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. . Data Fusion of Three-dimensional Measurement and CAD in Plant Construction 
(with the application to prefabricated manufacture of chemical engineering pipe line as an example) 
A.Matsumoto and F.Souda 
2™ Dept. Matsudo Research Laboratory, Hitachi Plant Engineering & Construction Co., Ltd., JAPAN 
Commission V , Working Group 3 
KEY WORDS : Chemical Plant , Total Station , Video Total Station , CAD , Stereo Measurement 
Abstract 
A system has been established with application of a three-dimensional measurement technology aiming at promoting a pipe pre- 
fabrication method in a chemical plant construction. This system makes it possible to measure the dislocation of pipe mounting 
flange of the equipment installed at the site, prepare As-Build CAD data for the pipe prefabricated pipe. Moreover, the system 
assures a positional measurement accuracy of X 1.0mm and an angular measurement accuracy of 3:05... 
As the three-dimensional measurement technology, a point measurement technique by a total station and a face measurement 
technique by stereo image using two servo - drive type video total station containing CCD camera have been applied. Especially, 
the latter technique is characterized by working out a problem of correspondence detection of stereo image obtained by applying 
CAD based vision which is being advocated in an image recognition field and improving the measurement accuracy by collating 
the sub-pixel of CAD diagram with an edge image by the image processing. 
1. Introduction 
The construction of a chemical plant is put forward following 
such processes as a plant design, construction of steel-frame 
building, installation of reactor, tank and other apparatus and 
mounting of manufactured pipe on apparatus. In the plant 
design, the introduction of a three-dimensional CAD and in the 
manufacture of pipe, a prefabrication method in the shop are 
becoming general. The introduction of the three-dimensional 
CAD is bringing about the affect of rationalization of the de- 
sign job, whereas the prefabrication method which makes the 
pipe in the shop is not always linking with the rationalization of 
the site job. The reason is that when an error in manufacture of 
the apparatus or an error in installation and further, an error in 
manufacture of pipe have come about, the manufactured pipe 
can not be connected to the apparatus at the site and it becomes 
necessary to do an adjusting work by cutting pipe and welding 
at the site. Generally, the field adjusting work costs a lot be- 
cause it involves the fabrication of scaffold, disassembling 
work and use of hoist, etc. In addition, for a double tube pipe 
line or a pipe made of titanium, the field adjusting work is 
difficult or cannot be done. To solve the problem, it is neces- 
sary to make accurate measurement of the installed locations of 
apparatus, modify CAD data based on the judgment of the 
designer and make sure of the manufacturing accuracy of pipe 
and for this, a three-dimensional measurement is absolutely 
necessary. 
Therefore, the author et al. embarked on building up a three- 
dimensional measurement system with the object of promoting 
the prefabrication method in the construction of chemical plant. 
A system employing a total station requiring a target at a meas- 
uring point has been built up and at present, the system has 
been applied at the site. This system is such that for measuring 
à point at a high place, a target has to be put on by using a 
ladder or a footing. Therefore, in order to save the time and 
labor for putting this target on place, a three-dimensional 
measurement system has been examined which is available by 
collating a stereo image with CAD diagram with the use of 2 
units of servo-drive type video total station containing CCD 
camera and the prospect of putting the system to practical use 
has been obtained. 
This report describes the outline of the system built up with 
the total station requiring the target and the results of applica- 
tion to the chemical plant site and at the same time, it covers 
the summary of the three-dimensional measurement system 
( CAD base measurement system ) available with the stereo 
image and the results gained by making sure of the measure- 
ment accuracy. 
2. Measurement at chemical plant 
Fig.1 shows the layout of the chemical plant. the apparatus and 
pipe have been bolted through flanges and the pipes connecting 
between the apparatus are bent three-dimensionally and the 
2 
c Y Tank 
j X 
Reactor: 
    
  
Reactor 
Fig.1 Layout of the Chemical Plant 
shape is complicated. However intricate the midway route of 
the piping may be, when the pipes are connected, it is impor- 
tant that the centers of the flanges fitted to the apparatus and 
pipe, inclinations of the faces and bolt hole positions are in 
353 
International Archives of Photogrammetry and Remote Sensing. Vol. XXXI, Part B5. Vienna 1996