Lucrosol Pilot Two Proposal 9/21/2021 7:48 PM
Intel Metrology Pilot two
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Yellow Highlight was request, proposal below restructured to satisfy request |
Introduction
Defined problem statement
Proposed solution
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- Outline the actual process or workflow and clarify all required considerations safety and execution. Include how you will work with subcontractors on processing the data and putting it in a usable format for their shop fabrication and most importantly field installation
- Define any/all help needed from subcontractors
Define the desired outcome and how it will be monitored (What are the conditions of satisfaction)
Duration of pilot (break out by line item)
Provide the cost (break out by line item) of the pilot
Contents
Trade contractor Help required
Legacy Durations, Existing vs. Projected
A working hypothesis infers substantial off-site fabrication production capacity in a shorter time frame using specialty measuring equipment and custom software. The proposed method eliminates a number of time consuming steps, increases accuracy, and simplifies the coordination of routing & subsequent spool fabrication.
The objective of this five day pilot is to record the durations required to measure, convert, and distribute useful subfab existing conditions. i.e. Factory Point Of Connection, hangers, open routing spaces, routing obstructions, or any physical item with possible route. Those duration's and the quality of the information as 3D centerlines, 3D as-built objects, will be reviewed for value to trades.
Reading the first pilot, appendix 1, (included as Appendix 1, an OLE object) is required to understand the work that paved the way for this second step – measuring inaccessible areas.
Primary goal is to extend on first pilot measuring as-built conditions along routes and/or proposed routing above "head height" anywhere in subfab, specifically areas only accessible via ladders, fall protection tie-off, and planking.
With reference to mapping inaccessible construction areas, two measurements types; 1) as-built condition, 2) proposed route, will be executed in order to determine cost feasibility and usefulness to trade Issue For Fabrication and physical install duration reductions. Again the two types of measurements are 1) as-built environments, and 2) proposed routing for factory layout, and tool install.
To further clarify, a "fall-protection certified" individual shall mount the 6 lb 3D-disto on unistrut, or other safe stable surface, turn it on, leave it mounted while in use, then retrieve it at later. Measurements will be taken remotely by operating the robotic 3D-disto from a tablet computer on the subfab floor.
Those measurements, as coordinate points, will be processed into 3D polylines based on the subfabs coordinate system and added to a 3D trade model or federated model.
- Further processing can occur at this time, i.e. sweeping the polyline into an oversized route representing the basic boundary or the process pipe, electrical trunking, hangers, etc. As the data is on the coordinate system of the fab being measured, 3D lines, or 3D objects are created and accurately located within properly transformed federated coordination models. This was proven in pilot one.
Or
- This processing of measured coordinates, or post processing, can occur by a trade detailer at their location. Coordinate sets, and 3D polyline files are plain text, tiny in file size and can easily be emailed, texted, from subfab or just outside a building if internal wireless in not readily available.
Pilot one verified work flow timing, accuracy, production rates and value. But now must include mapping and measuring inaccessible areas to validate value to trades in reducing duration's, rework, costs, man power, and ability to accurately fabricate offsite.
In order to understand the value of our solution we need to mount the 3D disto to hangers, unistrut, fire bracing seismic struts, and other steel in difficult to reach areas in order to measure the difficulty of providing trades accurate data to route, eventually fabricate from.
Based on metrics from Pilot One the routing data should be better, faster, cheaper, and more dependable than any laser scanning or manual process, notably because a laser scanner cannot be mounted where a 3D Disto can.
Offsite fabrication will not be addressed in this pilot. I can explain the reasoning which has two main components, 1) the best equipment so far is in Germany, 2) the pilot would disrupt the trade fabrication shop production. When we get pilot two data and it validates value, I can prepare the fabrication pilot.
There are not catwalks or open spaces allowing easy access to areas below “any and all” cleanroom popouts. Equipment in the cleanroom may not be located in an ideal location with relationship to accessing the popout where utilities emerge and require connection to subfab areas.
Reader should reflect on how successful coordination can occur in an area trades must route utilities in, yet have no reasonable access to. Beyond getting on a ladder, setting up a plank, and studying the conditions in person or from some distance away.
Successful 3D model coordination (any coordination actually) requires knowledge about what is around the popout, where a utility can be “hung” or “mounted” as the utility snakes through the maze of the subfab to it’s connection point, while staying within its routing zone.
While laser scanning has extensively been used to provide existing geometry to trade groups that solution is not available where a scanner cannot be placed or located. (inaccessible to a laser scanner)
Figure 1 - Scanner locations
The picture above graphically depicts scanner locations, with voids where no scanning occurs.
