineering design project within a challenging environment and would like some help and advice getting set up, drop us a message.

APPLYING THE 6P‘S TO PREVENT SPEED BUMPS IN YOUR PROJECT

Thu, 10 Nov 2022 19:03:31 GMT

APPLYING THE 6P‘S TO PREVENT SPEED BUMPS IN YOUR PROJECT

Date: 10th November 2022

Prior Planning & Preparation Prevents Poor Performance.

Like many engineers, this is something that has been drilled into me throughout my career. Having a detailed plan of action is an essential part of any project, so carrying out a detailed site visit is key.

There’s nothing worse than hitting speed bump after speed bump, especially if these could have been pre-empted, like:

Accessibility issues when scanning or reaching the intended area or machine.
Times of day where there may be more or less people within the space which might impact the quality of the scan.
Additions to the scope of the project.

When these factors aren’t considered before a project starts, it can have a massive impact on how long the task takes to complete. It can also affect what equipment might be needed, who needs to be involved in the project, the number of scans required, how long it takes to design and how much it’ll all cost.

This is where a site visit becomes the most valuable aspect of any project timeline.

When your surveyor is visiting the site, they won't just be thinking about how long it will take them to get there in the morning and where they might set up their scanner. They will be drawing up a detailed plan of attack, considering;

How many scans will it take to get the best quality point cloud data?
What scan positions might be needed to capture any areas that might not be in the direct line of sight for the scanner?
What’s the best route to take around the site?
Do I need to take into account any roads or other obstacles that might affect the scan quality?
How will this new design fit amongst the current floor plan?
How accessible is the space? Is this design realistic or will other considerations need to be taken into account?
Which 3D laser scanner will be the best fit for this particular job?

Even if they have been to your site before, the requirements for every job will be different so a site visit is never a wasted opportunity. Plus, it will allow them to be as efficient as possible and can prepare for any potential speed bumps ahead of time so that they don’t impact your final timeline or outcome.

If you have any questions about our mechanical design or 3D laser scanning services, get in touch with us today at https://www.ohare-eng.co.uk/contact .

WHAT YOU GET WHEN YOU CHOOSE TO WORK WITH A SMALL ENGINEERING TEAM…

Thu, 27 Oct 2022 10:52:27 GMT

WHAT YOU GET WHEN YOU CHOOSE TO WORK WITH A SMALL ENGINEERING TEAM…

Date: 19th October 2022

It’s a decision nearly every Project Manager has to make in their career…

Do I work with a small, local engineering team or a larger firm?

In today's competitive market, there’s rarely a difference in skills and capability which could sway your decision one way or the other. This means that, often, this decision is based on price and what the organisation has done in the past when they worked with a larger firm.

But, what else do you get when you choose to work with a small engineering team?

1. Shorter communication channels

Communication channels are one of those things that can get very messy very quickly. The fewer points of contact and the simpler you can keep things the better.

When there’s only a few points of contact, like in the diagram below, the paths for communication are very clear and easy to follow.

Communication in a 3-person team.

But, when you increase the number of contacts to, say, 16 these lines become a lot messier…

Communication in a 16-person team.

When you’re working with a smaller engineering team, there are far fewer points of contact within the project, meaning that communication is much tighter. This makes it far easier to ensure that everyone involved is on the same page, clear about what their role is and who the best person to contact is depending on the situation.

2. Less wasted design time

Although it is great to have a lot of different perspectives available during the design phase of a project, there is a point where all these different ideas become overwhelming and actually begin to slow down progress. Having one designer (or a small number of designers) on your team will not only mean that they are committing all of their time and focus to your project, but also that they’re only following one set of instructions, so they are much clearer on the brief. This reduces the amount of time they waste on designs that don't match your brief exactly.

3. Fewer errors down the line

I’ve worked on engineering design projects before where there have been so many people involved in a project that it’s unclear exactly who is responsible for which aspect of the design. Often, this means that later down the line, fabricators have taken it upon themselves to make ‘executive’ decisions about the build. Even small changes, if not considered as part of the bigger picture, can add unexpected knock-on effects and costs, cause the project to fail unnecessarily or set the project back to the start if a redesign is needed to fit the new requirements.

