An energy technology company specializing in operational efficiency improvement and carbon emission reduction solutions was tasked with inspecting multiple identical multi-stage geared centrifugal air compressors at a Carbon Capture, Utilization, and Storage (CCUS) facility.
Each compressor measured approximately 3m × 3m × 3m and required highly accurate inspection of all inlet and outlet flanges, as well as the positions and connection interfaces of the existing piping system. The objective was to identify deviations between the actual installation and the CAD model while also evaluating potential differences among compressors of the same type.
Due to the large dimensions and complex geometry of the compressors, using conventional measurement equipment was practically impossible.
Mechanical tools such as calipers are only suitable for simple components and cannot capture complete data from the complex surfaces of compressor assemblies. At the same time, the equipment dimensions exceeded the working range of many Coordinate Measuring Machine (CMM) systems.
Laser Trackers were also not an ideal solution because the project required data collection from five sides of each unit, including the front, rear, both sides, and top surfaces. Not all of these surfaces could be observed from a single instrument location.
In addition, several optical measurement systems faced limitations because the height of the compressors exceeded the standard working range of their supporting structures and fixtures.
In this case, optical measurement technology was the only solution capable of meeting both data coverage and accuracy requirements.
Beyond measurement limitations, traditional methods are highly dependent on operator experience.
For example, when performing gap measurements or manual inspections, the results are often a collection of individual numerical values that provide little overall visualization. Data analysis and comparison with engineering drawings also require significantly more time.
In contrast, optical measurement technology delivers highly accurate and visual 3D data. Engineers can easily identify deviations, evaluate dimensions, and analyze the actual condition of equipment quickly and clearly.
All measurement work was carried out directly within the production environment, specifically in assembly and piping installation areas.
As a result, the selected solution needed to be easily transported across different locations within the facility while also supporting on-site inspection services at customer facilities when required.
Furthermore, the equipment had to operate reliably under a variety of environmental conditions, ranging from indoor manufacturing areas to outdoor industrial sites.
Given the large size of the compressors, the engineering team combined photogrammetry technology with the FARO CREAFORM MaxSHOT 3D system and the FARO CREAFORM HandySCAN 3D Black to ensure accuracy across the entire assembly.
MaxSHOT 3D was used to establish a highly accurate reference framework for the large compressor assemblies. HandySCAN 3D then captured detailed geometric data from flanges, piping systems, and critical connection surfaces.
For large areas, Far Mode enabled rapid scanning from greater distances, reducing the number of required targets. Meanwhile, Near Mode allowed high-resolution data acquisition in regions with complex geometries.
For medium-sized components, Scale Bar Mode provided an effective alternative to conventional photogrammetry methods while maintaining the required level of accuracy.
Thanks to its handheld design and optimized weight, the HandySCAN Black 3D scanner could be used flexibly throughout the facility or at customer sites.
Measurement operations were no longer restricted to a dedicated inspection room and could instead be performed directly on the production line or in assembly areas.
This capability was especially valuable when accessing difficult locations surrounded by dense piping systems or confined workspaces.
One of the key advantages of the FARO CREAFORM HandySCAN 3D and MaxSHOT 3D system is its ease of use.
Operators require only minimal training to perform accurate measurements. The system provides intuitive color-coded indicators that simplify setup and alignment procedures.
The Creaform Metrology Suite software is also designed with user-friendliness in mind. With only a few simple steps, technicians can begin scanning and monitor data acquisition progress in real time.
Beyond technical specifications, the company prioritized solutions that have been widely adopted throughout the industrial metrology sector.
The combination of HandySCAN 3D, MaxSHOT 3D, and Creaform Metrology Suite ensures long-term technical support, regular software updates, and access to advanced training programs.
As a result, the company can maintain consistent inspection performance across large-scale industrial projects.
The ability to adapt to various working conditions significantly reduced project implementation time.
Whether dealing with large components, complex geometries, or hard-to-reach environments, measurements could be performed quickly and directly on-site.
Thanks to the straightforward workflow and short learning curve, multiple team members could participate in inspection activities without requiring extensive specialized training.
Bringing high-accuracy measurement technology directly to the production environment eliminated unnecessary internal transportation steps.
Engineering teams could perform inspections anywhere within the facility, reducing waiting times and enabling multiple projects to be executed simultaneously.
For engineering service providers, adopting advanced measurement technologies improves work quality while shortening response times for customers.
Faster project delivery, more accurate data, and greater flexibility in handling customer requirements help build trust, improve customer satisfaction, and create new opportunities for future collaboration.
As industrial plants and manufacturing systems become increasingly complex, implementing 3D inspection technology not only improves measurement accuracy but also reduces project timelines, minimizes errors, and optimizes operational performance. For large-scale equipment, complex geometries, or applications requiring comparison with CAD models, 3D scanning has become an essential tool for inspection, maintenance, and system improvement.
If your company requires dimensional inspection, as-built 3D scanning, assembly deviation analysis, or engineering data digitization for design and manufacturing purposes, 3D Master is ready to support your projects with an experienced engineering team and high-accuracy industrial 3D scanning equipment.
We provide comprehensive, fast, and reliable measurement solutions powered by Creaform technology for industries including manufacturing, energy, oil & gas, tooling, automotive, and heavy industry.
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