As useful as they might be, Laser scans require quite a bit of labor, hardware, post processing, learning, to use. The files are large and take storage resources, there can be hundreds in use at any given time. There is an inherent inaccuracy with laser scan data. Laser scanning is a multimillion dollar solution with limits. More analysis is available here. (Slicing Scans, Meshing scans)
To overcome these limits the author has investigated and continues to investigate specific methods like hand scanning with a small easily deployable unit one could get into inaccessible areas, tiny new laser scanners that easily fit into these inaccessible areas. The hand scanners have accuracy and quality of data issues, along with large post processing, stitching issues, and large file size challenges making it’s use difficult at best.
Using small accurate cameras with photogrammetry software to create 3D models of inaccessible areas is also something the author stays attuned to. Accuracy, hardware costs, large file sizes, post processing software and processing times, lighting and number of actual pictures required disallow this as a viable solution to mapping inaccessible areas.
The exceptional value to cameras and laser scanning is the “picture” each can provide. A picture of the area is very valuable. Anyone and see if there is something in the way of a route. Getting a reasonably accurate measurement is the next requirement unless you guess, then model and fabricate from a “approximate” measurement. Until installation time you do not know if items will fit or if you missed something.
Two person crew goes to designated area in subfab. Process starts with “survey resection” procedure to establish the 3DDisto coordinate (position) from sub-fab control points (brass, targets). Every time you move the Disto they need to re-establish their position to subfab control points.
The 3D Disto has a small form factor, and weighs six lbs. It will be used in high remote hard to reach areas. The constraints are human accessibility of the actual placement of the unit. If a person cannot access the space and set up the magnetic or mechanical base to attach the Disto it cannot be used.
The Disto measures (operates) by remote control from the phone/tablet/notebook. You control the Disto wirelessly placing the laser dot on the point to be measured in the picture shown on your screen.
Videos are available showing the vertical and horizontal movements. (one such video here) The Disto can measure non-line-of-sight points, i.e. offsets, this requires a person to hold a specialty target on the object while a second person measures two points.
The trade team will determine any routing in the tool package as they normally do.
When field verifying the proposed routes the Disto would be used to record coordinates along the route, or map the area around tight areas along the route.
Specifically, points where the route changes direction, elevation, turns are recorded by measuring that location. Field notes are “associated” with the measurements to clarify the coordinate. The Disto can record pictures for additional clarification or future reference.
The location of the Pop-out penetration, FPOC, hanger placements and or any other important or significant place in space is measured and described.
If properly sequenced the Disto could be set up in advance of the tool routing walk and teams could review routing questions from the floor by using the disto to remotely look at the obscured area above their heads using the camera of the unit.
The disto operators can convert the points into a 3D line, even extrude a circle, square, rectangle around it (creating an oversized route envelope) and email it to the office detailer using wireless secure internet connections.
These 3D objects (the extruded routes) can be visible within a Hololens virtual reality environment in a very short time ( projected as 30 seconds) Additional analysis can be performed in the field by the person measuring the point’s whether the route is within the correct routing zone, or outside the correct routing zone.
The process of measuring the route will be accomplished using a number of techniques including but not limited to:
- Directly measuring from any unistrut (or offsetting from any unistrut)
- The catwalks, any FPOC
- Climbing up a ladder
- Climbing up a ladder and on to a workmans plank.
- Holding a lightweight rod with small target mounted to it.
- Measuring two points of a lightweight plastic rod offset from a point
- Directly measuring any point and offsetting it 90 degrees i.e. unistrut in ceiling slab 10” down, or unistrut in column and 8” away from face of column.
While I’ve described measuring of the routes the same techniques apply to any existing condition or newly installed material, as-built conditions can be emailed to detailers as quickly as teams can set up and measure conditions.
(optional) We intend to test a smart writing system for all written field notes shall in order to maintain electronic records. This process quickly provides accurate information to the office detailer as directed by the field foreman of the trade preforming the work.
This metrology work flow is not meant to displace other methods in place by the trades, it’s another tool for everyone.
Any person placing the equipment shall be certified in fall protection (and or any current requirement)
Magnetic and mechanical mounts shall be used for the Distos.
The magnetic mounts are switched on and off for ease of use. Magnetic mounts have max breakaway: 150 lbs / 68 kg. Mechanical mounts are physically pressure screwed to the unistrut or other object. A rope safety tether is attached to mount for added safety at all times. The mag mounts are basically four inch cubes and weigh 11.2 oz.
For the pilot we prefer a seasoned process pipe installer who works (actually installs the materials in inaccessible areas) to mount he unit.
The six pound 3D disto unit is comparable to any other tool or item which has to be lifted into place and the same process will apply.
Any ladder use will follow Intel protocol.
