3D scanning as the basis for precision-fit repairs in refineries

In oil and gas refineries, leaks in pipeline systems are among the most critical incidents. Valves, flanges, and connections are continuously exposed to corrosion, pressure, and material fatigue. The Colt Group is increasingly relying on 3D scanning to precisely prepare and execute repairs under live operating conditions.

For more than four decades, the company has specialized in repairing pressurized pipelines and operates at over 30 locations across the United States directly within customer facilities. The goal is to fix leaks without interrupting production, as shutdowns in continuously operated plants would have significant economic consequences. Traditionally, such repairs were based on manual measurements and sketches, which are increasingly reaching their limits when dealing with irregular or hard-to-access geometries.

“We fix leaks ‘online.’ The faster we respond, the faster we can seal a leak for a customer and reduce the risk of an interruption,” explains Wally Whitley, IT Director at the Colt Group. “In addition, we help our customers save money by minimizing product losses and maintaining productivity.”

The solution is the use of the wireless 3D scanner Artec Leo from manufacturer Artec 3D. The device captures complex pipeline geometries directly on site and generates a complete digital model within a short time. According to Wally Whitley, IT Director at the Colt Group, this enables a significantly faster workflow, allowing leaks to be sealed more quickly and product losses to be minimized.

The captured scan data is further processed in the Artec Studio software and serves as the basis for designing precision-fit repair components. These can then be manufactured— increasingly using additive processes. In particular, custom-fitted clamps and enclosures can be produced without extensive rework.

“We use Artec Leo for unusual geometries that occur in the field. They are not always circles or squares that are aligned. Some geometries are unusual, others impossible to measure because it would take so much time that it would not be worthwhile,” says Mike Yates, Head of Engineering at the Colt Group.

By combining 3D scanning and digital design, the Colt Group has been able to reduce rework and handle multiple projects in parallel. This demonstrates how digital capture and additive manufacturing can lead to measurable efficiency gains even in industrial maintenance.