Using 3D Scanning to Model Existing Plant and Equipment
Designing modifications for an existing industrial facility often begins with a basic but difficult question:
What is actually installed on site?
Original drawings may be incomplete, unavailable or no longer consistent with the current plant. Equipment may have been replaced, pipework rerouted, platforms altered and new structural supports added during years of maintenance and production.
Traditional site measurement can provide the dimensions needed for a small modification, but complex or congested plant areas may require hundreds of interconnected measurements.
3D laser scanning provides another approach.
A terrestrial laser scanner can capture existing machinery, pipework, structural steel, platforms, conveyors and surrounding building geometry as a detailed three-dimensional point cloud.
Relevant information from the point cloud can then be converted into usable SolidWorks geometry for equipment replacement, brownfield mechanical design, reverse engineering and fabrication planning.
Hamilton By Design provides 3D scanning and point-cloud modelling services for industrial projects across Australia.
Why Existing Plant Can Be Difficult to Model
Existing industrial facilities are rarely simple or uncluttered.
A plant area may contain:
- Pumps and motors
- Tanks and pressure vessels
- Pipework and valves
- Conveyors and transfer chutes
- Platforms and access stairs
- Structural steel
- Cable trays
- Ductwork
- Guards and handrails
- Equipment supports
- Building columns and walls
- Temporary or undocumented modifications
Many of these items overlap when viewed in photographs or conventional two-dimensional drawings.
Access may also be limited by operating equipment, production requirements, elevated work, restricted areas or short shutdown periods.
When the available drawings do not reflect the installed plant, designers may need to rely on site sketches, individual measurements and assumptions.
A point cloud provides a more complete three-dimensional reference for understanding the relationship between the existing equipment and its surroundings.
What Is 3D Laser Scanning?
3D laser scanning uses a laser scanner to record the visible surfaces of an object or environment.
The scanner measures a large number of individual points, each with a three-dimensional coordinate. Together, these measured points form a digital dataset known as a point cloud.
A registered point cloud can show the visible geometry of:
- Mechanical equipment
- Pipework routes
- Flanges and valves
- Structural beams and columns
- Conveyor centre lines
- Chute interfaces
- Platform elevations
- Floor and roof levels
- Building walls
- Access clearances
- Nearby plant and services
The point cloud can be viewed from different angles, sectioned and measured after the site visit.
This makes it a useful reference when developing SolidWorks models of existing plant and equipment.
From Point Cloud to SolidWorks
A point cloud is not automatically a finished SolidWorks model.
The scan records the visible surfaces of the site. A designer must then interpret the data and recreate the required plant geometry as usable CAD features, parts and assemblies.
Depending on the project, the SolidWorks model may include:
- Simplified equipment envelopes
- Detailed machinery components
- Pipe centre lines and outside diameters
- Flange positions and orientations
- Structural members
- Platforms and handrails
- Conveyor frames
- Chute geometry
- Tanks and vessels
- Equipment bases
- Mechanical interfaces
- Proposed modifications
The level of modelling detail should be selected according to the intended purpose.
A model developed for a preliminary equipment-layout study may require only simplified geometry. A model intended to support fabrication drawings or a precise equipment connection may require substantially more detail and verification.
Selective Modelling of Existing Plant
It is rarely necessary to convert every point in a large industrial scan into detailed SolidWorks geometry.
Selective modelling focuses on the existing items that directly affect the proposed design.
For example, a pump-replacement project may require modelling of:
- The existing foundation
- Suction and discharge pipework
- Nearby valves
- Pipe supports
- Structural obstructions
- Electrical-motor space
- Maintenance clearances
- Surrounding access ways
Equipment located outside the project interface may remain visible only within the point cloud.
This approach can reduce modelling time while still providing the information required for mechanical design and clash assessment.
Applications for Point-Cloud-Based SolidWorks Models
Equipment Replacement
Replacing an existing pump, fan, motor, vessel or processing machine may involve more than selecting a new item with similar performance.
Replacement equipment may have different:
- Overall dimensions
- Baseplate arrangements
- Shaft heights
- Flange positions
- Nozzle orientations
- Motor sizes
- Service clearances
- Maintenance envelopes
- Support requirements
A point-cloud-derived model allows the existing area to be recreated in SolidWorks.
The proposed equipment can then be positioned within the existing environment to review its fit, connections and surrounding clearances before installation.
Pipework Modifications
New pipework must often be routed through congested areas containing existing mechanical, structural and electrical services.
Point-cloud information can help identify:
- Existing pipe routes
- Pipe diameters
- Flange locations
- Valve positions
- Structural obstructions
- Potential support locations
- Available routing space
- Access requirements
- Proposed tie-in points
The new pipe route can be developed within the existing SolidWorks model and reviewed for spatial conflicts.
Pressure design, material selection, thermal expansion, flexibility, support loading and applicable piping standards remain separate engineering requirements.
Conveyor and Chute Design
Conveyor and chute modifications frequently depend on the relationship between several existing assets.