Any and all subfab presence will follow Intel protocol.
I’ll remain the domain expert in all steps and their process flow. Software in use is categorized as hardware based, custom scripting, standardized. Examples:
- Disto has its own software requiring its own learning curve.
- Coordinate exports have to be cleaned. I use a script inside a text editor. There are no barriers transferring this to others.
- 3D centerlines and subsequent extrusions are created using an AutoLISP program & standard AutoCAD commands. I’ve also scripted this in Python for FreeCAD.
- AutoCAD or FreeCAD required
- Appending into Navis should be understood as a normal coordination process.
- Route extrusions and 3D polylines are clashable in Navis and easily intergrate into existing coordination process and Issue for fabrication.
I’m vaccinated against Covid with Pfizer and carry proof, we’ll not include any unvaccinated persons on our side of this pilot.
Items missing?
Person to place disto, secure it, turn it on and retrieve it when measurements are complete.
Coordinates of all brass, targets, or other control in the areas we’ll be operating in. (Rock solid requirement)
Coordinates should be on site system, i.e. campus system.
Escort or badging
Fall protection certification – if we can’t use trade.
Transportation around campus (Golf cart access, not full time cart)
Training / certification to enter space we’re operating in.
Optional: email access to trade modeler with appropriate skill to append to files on site coordinate systems, the same coordinate system we are resectioning to.
Report containing the following elements, i.e. minimally these metrics will be gathered:
Start time, duration, end time with description of task. This allows us to apply labor costs to amount of useful information acquired, thus we have a basic cost value figure.
Chronologically the tasks are sequenced like this:
- Record each resection task, averaging all resections as well. (Link to resection definition) AKA free stationing
- Decide access to area
- Prepare mounts in inaccessible area
- Mount the Disto
- Confirm you see three control points to resection, if not move disto
- Measure route or items
- Remove disto
- Post process data collected
- parse points
- import into FreeCAD / Autocad (& export as DWG/DXF)
- Create
3D polyline
insert object from library based on coordinate.(AutoCAD)
Transfer into Federated model as sanity check (or coordinate control file)(Append Navis)
Repeat
A report of lessons learned, tables of data collected, charts and projected value to trade in terms of reducing risk to cost and durations will be compiled and presented for peer review.
Reduced risk shall be interpreted as being able to safely coordinate routes for fabrication faster than existing processes used. The information on how long it takes to get into an inaccessible area, and how to best measure within a congested area will be compiled and reported.
All improvements that can be made will be stated. Usefulness of the information is how readily it allows pipe, conduit, duct, trunking and any associated hangers to be installed.
We may find the value of this solution to be in pre locating the hanger systems that define any given utility route.
Though this idea has been vetted yet, there is also the possibility or installing or placing hangers and recording their locations while in the inaccessible area. The thought is founded with some broad assumptions, listed as:
- Team knows in advance the projected scope of the particular area
- Material needing placement is well known, design capacities are set
- Pre routing had been completed and unknowns are one of the few barriers
- Trade teams are ready to install hangers
- Designer of trades are ready to coordinate that morning or afternoon
- Teams agreed access and importance of this areas installations warrant the effort of:
- Mapping
- Coordinating
- Approval to construct
- Construct
- Record As-builts
- De-mobilize the area
Text
7:30 – 8:00 start time arrival at Lobby and security check.
Transfer of coordinates (if not already received) Process import of coordinates and check for accuracy to translation to site coordinate system, and completeness of points. i.e. Are all the brass caps accounted for, are the targets accounted for, are they numbered, described. Elevations or Z included.
Team assembly, process review, checklist, PPE, setup disto and confirm wireless communication between tablet & unit.
Transportation to subfab. Unload and setup in work area.
Identify specific inaccessible area to measure
Setup barrier or tape (if required), ladders (if required), climb up and place unit, setup desk on floor, connect to power & wifi
Confirm communication with remote disto unit
Measure from Popout along route to FPOC. Repeat. Measure cabinets and equipment POCs. Measure what is decided we need to measure.
Post process as time allows, or have secondary operator post processing at table or remotely in trailer. Remote post processing requires text, email, wireless capabilities.
Apply any learnings, changes, or modification to process, repeat.
Vary the types of routes.
Lunch and leave at 5, 6:00 PM
Day two
Repeat of day one with longer routes, more complex access challenges, get metrics on extensive use of Disto in high areas with mounts, and spot designing hanger locations. Set arbitrary position and measure back into control – transforming all previous measurements to correct coordinate system.
Optionally: Use Disto to assist in pipe layout using floor to represent fab shop table top. Plastic pipe will be used. Sizes of 2” possible. Use Home depot PVC materials if permitted (cleanliness?)
