Solution

Laser scanning of wind turbines

Project Highlights

Project Name:

Wind turbine scanning, documentation, and deviation analysis

Location:

Randolph, NE

Objective:

 Point cloud scanning for reality capture and conversion to as-built 3D models for maintenance planning and deviation analysis.

LOD:

300

Category:

Industrial 

Technology Used:

3D laser scanning, point cloud to model conversion, 3D model analysis

Project Overview

The client was a market leader in the renewable energy segment. They required a 3D scan of wind turbines to identify deviations from factory specifications due to equipment failure.

3D laser scan of wind turbine

Client Overview

As told above, even the client was into renewable energy and therefore sought an advanced approach to document their wind turbine assets for maintenance. The document was supposed to streamline the periodic inspection and maintenance schedules.

Project Highlights

  • Scanning of wind turbines
  • Point cloud data generation
  • Point cloud to 3D model conversion
  • Report for asset assessment

Challenges

  • Complex Structural Geometry and on-site accessibility: Wind turbines are too big and complex of assets for a normal human and therefore require powerful, high-density reality capture technology.
  • Environmental Constraints: Windy weather conditions were also one big-time constraint affecting scanning efficiency.

Process & Execution

Initial
Scanning

3D laser scanning was done for the commencement of the project to reality capture the turbine assets.

Data Processing &
Registration

Then the generated point cloud data was refined and processed to be a 3D digital replica of the real one. Then the model was compared with the old turbine models for identification of structural deviations.

Deviation Analysis & Reporting

Post this, comprehensive reports with supporting 3D models were created to properly document the conclusions obtained for future references.

Wind energy

Solutions
How the Result Was Achieved

  • Site Preparation: A thorough site study and strategic positioning of laser scanning equipment were planned for executing the task.
  • Tripod-Based 3D Laser Scanning: Multiple scans with tripod-based scanning were done to capture the entire turbine structure.
  • Scan Registration & Data Processing: The point cloud data was then worked on to be converted into a CAD model for examination.
  • Comprehensive Scan-to-CAD Analysis: Any structural variations were shown graphically documented thoroughly plus verified for dimensions in the final step.

Results & Benefits

  • Highly Accurate Deviation Reports: The scan-to-CAD approach induced proactive maintenance and intelligence on identifying structural deviations.
  • Seamless Data Integration: Visual data reports effectively communicated the project achievements and statuses throughout the stakeholders involved.
  • Cost & Time Efficiency: Completely eliminated the need for manual inspections and therefore reduced the project turnaround time.
  • Expanded CAD Database: The model data acquired and report prepared are still acting as the base knowledge repository for effective management of wind turbines on-site.
wind turbine scanning services

Solution

Key Insight

Slight variances are frequently caused in big and complex assets like wind turbines by outside variables like equipment failure, environmental wear and tear, and structural changes. Advanced scan-to-CAD based analysis enhanced the accuracy and efficiency of the wind turbine documentation process, further making it easy for stakeholders to keep a check on asset changes.