This scenario is far more likely to occur when your team is passed from pillar to post when they have questions or ideas about the design. Working with a smaller design team creates far more opportunities for relationships and trust to be built within the team much earlier on in the project. This means that fabricators and project managers are far more likely to know who to come to with questions regarding design intent.

4. More flexibility in the design process

No project ever looks the same at the end as you imagined it to be. There’s always new ideas, workarounds and tweaks that need to be made because they are more desirable. This means that, when choosing your design team, you want to factor in their ability to be flexible around the brief and, again, this is much easier with a smaller team.

That isn’t me saying that a large engineering team won’t deliver what you require at the end of a project. However, with a smaller team, the consolidated communication channels, the flow of information is streamlined and therefore any changes you require can be discussed and approved in a much timelier manner. As a result, there is further opportunity to develop your ideas and make amendments as you go, while minimising additional costs.

There are plenty of considerations to take into account when starting a mechanical design project. If you’re interested to find out what our engineering team could bring to your project, book a free design consultation with us today so we can answer any questions.

HOW 3D MODELLING AND VISUALISATIONS CAN HELP REDUCE ERRORS IN FABRICATION

Tue, 20 Sep 2022 07:58:17 GMT

HOW 3D MODELLING AND VISUALISATIONS CAN HELP REDUCE ERRORS IN FABRICATION

Date: 20th September 2022

Errors in fabrication can be an expensive mistake for any organisation, so finding ways to mitigate these risks is important.

3D modelling and visualisations aren’t always the first option which springs to mind in the design phase of any fabrication project, but the benefits of doing so can include…

Ensuring that all questions and concerns about the design are considered and addressed before investing in fabrication
Ensuring all health and safety points have been considered and mitigated in advance
Reductions in waste fabrication materials from redesigns and breakages
Less time and money wasted on projects that are bound to fail in the first 10 minutes due to oversights

So, how is this possible?

Creating assembly drawings instead of single parts.

One of the biggest advantages of using 3D modelling and visualisations in your design process is that, instead of creating single parts you can create assembly drawings. These allow you to carry out interference testing of the design to confirm that it will fit into its designated space on the shop floor around existing equipment. This means that any problems are identified way in advance to reduce the need for redesigns and ad hoc changes when the fabrication is being installed.

Assigning parts materials in advance of fabrication.

Assigning your design the correct materials during the design process isn’t just used to make it look smart. It can also be used to calculate the estimated weights of each part and of the design to aid in transportation and manoeuvrability. This is also important from a health and safety perspective as it ensures you can arrange for any required equipment to be available to aid in the installation of parts.

Stress testing

The software we used to create visualisations is also a really useful tool when it comes to testing the feasibility of designs. Once they have been assigned a material, parts like brackets and even the intervals between the brackets can be stress tested to;

a) Check that the assigned materials are strong enough to deal with the stress and pressure put upon them.

b) Reduce material fatigue.

c) Avoid wasted time, money and effort further down the line to fix breakages or damages.

Preparing for logistical challenges that could prove expensive mistakes.

Can you get a welding head into that specific radius? Do you have the machines available to produce this design or will additional budget be required to fabricate this? Can this design be fabricated and built on site or will it need to be outsourced and transported? These are all important questions that come with huge cost and material repercussions if you get it wrong. 3D modelling and visualisation has the capability to give you clarity on all of these points, reducing fabrication errors further down the road.

If you would like to find out more about how 3D modelling and visualisations could benefit your next design project, book a free design consultation with us today.

3 USES FOR 3D LASER SCANNING YOU MIGHT NOT HAVE CONSIDERED BEFORE…

Tue, 06 Sep 2022 10:00:00 GMT

3 USES FOR 3D LASER SCANNING YOU MIGHT NOT HAVE CONSIDERED BEFORE…

Date: 6th September 2022

3D laser scanning is a useful tool for any Project Manager to have in their arsenal. But very few are aware of the full capabilities of this piece of equipment. As well as creating a highly accurate image of your site, these scans have a huge variety of uses that might benefit your next engineering design project.

