Power Plant: Existing Structure Safety and Analysis

Project Summary

This project involved digitizing the existing geometry of the steel construction supporting the main boiler room at an operational power plant in Izmir for static verification. Deflections (deformations) in the structure operating under high temperature and vibration were detected using laser scanning, and an as-built model was produced to serve as a base for static analysis software (SAP2000, Tekla).

Engineering Problem

Plant operations noticed visible tilting in some steel columns in the boiler room and deflections in beams. The structural engineering firm needed "real and up-to-date" geometry to determine the structure's earthquake safety and operational lifespan.

Why Were Old Drawings Insufficient?

• On-site revisions (redlines) during construction had not been recorded in projects.
• Thermal expansion and loads over the years had deformed the structure.
• Project drawings were 2D and insufficient for 3D analysis.

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Solution: Reverse Engineering

Each node point, bolt group, and profile cross-section of the structure was measured with ±2mm accuracy using laser scanning.

Profile Identification Process

Library equivalents of steel profiles (HEB, IPE, UPN, etc.) were identified using automatic and manual methods on point cloud data.

| Structural Element | Detected Section (Example) | Point Cloud Match Accuracy | |--------------------|---------------------------|---------------------------| | Main Columns | HEB 600 (Reinforced) | 99.5% | | Intermediate Beams | IPE 400 | 98.0% | | Wind Bracing | L 100x100x10 | 95.0% |

Note: Non-standard or corroded profiles were modeled with actual dimensions as "User Defined".

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Deformation Analysis Results

Prior to static analysis, differences between the structure's "design geometry" (plumb) and "as-built condition" were reported with colored maps.

1. Column Tilts: 45mm axial deviation detected at +12.50m level in column on K-4 axis.
2. Beam Deflections: 30mm permanent deflection measured under load in main platform beams.
3. Flange Rotations: 2-3 degree angular distortions reported in some connection plates (base plate).

Critical Findings: This data was entered into the static analysis model as "initial imperfection," calculating that the structure's actual load-bearing capacity was 15% lower but still within safety limits. The improvement project was prepared based on this data.

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Why Laser Scanning?

Why were traditional methods (Total Station or Tape Measure) impossible for this project?

• Access: It was impossible to measure beams at 30 meters height without scaffolding.
• Speed: Plant shutdown lasted only 2 days. We scanned the entire site in 1.5 days.
• Data Density: Not just a single column, but the 3D behavior of the entire system needed to be analyzed.

As Eos Proje, we combine the most advanced measurement technologies with our engineering knowledge for the safety and sustainability of industrial facilities.

For industrial facility measurements and deformation analyses, get a quote now.