Training Path Module 5
Overview
Selecting Visual Report from the main application menu following a survey compares captured field observations against design specifications (`.DES`).
The visual analysis suite enables surveyors to rotate and translate models, include or exclude specific flanges from least-squares fit calculations, zero individual tie-ins, adjust fit weighting preferences, and isolate gross fabrication errors.
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Graphical visual analysis display comparing survey to design
File Dependencies and Opening Surveys
Analyzing survey data requires two corresponding files:
- Survey File (`.SUR`): Contains observed field coordinate data.
- Design File (`.DES`): Contains baseline CAD model geometry.
To analyze a previously completed survey, select Open for Analysis adjacent to **Survey File:** on the main interface—the corresponding design file loads automatically. If a survey was just completed, click Visual Report directly.
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Main menu analysis launch controls
Visual Report Controls
Navigation and Interface Controls
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Main visual report button layout
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Reset camera view (North to top-left) -
Toggle back vectors on/off -
Toggle observed points spheres on/off -
Toggle model full shrink -
Toggle model full size -
Toggle free rotate vs. turntable mode
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Expanded viewer controls and display scaling sliders
Video guide: Controls for Iso View in Analysis (2:41)
Summary: Demonstrates camera rotation, wheel zoom, mouse pan, camera resets, showing observed point spheres, scaling vector arrows, and adjusting model shrink parameters.
Flange Parameters and Context Details
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Flange context details panel
Bolted-Up Condition
automet® FAB automatically calculates whether a flange is bolted to an existing tie-in by measuring the distance between the **diameter-point plane (D)** and the **stop point (S)**. Operators can manually toggle this state if physical field conditions differ.
Measurement Reference Planes
- D (Diameter Plane): Represents the primary flange face plane defined by diameter points.
- S (Stop Point): Represents the rear or opposite flange face observation.
- Gap & Flange Thickness: Can be edited to reflect tape-measured field values rather than database defaults.
Ignore Length Option
Disables vector error calculations along the longitudinal pipe axis.
- Open Pipe Ends (PE): Enabled by default for un-flanged pipe ends to allow for weld prep trimming allowances without skewing best-fit calculations.
- Custom Flange Configurations: Can be manually enabled on any flange if axial fit flexibility is required.
Fit Preference Slider
Controls mathematical optimization weighting across active components:
- Position: Prioritizes minimizing positional vector errors (black arrows). Default setting for standard surveys.
- Alignment: Prioritizes minimizing angular touch-point gaps (gold values) and flange face parallelism.
- Balanced Weighting: Operators can slide between Position and Alignment to evaluate fit trade-offs. Click **Reset to Defaults** at any time to restore initial state.
Bolt-Hole Observation Table
Displays pitch angle deviations and radial pitch circle diameter (PCD) errors for individual bolt-hole observations on the selected flange. If an individual bolt hole contains a large localized error (e.g., misaligned magnet), uncheck its **Fit** box to remove it from PCD calculations.
Touch Point at OD
Toggles touch-point gap calculations between the **raised face** diameter (default) and the full **outside diameter (OD)** of flat-face flanges.
Fit Optimization, Zeroing, and Fit Isolation
Fit Checkboxes
- Fit Checkbox: Unchecking a flange excludes its points from the mathematical least-squares averaging calculation, isolating gross errors without deleting data from reports.
- Show Checkbox: Toggles visual display of circle-fit centerlines on screen and in printed reports.
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Flange fit and show check-box options
Zeroing a Flange vs. Least-Squares Averaging
By default, automet® FAB uses least-squares averaging across all flanges to minimize overall error. However, this averaging process can **mask a single gross fabrication error** by distributing deviation across all flanges.
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Default least-squares fit showing distributed error
1. Zeroing Flange 1: Select the **Zero** checkbox for Flange 01 and click **Apply Selections**. Coordinates translate along grid axes so Flange 01 displays zero vector error.