Here are 3 uses for 3D laser scanning you might not have considered before…

1. Early doors design staging

At the beginning of any design project, ensuring that everyone on site, from your fabricators to your shareholders, are on the same page can be a challenge in itself.

Using a 3D model in the early stages of a build to identify bits of equipment, model new or upgrade existing equipment and sanity check how each piece will fit among the existing set up, is a great way to overcome this challenge.

A lot of organisations don't consider 3D scanning and modelling for this purpose as internal designers know the site and have a vague idea of sizing and layout in their heads and from photographs. Problems arise when it comes to communicating design intent with the design team, fabrications team and construction team who don't have this specialist site knowledge. A 3D model is a great way to get everyone onboard with the project in a way that will also save time in the long run as it will mean less questions will be passed back and forth during the construction phase.

2. Reverse engineering a design projec t

We don’t like to think about when things go wrong in our organisations. But the reality of the situation is that it does happen. Equipment does break, it corrodes and comes to the end of its warranty and when this happens, it needs to be replaced. If you don't have the original drawings though, it can feel like a mammoth task to manually reverse engineer each part in question.

Using a laser scanner to aid in this reverse engineering process is a much faster and more accurate solution that’s often overlooked. Creating a scan of each individual piece or the site as a whole, will help to ensure that;

The replacements match design specifications exactly
Fabricators are working to the same specifications
Any damages or weaknesses are identified and addressed before fabrication begins
Drawings are up to date and on file for use in future design projects or site moves

3. Virtual workshop

There’s currently a lot of excitement around the idea of ‘digital twinning’ within the engineering sector. But being able to create a digital representation of a piece of equipment, system or site and aligning this with your document control processes has been achievable with 3D laser scanning technology for a good few years now.

By using your scan images to create a virtual shop floor, you can then link all your files and data to each piece of equipment and its position on site. This can include information like when it was installed, how much it cost, who the manufacturer was, the date it was commissioned, the equipment's last service log and any pipework or add ons that might be tied into it. I’ve previously written about why good document control is so important, but having all of this information in a virtual 3D database helps to avoid confusion, prevents information from getting lost and makes sure that everyone has access to the same and most up to date drawings and documentation.

If you hadn’t considered any of these options before but are interested in finding out how 3D laser scanning could help in your organisation, get in touch with us today. We’d be happy to answer any questions you have and even offer a free laser scanning demo if you're interested in seeing the scanner in action.

HOW TO SPOT AN EXPERT FROM A YES MAN: 3 QUESTIONS TO ASK WHEN CHOOSING A LASER SCANNING SURVEYOR

Tue, 23 Aug 2022 10:00:05 GMT

HOW TO SPOT AN EXPERT FROM A YES MAN: 3 QUESTIONS TO ASK WHEN CHOOSING A LASER SCANNING SURVEYOR

Date: 23rd August 2022

There’s nothing worse than getting a couple of months into a job and realising the person you’ve hired is a yes man. They seemed to say all the right things in the initial consultation, but now they’re on site they just aren’t matching up to expectations.

So, is there a way to separate the yes men from the experts in their field?

Yes! And these 3 simple questions will help you do just that…

Question 1: Which scanner are you thinking of using for this job?

Questions around equipment, accuracy and range are always a great way to tell a yes man apart from someone who is experienced in the field. No industry expert will get frustrated with you showing a genuine interest in the job and the equipment. Plus, it’s an easy way to spot whether someones syphoning back to you what they’ve read on the box and someone who’s really considered the job at hand.

A few weeks back, I was asked near enough this exact question from a potential client during their initial site visit. I was thinking of using either the P40 or P50 LEICA based scanner even though it is slower, it's far more accurate at a longer range than the RTC360 (a possible alternative I'd considered before arriving on site) which is a shorter range scanner.