Note, mock up fabrication is optional. Most important aspect of pilot is measuring and providing accurate geometry to trades.
Day three, four & five
Determine work flow of all learnings. Return to any difficult measuring tasks and understand work-arounds. Repeat day one and two tasks
HoloLens “use case” will be included if we have it set up and operational. (Others will need to be responsible as I have no practical use experience to contribute)
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Working Budget |
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Cost |
Description |
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$6000 |
My cost or fee for the ten days |
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$3000 |
Leica 3D Disto Rental Might add second disto to aid in resectioning where we can set our own control temporary points $1500 vs $3000 |
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$200 |
Mounting hardware for Disto: (magnetic mount and safety tether) |
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$3000 |
Computers / tablets for disto software & post processing, cabling, accessories. |
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$1475 |
Accommodations near site budgeted as: $800 (hotel six/six nights) |
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$340 |
Software rental, $120 for Navis & $220 for AutoCAD, any remaining software will be provided at no charge |
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$1500 |
General Liability for me as services provider (if required) |
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$1,551.50 |
Allowance of ten percent for omissions or missed items, price increases, etc. |
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$17,066.50 |
working estimate |
Budget notes:
- Schedule: Six days (five plus travel wasted time) added Sunday travel to start early Monday
- Does not count and Intel sub fab access training requirements (note I received Raptor sticker to enter F43 during last pilot)
- Any mandatory training / certification times must be added to five day requirement. (fall-protection?)
- Mounts and safety tethers must be received and tested one week before arrival on site. Disto must be received week before pilot and all required software installed and tested. Therefore a week is added to the working week schedule wise. Batteries used in disto mandate specific shipping and handling.
- Disto Mounts & safety harness
- Notebook / tablet / phone
- Brass monument & target coordinates – MUST have Z or elevation.
- Intel escort
- Travel arrangements, Travel & accommodations reservation made two weeks in advance.
- Golf Cart to transport equipment
- Intel overhead and or requirements to enter subfab I’m not aware of.
- Pre-onsite hardware setup & testing, mini multi hour dry run.
- My software AutoCAD/FreeCAD/Navis
Address an Indemnity issue if any exist.
Indemnity is a contractual obligation of one party to compensate the loss incurred to the other party due to the acts of the indemnitor or any other party. The duty to indemnify is usually, but not always, coextensive with the contractual duty to "hold harmless" or "save harmless"
Looks like work can occur five weeks after budget approval
(Let’s discuss this section)
A table comparing the existing and proposed work flow with durations (days) in red if you were to displace the traditional BIM process.
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Existing Work Flow |
Proposed work flow |
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Field walk after release of LSP to determine constructability (1/4 day or 2hr) |
Metrology team measures selected route centerlines and hanger locations at direction of trade piping foreman or detailer. Trade detailer establishes design route. (1/2 day or 4hr per route, multiple routes will be combined) |
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Order and execute laser scans (3 days) Note scan file sizes are 60 to 110 megabytes each and require target placement & removal |
Within minutes of measuring routes centerlines, coordinates, pictures, and select as-built surrounding conditions are provided to detailer via email (0.01 day per route or 48 minutes) Note tiny file size, control points have to be available |
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Laser scans are registered and transferred to trade (1/2 day) |
Trade detailer adds detail to and or reviews 3D piping, ducting, wireway, (etc.) route and uploads to 3D coordination model. Route is now established within a few days at most. (Assume 1/2 day) Note lack of 3D detail |
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Routing in 3D is performed with multiple software platforms, techniques, and trade detailers. Detailers upload route for coordination (3-5 days) Note multiple field changes likely because of detailer inexperience (historic basis) |
Upon milestone of final route acceptance 3D model, route centerline information is used to create spool drawings. (Assume ten minutes each with correct process) |
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Coordination process – possible field visits – changes until final issue for fabrication (2-3 days) Note multiple parties involved in coordination, multiple resources. |
Spool drawings transferred to shop and are fabricated. Metrology equipment is used to validate spool construction geometry. (1/2 day) |
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Models converted to spool drawings (ten minutes per spool) |
Spools tracked and shipped to install (1/2 day) |
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Spool drawings transferred to shop floor and fabricated (1/2 day) |
Field Install – variations tracking mandatory (1 day) |
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Spools shipped to factory and Installed (1 day) |
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Total 12.1 days |
Total 3.51 days |
Duration compare table
This metrology work flow is not meant to displace other methods in place by the trades.
Should metrics show value to trades, initially this work flow could be used for the difficult, critical, long lead and prefabrication production work.
This is about insuring the work get done in time, accurately and safely with a smaller labor footprint in the subfab.