In Q4 of 2023, Viewport3 were approached by a well-established North East of Scotland engineering contractor who was supporting the management of a chemical plant in the Mediterranean region.
Among a long list of required actions was the urgent repair of a weeping flange—critical to the continued operation of the plant. The flange had to be addressed, but without extending plant downtime by a single minute more than was necessary. The client identified 3D photogrammetry scanning as the most effective method for capturing a sub-millimetric 3D replication and subsequently awarded the project to Viewport3.
With the end-client keen to expedite the repair, a specialist contractor had already been assigned the task of designing a repair clamp, and their preliminary design was made available to Viewport3 for reference purposes.
As we demonstrated the capabilities of 3D photogrammetry and its proven reliability in capturing high-fidelity 3D data, the client quickly recognised the long-term value of investing in a topside 3D photogrammetry kit. This decision would enable their team to develop in-house skills for future topside image collection.
Armed with a project-specific procedure, HAZMAT protection and the advice of our imaging lead still fresh in his mind, the client’s technician travelled to site to capture the necessary image data.
We initially recommended planning for a second visit to correct any potential imaging errors. However, despite the technician having limited photography experience and facing a language barrier, the image set was captured correctly on the first attempt, strictly following the provided guidance.
Following a successful 3D reconstruction—achieved with an indicated accuracy of 0.18mm— the supplier responsible for designing and manufacturing the repair clamp confirmed that we should deliver via a 3D ‘.STEP’ file, which is a widely compatible parametric 3D format compatible with most modern CAD and design tools. This allowed them to bring the real-life data directly into their preferred design software to complete a ‘wrap-around’ design.
In addition to the 3D dataset, Viewport3 supplied a written dimensional analysis report highlighting several key anomalies that the designer would need to consider.
Due to sub-optimal alignment between the two spools, it was clear that successful clamp installation would require rotation-specific placement. To support this, we selected a clearly identifiable datum on the actual spool to define a ‘12 o’clock bolt’ position, which was explicitly annotated in the delivered 3D dataset.
Shortly thereafter, we were informed that the design contractor had reviewed and accepted the 3D data, and the repair clamp design process was underway.
To date, Viewport3 has completed dozens of projects where our technical-grade 3D data has enabled the fabrication of first-time-fit solutions. This is an increasingly popular part of our service offering as our customer-base increase their understanding of the value that can be extracted from high-fidelity 3D data. In this instance, we were especially pleased to support the resolution of a critical plant issue—delivering with both clarity and precision whilst helping to ensure the highest possible value to the end-client.