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Zeroing Flange 01 selection -
Flange 01 zeroed with error shifted to Flange 02
2. Isolating Gross Errors: Large touch-point or positional errors on Flange 02 are now clearly isolated, exposing the exact location of fabrication defects.
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Isolating gross misalignment on secondary flange
Dropping a Flange from the Fit
Unchecking the **Fit** box on a problematic flange ("dropping it from the fit") forces the software to optimize geometry strictly using remaining flanges. On a two-flange spool, dropping Flange 02 fits Flange 01 perfectly to design while displaying full positional and angular deviations on Flange 02.
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Multi-flange spool with isolated fit calculations
Video guide: Zeroing Flanges & Isolating Gross Errors (2:14)
Manual Transforms and Model Adjustments
The **Transform** module allows surveyors to manually translate and rotate survey models across six degrees of freedom (X, Y, Z axes).
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Analysis transform interface
Open Tie-In Surveys
When analyzing open tie-in site surveys, enable the **Open Tie-In** function to prevent coordinate fit distortions.
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Open tie-in analysis control panel
Report Generation
automet® FAB generates three specialized documentation reports following analysis setup:
Visual Error Report
3D graphical view displaying vector arrows, rotational offsets, and face touch-point gap dimensions.
Text Report
Tabular coordinate listing showing actual vs. design coordinates, D-point locations, and alignment angles.
QA Integrity Report
Quality audit verifying face planarity, PCD errors, device types, and multi-setup instrument move precision.
Visual Error Graphical Report
All displayed values represent deviations from design; a perfectly manufactured spool yields all **zero values**.
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Full 3D graphical visual error report
- Vector Errors (Black Arrows): Indicate displacement magnitude and direction (+1.4 mm Z, +0.6 mm Y North, +0.8 mm X East). Correct by adjusting physical flange in the opposite direction (-1.4 mm Z, -0.6 mm South, -0.8 mm West).
- Bolt-Hole Rotation (Blue Curved Arrow): Shows rotational error magnitude (in mm) and direction.
- Touch Point (Gold Value): Identifies the raised-face high point contacting the mating flange first. The value represents the gap opening on the opposite side.
- Open Pipe End Long Point: Identifies the longest point on un-flanged pipe ends to guide field bevel grinding.
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Positional vector error arrows -
Bolt-hole rotational error arrow -
Flange touch point high-point gap -
Open pipe end long-point gap
Text Report
Contains tabular alignment, orientation, and global coordinate comparisons essential for field site surveys.
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Text report coordinate summary page
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Flange specification and gasket summary -
Calculated work point centerlines -
Plane point coordinate locations -
Individual observed point coordinates -
Flange midpoint coordinate summary
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D-point location reference states
QA Integrity Report
Validates observation quality, face flatness (plane error), target seating (Max OD error), and instrument setup resection accuracy across multiple station moves.
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QA integrity report page 1 -
QA integrity report page 2 (support plates and instrument moves)
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Plane error warning (face planarity > 2 mm) -
Max OD circle error (unseated target device) -
Pitch Circle Diameter (PCD) error diagram -
PCD deviation readout -
Max bolt-hole pitch error diagram -
Max pitch angle deviation readout
Live QA Report During Capture
QA integrity reports can also be reviewed live during survey capture via the **Objects Tab**, allowing operators to identify and re-shoot flawed points before disturbing total station setups.
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Live capture QA report view 1 -
Live capture QA report view 2
PDF Export Preview
To generate customer-facing PDF documentation, align the 3D model on screen to present all relevant callouts clearly, then click **PDF Preview**.
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PDF export preview window
Training Path Completion & Next Steps
Congratulations on completing the **automet® FAB Self-Guided Learning Path**.
To continue expanding your technical expertise, explore the following specialized workflows:
- Automet® FAB - Site Survey – Detailed field site survey procedures.
- Automet® FAB - Control Capture Methods – Advanced resection networks and control station management.
- Pressure Vessels – Modelling and surveying pressure vessel nozzles and shell alignments.
For technical assistance or training inquiries, contact MLTech support at **info@mltech.co.uk**.