If a surveyor can’t explain these initial considerations, then there’s the potential that the work they produce at the end of the job won't be as accurate as it could be.

Q2 - How long will it take for you to complete the work on site?

If you’re surprised by how soon they recon they can get the work done, the chances are that they’re forfeiting something important in order to achieve this quick turnaround. And 9 out of 10 times, this cost is accuracy. I explain the cost of getting your design project across the line in record time in this blog, and on scanning jobs, this cost is the same.

Anyone who has lots of experience surveying sites probably won't fix the time they expect to be on site. The reason for that is that there’s a lot of variables that can affect the quality and accuracy of the scans they collect. For example, some workshop floors might need more scans due to the amount of equipment blocking the line of sight for the scanner. Some jobs might need images from multiple scanners in order to get the most accurate final design. Others will be affected by light levels and accessibility challenges that need to be overcome.

Quite often, this will come down to gut feeling. If their proposed timescale sounds too good to be true, then chances are it will be.

Q3 - Will you be scanning the site using GPS coordinates?

I spoke about this on LinkedIn recently, but plant design using GPS coordinates just doesn't work… The reason behind this is that GPS coordinates quite often reach the extremes of what CAD softwares can accurately process.

That being said, I’ve worked with surveyors in the past who just plonk their scanner down on site and away they go. This is another approach I’d be wary of as, without these fixed foundation coordinates, your CAD drawings will be rotated to match the initial orientation the scanner was placed in. This means that every time you access them, the drawings will need to be manually rotated around a specific point in order for every designer working on the job to be on the same page.

Instead, I usually set a site coordinate system (whether they have one already or not) based on what I’m trying to achieve on the day. This makes it easier for everyone working on the project to understand and is something I make the clients aware of when I’m starting the job.

If you’re tired of bringing yes men into your team and want to find out what an expert approach to laser scanning surveying can bring to your project, get in touch to book a free laser scanning demo today. And don't forget to ask us these questions to check we’re up to the job.

WHY DOCUMENT CONTROL IS EVERY PROJECT MANAGERS SECRET WEAPON ON MECHANICAL DESIGN PROJECTS…

Thu, 11 Aug 2022 09:54:04 GMT

Why Document Control is Every Project Managers Secret Weapon On Mechanical Design Projects…

Date: 11th August 2022

“We have a guy for that.”

I hear this from Project Managers all the time when showing up on site for the first time.

It’s always great to hear that an organisation has a Document Controller. But, as the lead of a design project, it’s important to be involved in this process and the documents surrounding document control yourself. The main reason for this is that, when designers aren’t working to the most up to date documents or specs, errors happen - and these can be costly in more ways than one…

So just how important is document control in mechanical design?

The sign of any great mechanical design is in the details. And, in order to achieve this high level of detail and accuracy, your designer needs to be working from the most up to date set of drawings.

Recently I was working on a job where, straight off the mark we were sent the wrong version of drawings from another design office.

It wasn’t until we arrived on site for the initial visit that it became clear the drawings didn't match the current site layout. We requested the latest version of the drawing which was happily provided; however, on analysis, this drawing still didn’t accurately represent the site so required some modification.

In this case, the project was only set back by a few weeks to allow time for these revisions to be made. Without noticing these discrepancies though, the design could have potentially…

Been built to the wrong specifications
Required a full redesign later down the line at an additional expense
Been manufactured and been in breach of health and safety requirements
Caused a huge environmental or safety risk for people and the surrounding area

How could this be avoided on your next project?

Hindsight is a wonderful thing. In this instance, this whole situation could have been avoided with a clearer process around document control - and this is often the case.

It would have taken just one conversation, one follow up email confirming the designer had received the correct drawings and one set of updates to the drawings to ensure that everyone was singing from the same hymn sheet.

