Maintaining complex piping systems in petrochemical plants demands a high level of precision, speed, and operational continuity. In many cases, halting production is not a viable option—particularly when reactors are running or aggressive media are being transported. To address this, U.S.-based service provider Colt Group, which specializes in pipe repair, relies on mobile 3D scanning technology to detect leaks accurately and without the need to shut down operations.
The company uses the portable Artec Leo 3D scanner, which enables real-time data capture in the field thanks to its wireless operation and integrated display. Compared to traditional methods—where pipe sections were manually measured and sketched—Colt reports an 18-fold reduction in effort. The system is particularly effective with complex, non-standard geometries, providing reproducible results that can be used directly in the design of custom repair components.
“We do ‘online’ leak repair. The faster we can do the job, the faster we can seal the leak for a customer, and decrease the likelihood of having to shut down,” explained the Colt Group IT Director Wally Whitley. “We’re also helping save our customers quite a bit of money by minimizing lost product and maintaining productivity. We keep them from having to shut down their process. The quicker we can do each step of our process, the more valuable we are to the customer.”
Captured models can be further processed using Artec Studio software. For beginners, the Autopilot mode offers an automated selection of the appropriate algorithms for data refinement. Mike Yates, Colt’s Head of Engineering, noted that past experiences with low-quality point clouds had initially shaped his skepticism toward 3D scanning.
“I have received scans before over time. One of our customers previously had a team come out and do some kind of scan,” recalled Yates. “Essentially, a bunch of data points were taken, but it wasn’t anything we could turn into a solid part. It was kind of unusable. That was around ten years ago, and that framed my opinion of 3D scanning. So honestly, I was skeptical.”
Today, the Colt Group uses the Artec Leo on a wide range of projects. Its precision reduces rework, and its speed increases throughput.
In terms of accuracy, he adds that “Leo is obviously superior,” but the Colt Group has benefited more from the new level of pace and customization it’s now able to measure with. “What we use the Leo for is the odd geometries that show up in the field,” Yates continued. “Not everything is circles or squares and follows a path. Some geometries are odd, some are impossible, and measuring others would take so long that it’s not worth the effort.”
Looking ahead, the company plans to capture the majority of the geometric models it requires each year using this method. For operators of critical infrastructure, this translates to shorter response times and minimized production losses.
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