Examples of 3D analysis

May 7, 2022
Seikowave

Contents

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2021/5/31

Abstract
Introduction of tools
Examples of steel structure measurement & analysis
Fitness for service examples compliant to wes2820 (Japan), API-579
Examples of concrete structure measurement & analysis

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Abstract
Limitation of the traditional way•

Objects to measure––•

Solution using non-contact, optical way••

Bridges in Japan
Tunnels•Using UT, but––

Proposed solution–

720,000+10,000+––

Digitization and visualization of inspection area by patternlight projection

Corrosion on production plants needs precise measurement
for better life estimation, but hard to get detail figures.

Other issues–•Tunnels and bridges need close-looking for evaluation, but
too many to execute using traditional tools.

Unable to use from the corroded side
Unable to use around welding lines•Measurement from a damaged surface is possible•

By 3D coordinate conversion of the target location

Visual inspection including photographing•Tends to subjective evaluation•Hard to quantify. Hard to predict life expectancy––

Color contour diagram (visualization)–

CSV file (quantified) with grid basis figures»Thus, the evaluation may vary by inspector by inspector

In local area, lack of human resources
There are many area hard to measure by the traditional way–

Easy to understand the progress of deterioration

From subjective judgment to objective judgment by
numerical value•

By standardizing equipment and analysis means, anyone canobtain almost constant results.
–

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Can be a trump card to solve the shortage of local human resources3

3D measurement toolEquipment appearance

Main specifications
Individual specifications•

3DSL-Rhino 400mm
•
••
•

•

3DSL-Rhino 200mm•

Features:•••••2021/5/31

No on-site calibration required
No need to attach a marker
No need for accurate positioning
Handheld measurement possible
Dustproof and splashproof

Area to measure @ 450mm standoff•
150mm x 270mm
Working distance range•
350mm ~ 470mm
Resolution•
XY: 400um, Z: 50um or lessCorrosion depth precision•
Z: +/-50um (1 sigma)•••

Area to measure @ 200mm standoff•
80mm x 140mm
Working distance range•
160mm ~ 250mmResolution•
XY: 200um, Z: 30um or lessCorrosion depth precision•
Z: +/-30um (1 sigma)

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Common specifications
••
•

••
•

Number of 3D coordinates
per single scan
• 300,000
Time to capture images• 80ms @ 300fps• 34ms @ 700fps
Data file format• Seikowave original(.skw)• Can be save with .plyformat
PC interface• GigE (1000 Base T)
Operation hour
• 6 hours + by 100Wh
battery packOperation temperature• -10C ~ +40C4

Structured Light Projection

It enables very fast measurement of whole area
Vision of Camera A2021/5/31

Parallax

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Three patterns, total 24 framesDistinguishable depthDistinguishable depth

32f pattern
8f pattern
Distinguishable depth

1f pattern

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EXAMPLES OF STEEL STRUCTURE
MEASUREMENT & ANALYSIS
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Area, hard to access by traditional tools
Surface of corroded flange
Corrosion next to wall
Corrosion around welding line

Corrosion under bolt

Corrosion under bolt

UT or Depth Gage are not usable
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Detection of corrosion and wall thinning in difficult-to-access areas
Color map On

1.12mm

1.78mm

1.14mmColor map off

List of corrosions

1.65mm

1.30mm2021/5/31

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External mechanical damage on pipes

Dents by rocks

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Measurement of external damage
Complicated deformation

Precise data acquisition for FEM analysis
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Analysis of external damage

3D data

The collapse of the pipeline due to falling rocks was measured
three-dimensionally. By performing finite element analysis of thethree-dimensional deformation data, it was immediately analyzed
whether it could be used as it is or whether it needed to be
repaired, which contributed to the early decision on the start ofoil production.

Color map
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Bridge secular variation (painting, bolts and nuts)
Coating film expansion (fragile)

Anti-corrosion treatment
and deformation of nuts

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Bridge secular variation (painting, bolts and nuts)
Floating coating filmErosion

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Using IMC software “UnitFitness”

Fitness for service of thinned nut
Photo of thetarget
FFS assessment

Pass3Dmeasurement

Analysis2021/5/31

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Quantification of changes over time in paint film swelling
As of January 2018

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Coating film swelling, transition of 3D data
As of Jan. 20192021/5/31

As of Apr. 2021

As of Feb. 2020

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Quantifying the degree of swelling of the coating film
As of Jan. 20192021/5/31

As of Feb. 2020

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As of Apr. 2021

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Painted bridge repair work site2021/5/31

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Thinning due to raindrops
Photo2021/5/31

3D data screen shots

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C15-S3.PLY

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Cross section profile

Depth analysis
BA-a

B-b

Aa

Zero pointb深い

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CSV file output, color and graph by Excel

C15-S3 1mm x 1mm avg.xlsx

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Deterioration of bolt rust prevention treatment
Photo

3D data screen shot

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S3G1-ALL-1.PLY

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Remaining volume after cleaning
Height color map

Remaining volume of nut
高いRemaining volume in green square is listed in the table below.

基準平面2021/5/31

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Remained
volumeMax height24

CSV file output, color and graph by Excel

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S3-G1SEIKOWAVE
bolt 1mm x 1mm avg.xlsx25

On-site measurement of exposure test pieces
Photo of an exposure testpiece

3D measurement image of exposure test
piece (No shading information)
Quantification of
the amount of
excitement

Effect: Conventionally, the exposure test piece was removed and the shape was precisely
measured in the laboratory. Therefore, the number of test pieces is reduced by removing the test

Max heightpiece. Since it can be measured in the field, continuous observation is possible, and the number oftest pieces can be reduced = the exposed field area can be reduced.