So, here’s 5 important things to keep on top of when it comes to document control on your next design project…

Make sure that everyone involved in the project has the most up to date revisions of every document. If you can make sure of this before your designer arrives on site - even better!
Follow up on every change to check its been received. We’ve worked with so many organisations who email updates and changes but never follow up to confirm the designer has received and is working to the new spec. It’s always better to slow the process down by a day or 2 to make sure everyone’s working to the new revisions than to find out too late they missed your email.
Effective communication is a 2 way street. Not only should your designer be regularly communicating any questions, concerns or document requirements they need from you, you should be doing the same.
Keep an up to date document register that everyone has access to. This allows everyone on the project to easily see the latest revisions of the documents and which are being worked on to check they have been sent the latest information.
Where possible, hire or elect a dedicated document controller for the project. They are invaluable and make communication on a project a lot easier between each department.

If you’ve got any questions about how we work and what document control processes we have and require from you, drop us a line.

WHAT HAPPENS IF SOMEONE WALKS THROUGH DURING THE SCAN?

Tue, 12 Jul 2022 06:46:20 GMT

WHAT HAPPENS IF SOMEONE WALKS THROUGH DURING THE SCAN?

Date: 12th July 2022

On average, it takes around 2 minutes and 50 seconds to complete a single site scan position. To create a complete point cloud file of the entire site, this can be around 50-400X [number] scans positions.

When you consider how long this would probably take to complete, you might be less surprised to hear that someone taking a split second to walk through a scan barely even registers on the end point cloud.

What effect does this have on the final image?

It’s actually very rare that this has any effect on the scan data at all. If the scanner were to pick up on someone walking through though, they’d appear more like a worm moving through the centre of the screen.

It’s like taking a panoramic image on your mobile phone. The scanner doesn’t take in its environment all at once, it collects the data in stages, meaning that it will only register a person in the points it’s scanning when they walk though.

Can anything be done if they are visible in the image?

Often, the easiest way to remove any unwanted data is to just go into the point cloud file and manually remove it from the endpoint cloud. There is no real magic behind this process, and it’s relatively quick and easy to process once everything has been uploaded to an Ipad or computer. Some processing softwares also already has this functionality built in which means that this data is automatically removed from the image whilst it's being processed.

Our RTC360 scanners also have a double pass function for extremely busy site locations. This function means that the scanner can be programmed to scan the site twice from the same fixed position. The scanner will then compare the data it’s collected within the two scans and any data that only appears in one (not both) the scans will be overridden in the final point cloud file. It is quite common to use this method of scanning on a busy site but is not used as standard as double the scan data means double the amount of time required to complete the scan and collect this data.

It’s very rare that an entire scan position has to be deleted because something has moved through the areascan. Slow moving vehicles can sometimes cause this if the scan has to happen across a road or warehouse entrance. In this case, we would just reset the scan and hope that the driver wasn't lost and about to drive back the other way in the next 2 minutes and 50 seconds.

Despite what many think, the impacts of a busy worksite on a scan image are minimal. So, if you have a busy site which you need scanning, book a free laser scanning demo with us today.

HOW DO 3D LASER SCANNERS ACTUALLY WORK?

Tue, 05 Jul 2022 10:00:50 GMT

HOW DO 3D LASER SCANNERS ACTUALLY WORK?

Date: 5th July 2022

3D laser scanning has grown more and more popular over the years. It has quickly become a must have tool in the arsenal when working within engineering.

I've had the pleasure of utilising this fantastic bit of technology for 15 years now and have watched the development of the technology grow in that time. From reverse engineering of Blackpool Pleasure Beach’s ‘The Big One’ track to shoehorning some really big plant equipment into some tight areas - the applications for this equipment have grown immensely.

In order to keep developing the applications for this technology, it’s important to understand how 3D scanning actually works so that we can keep pushing the boundaries of its capabilities in the workplace.

So, how does 3D scanning actually work?

When I first started working in the industry, a big part of my job when it came to 3D laser scanning was to put up hundreds of black and white targets around the site. It used to take a couple of hours out of the scan time to set these up but these provided known reference points within the scan to measure and test the accuracy of the image produced.

