Airport Fuel Tank Farm Scanned and Modeled for Design Review

Scan Hub was engaged by a fuel system management client to support redesigning components at the fuel storage site of an Australian domestic airport. The work formed part of an overall system review of aircraft refuelling at a capital city airport, where accurate existing-condition data was needed before any redesign could proceed.

This project is a strong example of 3D laser scanning in a hazardous, high-consequence environment, where safety, access, and precision must come together. This is a look at how the scan was carried out, why a fuel facility is so demanding to capture, and how the resulting 3D model supported a successful design upgrade of the refuelling system.

Scanning in a Hazardous Environment

A fuel storage facility is a highly dangerous environment for any work activity. Entering and working on a live fuel farm means adhering to strict safety protocols and procedures, and there is no room for shortcuts. Scan Hub operators have experience working within those protocols, entering the site safely and carrying out extensive 3D laser scanning without disrupting the facility or compromising safety.

Beyond the safety demands, the facility itself is complex. Fuel farms are dense with pipes, valves, pumps and gantries at every level, tightly packed and interconnected. Documenting that by hand would be slow, incomplete and, in this environment, unsafe. Laser scanning is non-contact and fast, capturing the entire facility accurately while keeping personnel time on site to a minimum, which is exactly what a hazardous site demands. The complex nature of the pipework, valves and gantries required a level of precision that Scan Hub is very familiar with.

Our Approach

Scan Hub completed a detailed 3D laser scanning survey of the site, then produced an accurate 3D CAD model of the defined pipe and pump components for the engineering team. The captured point cloud provided a complete, reliable record of the facility as it existed, and the CAD model translated the relevant components into usable engineering geometry.

The project ran like this:

1.      Planning and safety: we confirmed the scope, access and the strict site safety procedures required to work on a live fuel facility.

2.      Site capture: our operators scanned the facility, capturing the pipes, valves, pumps and gantries in full.

3.      Registration and processing: individual scans were aligned into one accurate point cloud of the site.

4.      CAD modelling: the defined pipe and pump components were modelled accurately for the engineering team.

5.      Verification: the model was overlaid with the 3D scan point cloud in Navisworks, so accuracy could be checked directly against the captured reality.

Accuracy Embedded at Every Decision Point

A key part of this project was confidence in the data. The finished model was overlaid with the 3D scan point cloud in Navisworks, allowing the engineering team to verify the model directly against the site's real, captured conditions. With that verification in place, our client could reliably inform the airport operator of redesign options, knowing accuracy was embedded at every decision point.

That is the real advantage of a scan-based model in a facility like this. Every design decision rests on a measured record of what is actually installed, not on assumptions or outdated drawings, which is critical when the asset is a live fuel system at an airport.

Project Outcome

The accurate digital model supported the successful refuelling system upgrade. Projects like this show how Scan Hub's 3D laser scanning and 3D modelling services help industrial clients across Australia improve engineering decisions, reduce project risk and extend the life of critical assets, even in the most demanding and hazardous environments.

What Clients Do With the Data

Accurate 3D data of a fuel facility or similar hazardous site supports a range of engineering work, including:

●     Redesigning pipework, pumps and components based on real conditions

●     Verifying models against captured reality using tools like Navisworks

●     Reducing time personnel spend in hazardous areas by capturing everything in one survey

●     Producing as-built documentation where drawings are missing or outdated

●     Supporting system reviews, upgrades and asset life extension

●     Giving operators reliable options for redesign, backed by accurate data

Frequently Asked Questions

Can you scan hazardous sites like fuel facilities?

Yes. Our operators have the experience to work within strict site safety protocols and procedures. Laser scanning is non-contact and efficient, so we capture the facility accurately while minimising time spent in hazardous areas.

Why use 3D laser scanning on a fuel tank farm?

Fuel farms are dense with pipes, valves, pumps and gantries that are difficult and unsafe to measure by hand. Scanning captures the entire facility accurately and quickly, giving engineers a complete and reliable record to work from.

What is the point cloud overlaid in Navisworks?

It means the 3D CAD model is checked directly against the Autodesk Recap scan point cloud in Navisworks. This verifies the model matches the real, captured conditions, confirming accuracy at every decision point.

What deliverables did the client receive?

A detailed scan survey of the site as a registered point cloud in Recap format, plus an accurate 3D CAD model of the defined pipe and pump components for the engineering team.

How does scanning reduce risk on a project like this?

By basing every design decision on a measured record of what is actually installed, rather than assumptions or outdated drawings. On a live fuel system, that accuracy directly reduces engineering and safety risk.

Can the model support a system redesign or upgrade?

Yes. In this project, the accurate model supported a successful refuelling system upgrade, giving the operator reliable options based on real site data.

How accurate is the scan data?

Laser scanning delivers high-accuracy measurement of approximately +/- 2mm across a facility. Careful planning and registration keep that accuracy consistent across a complex, congested site.

Do you work at airports and other secure sites?

Yes. We have experience working within the access, safety, and security requirements of airports and other controlled environments across Australia.

How long does it take to scan a fuel facility?

It depends on the size and complexity of the site and the deliverables required. We plan the capture around safety requirements and site access and confirm timeframes before we start.

Do you provide these services Australia-wide?

Yes. Scan Hub provides 3D laser scanning and 3D modelling for industrial and infrastructure clients across Australia.

Talk to Scan Hub About Your Facility

If you need accurate 3D data of a fuel facility, plant or other hazardous site to support a redesign, upgrade or system review, Scan Hub has the experience to capture it safely and precisely. Contact us to discuss your project and get a fixed-price quote.