The designer may need to establish:
- Conveyor centre lines
- Belt elevations
- Pulley positions
- Existing discharge locations
- Receiving-equipment geometry
- Chute inlet and outlet positions
- Supporting steelwork
- Access-platform locations
- Maintenance clearances
A point cloud can provide the dimensional context needed to develop a replacement chute, transfer hood, skirt, guard or conveyor modification.
Hamilton By Design also provides chute design for mining and materials-handling applications.
Reverse Engineering Existing Equipment
Some industrial components remain in service long after their original drawings have been lost.
3D scanning can support reverse engineering of items such as:
- Guards
- Chutes
- Hoppers
- Machinery frames
- Covers and enclosures
- Pipe supports
- Access structures
- Cast components
- Replacement assemblies
- Custom brackets
- Fabricated equipment
The scanned geometry can be interpreted and recreated as SolidWorks parts or assemblies.
The model can then support replacement, modification, engineering assessment or fabrication-drawing development.
Learn more about reverse engineering with 3D scanning.
Brownfield Mechanical Design
Brownfield design involves adding new equipment or modifying an existing operating facility.
The proposed design must work around the plant that is already installed.
Point-cloud-supported SolidWorks models can assist with:
- Equipment positioning
- Interface design
- Tie-in planning
- Clearance reviews
- Maintenance-access assessment
- Structural integration
- Installation planning
- Clash identification
- Fabrication development
- Shutdown preparation
The existing-condition model gives the designer a three-dimensional reference for developing the proposed modification within the available space.
This can reduce reliance on assumptions and improve communication between designers, engineers, fabricators and site personnel.
Clash and Clearance Review
A proposed SolidWorks assembly can be reviewed in the context of the existing plant model and point cloud.
Potential conflicts may include:
- New pipework intersecting structural steel
- Equipment obstructing an access way
- Valves without operating clearance
- Platforms conflicting with existing services
- Chutes contacting conveyor structures
- Motor-removal paths being blocked
- New supports interfering with floor penetrations
- Fabricated assemblies that cannot be installed as designed
Identifying these issues during design is generally easier than discovering them during fabrication or installation.
A digital clash review does not eliminate the need for engineering judgement or final verification, but it can significantly improve understanding of the available space.
Supporting Fabrication Drawings
Once the existing conditions and proposed modifications have been modelled, SolidWorks can be used to develop:
- General-arrangement drawings
- Equipment-layout drawings
- Fabrication drawings
- Assembly drawings
- Sections and elevations
- Installation details
- Bills of materials
- Interface drawings
- Site-verification drawings
Where appropriate, the design may incorporate installation adjustment through:
- Slotted holes
- Oversized holes
- Adjustment plates
- Site-fit members
- Shim allowances
- Removable spool pieces
- Final verification dimensions
The required tolerances and installation strategy should be considered during the design process rather than left entirely to site fabrication.
A Typical Scan-to-SolidWorks Workflow
1. Define the project requirements
The intended use of the scan is established before site work begins.
Important considerations include:
- The plant area to be captured
- The proposed modification
- Required accuracy
- Critical interfaces
- Required deliverables
- Site-access limitations
- Available drawings
- Project timing
Understanding the final design purpose helps determine the appropriate scanning and modelling scope.
2. Complete the site scan
The scanner is positioned at multiple locations around the plant and equipment.
Overlapping scans are captured to record both the primary equipment and the surrounding geometry that may affect the design.
3. Register the scans
The individual scan positions are processed and combined into a coordinated point cloud.
The registered dataset is reviewed for coverage, alignment and suitability for the intended modelling work.
4. Review and clean the point cloud
Unnecessary information may be removed or separated to make the dataset easier to use.
The project area can be cropped, sectioned or divided into manageable regions.
5. Model the existing plant
Relevant equipment, pipework, structural steel and interfaces are recreated as SolidWorks parts or assemblies.
The modelling detail is selected according to the project requirements.
6. Develop the proposed design
The new equipment or plant modification is designed within the existing-condition model.
The design can be reviewed for:
- Fit
- Access
- Connections
- Maintenance
- Clearances
- Potential clashes
- Fabrication
- Installation
7. Produce the agreed deliverables
Project deliverables may include:
- Registered E57 point clouds
- Autodesk ReCap RCP or RCS files
- SolidWorks parts
- SolidWorks assemblies
- STEP files
- SAT files
- Parasolid files
- AutoCAD drawings
- General arrangements
- Fabrication drawings
- Bills of materials
The required file formats should be confirmed before modelling begins.
Benefits of 3D Scanning Existing Plant
Using 3D scanning to support SolidWorks modelling can provide several practical benefits.
Better dimensional coverage
A scan can record a broad area rather than only the dimensions identified during the initial site visit.
Fewer missed measurements
Additional dimensions can often be taken from the point cloud after the site work has been completed.
Improved design context
The designer can see how equipment, structures and services relate to each other in three dimensions.
Reduced design assumptions
Visible site geometry can be modelled from measured data rather than estimated from photographs or outdated drawings.