Now, I use scanners like the RTC360 from Leica which is a tripod mounted scanner. Unlike previous scanners, it uses technology known as Visual Inertial System (VIS). It works by using 5 cameras and an Internal Micro Unit (IMU) to calculate the position between scans setups in real time. It does this by using the images of the camera to track locations (such as corners of buildings, steelwork and other objects). This allows for in field registration on a tablet or IPad.

The scanner itself uses ‘time of flight’ to record the environment it’s in. It does this by transmitting a beam of light from whichever position the scanner is in and it counts how long it takes for that beam to bounce back and be received by the scanner. It then calculates the distance the laser beam has travelled based on the time measured from transmitter to receiver. It repeats this process a million times per second and records a coordinate position of each point the light bounces from. A scan takes around 2 minutes and 50 seconds to complete and each point is recorded in a point cloud file. This can then be used to create 2D/3D models of the plant or to create 3D design models within the existing scanned environment.

What does the future of 3D scanning look like?

There are many different directions the future of 3D scanning could take, but in the oil and gas industry as well as in many of the chemical plants we work within, the use of scanning in relation to health and safety compliance is seeing a large increase in demand. In particular, this technology makes it really easy to identify unsafe areas of the site and any equipment which requires some attention to reduce onsite injuries and accidents.

If you would like to talk more about how 3D laser scanning could be used in your industry, whether that be for health and safety or engineering design, book a free call with me today.

WHEN IS 3D LASER SCANNING NOT YOUR BEST OPTION?

Tue, 28 Jun 2022 10:00:05 GMT

WHEN IS 3D LASER SCANNING NOT YOUR BEST OPTION?

Date: 28th June 2022

The decision to bring a laser scanning expert on board to map your site is not a decision a lot of organisations take lightly. And there’s usually a good reason why a site is considering 3D laser scanning as opposed to some of the other alternatives available to them.

There are many reasons why 3D laser scanning might be at the top of your options list, like its 1km scanning range, accuracy up to 0.8mm and its ability to collect dimensional information required for project deliverables, often missed by traditional surveying techniques.

But, despite all of these benefits, there are a couple of scenarios where 3D laser scanning isn’t the right option for the job, such as small cut and shut jobs and jobs where the line of sight doesn’t meet requirements.

Quick “cut and shut” jobs

Small cut and shut jobs are those small jobs that could just as easily be completed in a few hours with a notepad and a tape measure.

Some “experts” will push to bring in the laser scanner on the grounds that it will produce more accurate measurements and will require less time on site. In reality though, the laser scanner probably won't:

Provide you with any more information than we can create measuring by hand.
Result in any less time spent on site once you take into account the time it takes to set up and pack away the equipment.
And, most importantly, it won't be cost effective for you as the buyer.

Line of sight limitations

In my blog “How does laser scanning actually work”, I go into much more detail about the ins and outs of 3D laser scanning, but one of the key factors to note about this process is its reliance on the laser's line of sight.

In essence, 3D environments are created by measuring the distance between the laser scanner and the point at which the light from the laser is reflected back when it hits an object. For most environments, it's easy to achieve complete scans by setting up from a couple of different locations within an environment. But sometimes, this can prove a little more challenging when you’re trying to scan, say, organic materials like a wall covered in ivy where there’s lots of variation in surface texture that our brains naturally interpret. Or in very small or high spaces where the required angle to create a complete scan is difficult to achieve.

Most of these limitations we have found manual get arounds for like scaffolding, cherry pickers and even sometimes drones. But very occasionally we come across sites (or sometimes areas of sites) where 3D laser scanning just isn't suitable for the job.

If you are unsure whether 3D laser scanning is the right choice for your project or site, book a free laser scanning demo with us today. We’ll quickly be able to identify what the right path for your organisation or project is, even if that answer doesn’t involve lasers.

WHAT'S THE DIFFERENCE BETWEEN VISUALISATION AND 3D MODELLING?

