Digital Twins/ Representations Can Help Understand the Real World Better and Gain Valuable Insights to Improve Business Processes, and Operational Efficiency

Oct 01, 2023

Client

Plant age : 100+ Years
GFA : 13,00,000 m²
No Of Scans : 1,00,000+
LOD : 500
No of Assets modeled : 20 million +
No of BIM resources used : 240
Areas : Smelters, Refineries, Captive power plant, RMHS and Jetty facilities operating 24x7x365

The 40-year-old Copper plant is one of the largest copper smelters in the world. The plant contains a higher density of mechanical and structural components, fully functional with vibrations. Generally, Remedial Engineering or Revamp Projects are costly, and need exposure to existing structures. They have a huge limitation in achieving perfection in Bill of Quantities.

Existing structures of a plant post-construction are subjected to loading and adverse environmental conditions. In the course of time, the structures encounter various problems like – Corrosion, cracks, unwarranted modifications, seepage, and improper welds.

Challenges

To capture the condition of the existing facility as built, with no existing documentation.
To create as-built structural drawings and provide Bill of Materials (BOM) and distress mapping reports.
No existing information about the plant was available. The plant was partially retrofitted instead of full demolition.

LTM Solution

Set up LiDAR Laser Scanning, LOD 500 + BIM Modelling, As-Built Drawings, BOM Extraction, Distress Mapping, GPR Reports, and Structural Auditing.
Provided detailed information on the existing condition and highlighted distress in structures.

Business Benefits

90% reduction in costs, time, and effort.
90% reduction in the frequency of site visits avoided.
100% reduction in paper documentation.
60% reduction in timeline with quicker capture of as-built condition.
Project timeline and cost reduced by 90%.
Established asset management and digital twin compatibility.
80% improvement in collaboration, better project tracking, and decision-making.