Earlier clash identification
Potential spatial conflicts can be reviewed before fabrication and installation.
Improved project communication
Point clouds and SolidWorks models can help clients, designers, fabricators and installers understand the existing and proposed arrangements.
Reduced repeat site access
A comprehensive scan may reduce the need to return to site simply to obtain an overlooked dimension.
Limitations of Point-Cloud Information
A point cloud records visible surface geometry. It does not automatically confirm:
- Material grade
- Pipe wall thickness
- Internal corrosion
- Hidden structural damage
- Weld quality
- Structural capacity
- Foundation reinforcement
- Operating pressure
- Equipment performance
- Underground services
- Concealed components
- Compliance with applicable standards
Additional inspection, testing, calculations or asset information may be required.
Critical fabrication interfaces may also need direct verification, particularly where very tight tolerances are involved.
How Accurate Is 3D Scanning?
The accuracy achievable for a project depends on factors including:
- Scanner type
- Distance from the scanner
- Number of scan positions
- Surface reflectivity
- Site vibration
- Dust, steam or moving equipment
- Registration method
- Control requirements
- Required deliverable
- Modelling method
Accuracy requirements should be discussed before the site scan.
A broad existing-condition model for plant-layout development may have different accuracy requirements from a replacement component that must connect directly to an existing machined interface.
Does Every Scanned Item Need to Be Modelled?
No.
The point cloud can remain as the broader site reference, while only the relevant plant and equipment are converted into SolidWorks geometry.
This can be particularly effective for large facilities where the project affects only one machine, pipework area or conveyor-transfer point.
The modelling scope should reflect the intended design outcome.
Can the Scan Be Used Directly in SolidWorks?
Point clouds usually require processing and a suitable workflow before they become practical for detailed SolidWorks design.
In many projects, the point cloud is used as the measured reference while the required existing geometry is recreated as conventional SolidWorks parts, assemblies, surfaces or simplified envelopes.
The best approach depends on:
- Point-cloud size
- Required accuracy
- Level of detail
- Available software
- Computer performance
- Intended deliverables
Large datasets may need to be cropped or divided into smaller project areas before modelling.
Why Use Hamilton By Design?
Hamilton By Design combines practical industrial scanning with mechanical engineering, SolidWorks modelling and drafting experience.
Services can include:
- Terrestrial 3D laser scanning
- Point-cloud registration
- Scan-to-CAD conversion
- Existing-condition modelling
- SolidWorks parts and assemblies
- Mechanical equipment design
- Reverse engineering
- Conveyor and chute design
- General-arrangement drawings
- Fabrication drawings
- Engineering review
- Design certification where included in the agreed scope
This integrated approach helps maintain continuity between the information captured on site and the way it is used during mechanical design.
Explore Hamilton By Design’s 3D scanning and 3D modelling capabilities.
Frequently Asked Questions
Can 3D scanning be completed while the plant is operating?
In many cases, scanning can be completed while the facility remains operational, subject to site safety and access requirements.
Moving equipment, vehicles, dust, steam and vibration may affect scanning conditions and should be considered during planning.
Can point clouds be used for equipment replacement?
Yes. Point clouds can help establish the existing equipment location, foundations, pipework, structural interfaces and available maintenance space before replacement equipment is selected or modelled.
Can a scanned plant be converted into a complete SolidWorks assembly?
Yes, but the time and cost depend on the size of the facility and the required modelling detail.
For many projects, selective modelling is more efficient than recreating the entire scanned area.
Can 3D scanning support fabrication drawings?
Yes. Point-cloud-derived SolidWorks models can support fabrication drawings, provided the required interfaces, tolerances and verification requirements are addressed.
Is 3D scanning suitable for pipework?
3D scanning can capture visible pipe routes, fittings, valves, flanges and supports. Engineering information such as material, wall thickness, pressure rating and internal condition must be obtained separately.
Can 3D scanning replace all manual site measurements?
Not always. Critical interfaces, concealed details and precision connections may still require direct physical verification.
What information is needed to quote a scanning project?
Useful information includes:
- Site location
- Photographs or available drawings
- Approximate scan area
- Type of plant or equipment
- Intended use of the model
- Required outputs
- Accuracy requirements
- Site-access conditions
- Required completion date
Discuss Your Existing Plant-Modelling Project
3D scanning can provide a practical foundation for modelling existing plant and equipment when drawings are missing, incomplete or no longer consistent with the installed facility.
Hamilton By Design can assist with:
- Industrial 3D scanning
- Point-cloud processing
- Existing plant modelling
- Point cloud to SolidWorks conversion
- Mechanical design
- Reverse engineering
- Fabrication drawings
- Brownfield plant modifications
Contact Hamilton By Design to discuss the site, required scan area, modelling detail and intended project deliverables.
Hamilton By Design
3D Scanning, SolidWorks Modelling and Mechanical Engineering Support
Sydney, Melbourne, Brisbane, Perth and throughout Australia
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