Tue, 21 Jun 2022 10:00:00 GMT

WHAT'S THE DIFFERENCE BETWEEN VISUALISATION AND 3D MODELLING?

Date: 21st June 2022

If you’ve ever worked with CAD you’ll have come across these two terms. They are quite often thrown around by designers and used interchangeably, but are they actually different?

In theory, both 3D modelling and visualisation are very similar in the fact that they are both methods of virtually rendering your environment or object. On paper though, they provide two very different outcomes for your project.

The main difference between 3D modelling and visualisation is this…

A 3D model is a more generalist representation of the part or set up a client is looking to implement. A visualisation is a more detailed model where texture can be applied to show the intricacies of the design.

3D modelling

If I handed you a 3D model of a fixture (like the one below), you could easily walk onto the site and be able to apply this image to understand the part in relation to its surroundings. It will show you the broad shape and layout of a site or fixture, it might even be colour coded, but you don't get the same level of intricate details that a visualisation would provide.

3D model of a process delivery pump

Models like this one would be used within the usual design and site mapping processes. Although they don’t detail the intricacies of the design, 3D modelling does provide the level of design detail required for design and in house fabrication purposes in a shorter time frame.

Visualisation

Visualisation on the other hand, is a more detailed representation of this part, where texture can be applied to create a more accurate model. As you can see in the image below, the instrument looks like the instrument is, the valve looks like the valve and you can see the individual parts and the orientation they will actually be in when positioned on site.

Visualisation of a process delivery pump

This render can take some time to produce due to the added level of detail required, however, you will get the details of every bolt and washer within the visualisation. This is not necessarily required for standard design and fabrication purposes but can be a useful tool for sanity checking the viability of the individual parts and elements of the design. For example, depicting accurate handle designs for the valve within this design could help determine the final orientation of the valve and the shape of the handle if it needs to fit in around other parts.

Having these smaller details available will help communicate the design intent between the design team, fabrications team and construction team. This will save time in the long run as it will mean less questions will be passed back and forth during the construction phase.

The high level of detail available in visualisations also makes them invaluable training materials within organisations and environments where the pipework or fixtures are not easily accessible. Some clients also use visualisations like the one above as marketing materials to share with potential shareholders and stakeholders. These designs show potential investors exactly what they’re going to get to to help demonstrate the viability of the project as well as the physical outcome.

Does this get your cogs turning? To find out more about how 3D modelling and visualisation could benefit your business, book a free design consultation today at https://www.ohare-eng.co.uk/contact .

THE COST OF GETTING YOUR DESIGN PROJECT OVER THE LINE IN RECORD TIME…

Tue, 14 Jun 2022 10:00:01 GMT

THE COST OF GETTING YOUR DESIGN PROJECT OVER THE LINE IN RECORD TIME…

Date: 14th June 2022

No matter what industry you're in, you’ve probably heard the age old motivational cliché “get the project across the finish line” being thrown around the shop floor more than once in your career. You may have even tried using it yourself when the momentum on a project starts to dip. But here’s the problem I have using this statement in design projects…

As effective as it may be at getting work moving and deadlines met ahead of schedule, it turns the project into a race. Whether it's your intention or not, putting pressure on your designer to get the job “done” in a timeframe that no longer reflects the scope of the project will always come at a cost. And 9 times out of 10, that cost is accuracy.

Accuracy is fundamentally the most important element in any engineering design project.

But cutting corners to hit time constraints normally just leads to additional costs. These can be upfront costs to cover the additional man hours required to get the design across the finish line, or costs later down the line, like rework due to design error.

Everything has a cost implication, and I’m not saying that targets don't need to be met. But, in most of the projects I've worked on in the last 18 years, the client often has design changes they wish to make once the project is underway. This can be down to an oversight at the concept stage, an improvement they wish to make to the concept or sometimes just adding in a couple of ‘nice to haves’ to the design.

There’s nothing wrong with changing your mind and moving the goal post, but if you do, you need to allow your design engineers the additional time to reflect these amendments and allow them to accurately implement the changes.