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Area of excite area

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Weathering steel bridge (progress of corrosion)Level 1 or 2 corrosion

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Weathering Steel Bridge Corrosion Evaluation

It is important to separate the level 2 from the level 3, but ...
It is important to separate the level 2 from the level 3, but ...

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Corrosion level (scoring) evaluation software
3D measurement

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Corrosion evaluation

Effect: By digitally determining the boundary between the level 2 and the level 3, it becomes possible to objectively determine thenecessity of repair without relying on personal factors.

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Oil tank; visual inspection of side wall plates

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Tank side wall:Problems and solutions for visual inspection• Challenges of conventional visual inspection: Excerpt from "Safety & Tomorrow“•All bottom plates are to be measured for thickness, but side plates are to be checked for thickness only when corrosion is observed. If corrosion
is found by visual inspection of the side plate, measure the corrosion depth using a depth gauge, etc., and in the case of the old method tank,confirm that the residual wall thickness is 3.2 mm or more. If it is less than 3.2 mm, the current Fire Service Act stipulates that repairs should becarried out. However, it is a self-evident fact that the location selection of the maximum corroded point and the accuracy of the measured
values are affected by the skill level and physical condition of the inspector, and it is confirmed whether the corrosion measurement point
position is the same at the next inspection or not. Often it is unclear. In this way, it can be said that the method using the depth gauge has somedifficulty in grasping the measurement accuracy and the history of corrosion progress.

• Solution by optical 3D measurement method• The maximum corroded location can be identified by batch measurement on a surface-by-surface basis.
• Data converges within a certain error range no matter who measures it.
• The marking points are converted into data together, and the measurement points are clear.

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Shape measurement results around the weld line

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Analysis of depth of corrosion

Repaired area

Repaired area

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Depth profile

The maximum wall thinning point is automatically detected, and the wall thinning depth in thelongitudinal direction and the circumferential direction is plotted.
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By POLYGONALmeister

Corrosion of tank bottom plate (side plate peripheral area)

Corrosion of the bottom plate under the lining progresses with the service life.
The bottom plate is originally not flat due to welding thermal strain during construction, and if pitting corrosion progresses, it becomes difficult to measure with an ultrasonic wall
thickness gauge or depth gauge. Conventionally, grasp of accurate corrosion amount (residual wall thickness) was difficult.
Seikowave has developed an analysis method that eliminates the influence of wavy strain on the plate by performing measurements using an optical three-dimensional
measurement that can be measured on a plane basis.

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Boiler internal water cooling pipe damage measurement
水管壁には上下方向に多少の歪みが発生しているが、この解析ソフトウェアでは、その歪みに影響されずに、キズ深さを検出可能。

キズ最大深さ 0.8mm
キズ幅 6.5mm

キズ長さ 74.0mm

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外形64mmSEIKOWAVE

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Uni-Fitness

FITNESS FOR SERVICE EXAMPLESCOMPLIANT TO WES2820 (JAPAN), API-579
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Thinned metal pipe
Target pipe

3D measurement

Nominal pipe thickness = 7.2mm
Outside diameter = 165mm
Inside diameter = 150.6mm

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Phase-shifted pattern is
projected to the target
surface.

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3D analysis
3D data (no texture)

Corrosion color map
Deepest point = 4.24mm

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CSV data of the corroded area

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Enter parameters of the pipe to analyze
Use “Uni-Fitness” by IMC

Standard to use forevaluation are• ASME FFS-2 / API-579
English version is alsoavailable.

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Load CSV data of thinned area

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Evaluation resultPass2021/5/31

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EXAMPLES OF CONCRETE STRUCTURE
MEASUREMENT & ANALYSIS
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Damage on concrete bridge
Measurement by 3DSL-Rhino

3D data

250mm

330mm

Total time for measurement and analysis is less than 1 minute.
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Visualization with color map
Depth map

Depth Profile

AAaB

337mmbb

Vertical profile

Horizontal profile

231mm

Ba

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Ref. height (zero)

Lost volumn

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Swelling on concrete wall
Measurement

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Area to analyze

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Visualization of swellingWith 4 data stitched

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Crack on concrete

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Visualization of crack

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Damage on concrete after earthquake
３Ｄ data

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Color map

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Profile of concrete surface

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Damage of concrete surface due toReinforcing bar swelling
3D data

Color map

Courtesy by Prof. Kitano, Nagoya Univ.

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Volumetric loss

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Damage of concrete surface due toReinforcing bar swelling

Deepest =17.73mm

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Cracks on the asphalt pavement

170cm

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Cracks on the asphalt pavement
Local analysis

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Cracks on the asphalt pavement

170cm

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Cracks on the asphalt pavement
Colored only for 4mm or deeper

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Analysis of Seismic isolation foundation concrete
Using a software, only voids with a depth of 0.5 mm or more and a length of 5 mm or moreare colored, and the total area and area ratio are calculated (conventional manual work).
Total time for measurement and analysis is less than 30 minutes

200mm

1,000mm2021/5/31

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All-around measurement and wear analysis ofship mooring chain
Wear location

Total time for measurement and analysis is less than 30 minutes
Corrosion location
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Inscription on the stone monument
Measurement

3D data

Total time for is less than 5 minutes

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Clarification of the inscription on the stone monument

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Conclusion• Problem-solving proposal– Digitization and visualization of inspection points by pattern light projection• Measurement from a damaged surface is possible• By 3D coordinate conversion of the target location– Color contour diagram (visualization)– CSV file (quantified) for each grid
» Easy to understand the progress of deterioration– From subjective judgment to objective judgment by numerical value• By standardizing equipment and analysis means, anyone can obtain almost constant results.
– Can be a trump card to solve the shortage of local human resources

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Contact

Minoru “Mini” NiimuraManaging Director, Seikowave K.K.
m.niimura@seikowave.jp

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