Designers may now be equipped with laptops and CAD softwares rather than tape measures and drawing boards, but the accuracy of any design still lies in the details. And these details take time.

The money and time you spend to get a high quality design will always be less than you would have to spend starting the design process over again when things go wrong or putting things right with a faulty machine.

Book a free design consultation today to discuss your design needs and get your project off on the best foot.

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Piping Isometrics: The Most Overlooked Safety Document in Process Plants

The Most Overlooked Safety Document in Process Plants

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How Energy Price Surges Are Shaping Petrochemical Plant Engineering

The Gap Between Consumer 3D Scanners and Scanners for Professional Engineering Design

The Gap Between Consumer 3D Scanners and Scanners for Professional Engineering Design

Reverse Engineering One Gingerbread House At A Time

Reverse Engineering One Gingerbread House At A Time

How Accurate Is Accurate Enough With Laser Scanning Tolerances?

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Why Accuracy Matters

Understanding Laser Scanning and Modelling Tolerances

Typical Accuracy Levels and Their Use

Deciding What’s “Good Enough”

Finding the Balance

Clashes in the Night! How To Avoid Design Nightmares Before They Hit Site

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BIM & 3D Piping Design: What Mechanical Designers Really Need to Know

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Why Site Awareness Is Critical for Reliable Design

Why Site Awareness Is Critical for Reliable Design

The Value Is in the Detail: Project Design, Plant 3D, and Where AI Fits In

The Value Is in the Detail: Project Design, Plant 3D, and Where AI Fits In

Design Quality Is a Choice

Where Does AI Fit In?

The IP Trade-Off…

A Process That Works

Is ISO 9001 Certification Worth It in Engineering? What Clients Actually Care About

Is ISO 9001 Certification Worth It in Engineering? What Clients Actually Care About

What ISO 9001 Certification Means

When Certification Really Matters

What Scenarios are ISO 9001 Not Required

What To Look For When It Comes To Quality

Final Thoughts

Case Study: Compact Effluent Treatment System for a Chemical Manufacturing Site

Case Study: Compact Effluent Treatment System for a Chemical Manufacturing Site

The Challenge

The Solution

The Result

Conclusion

Follow the (Digital) Bunny Trail: How Smart Engineering Drawings Help You Navigate Complex Sites

Follow the (Digital) Bunny Trail: How Smart Engineering Drawings Help You Navigate Complex Sites

The classic egg hunt… Why traditional documentation falls short

Why accurate site data matters

How better drawings improve decision-making

Engineering clarity is not just for Easter

Want to stop hunting for the right drawing?

How 3D Laser Scanning Helps Achieve Faster Project Approvals

How 3D Laser Scanning Helps Achieve Faster Project Approvals

Providing accurate, up-to-date as-built data

Improving stakeholder confidence

Reducing revisions and compliance issues

Clash detection and early issue resolution

Speeding up modifications and resubmissions

How to Calculate the ROI of 3D Laser Scanning for Your Next Project

How to Calculate the ROI of 3D Laser Scanning for Your Next Project

Understanding 3D laser scanning’s role in development projects

Why choose 3D laser scanning over traditional methods?

This is all great, but can you actually calculate the ROI of 3D laser scanning?

The direct and indirect cost benefits of 3D laser scanning

Calculating the ROI of your laser scanning project

Next steps

FEED studies: What are they and why are they important?

FEED studies: What are they and why are they important?

Ensuring Santa’s Workshop Meets Modern Elf And Safety Standards

Ensuring Santa’s Workshop Meets Modern Elf And Safety Standards

The different types of engineering design drawings and what they’re used for…

The different types of engineering design drawings and what they’re used for…

1. General Arrangement (GA) Drawings

2. Piping and Instrumentation Diagrams (P&IDs)

3. Process Flow Diagrams (PFDs)

4. Isometric Drawings (Isos)

5. Site Layouts

Conclusion

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Why bother with visualisations in pipework design for chemical plants?

Why bother with visualisations in pipework design for chemical plants?

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