Petrochem
Scan-to-Fabrication for Refineries, Upgraders, and Petrochemical Plants
Petrochemical and refining projects operate at the highest-stakes intersection of brownfield complexity and schedule consequence. A one-day TA extension on a refinery can cost $10M+. Tie-ins into live process units leave no room for a spool that doesn’t fit.
OnSite3D delivers engineering-grade laser scanning, scan-to-fabrication workflows, and VDC coordination built specifically for refining and petrochemical environments. Verified conditions. Fabricated to tolerance. First-time fit-up by design.
The Cost of Getting It Wrong in a Refinery Is Not Theoretical
Refineries and petrochemical plants are the most unforgiving brownfield environment in industrial work. Process units run hot, at pressure, with no tolerance for improvisation. The existing piping is congested. Access is restricted. The TA window is fixed.
When a fabrication package relies on legacy drawings, manual measurements, or “field verify” assumptions, the risk lands on the installation crew — and ultimately on the schedule. A non-fitup event in this environment isn’t a minor inconvenience. It’s a critical path failure.
OnSite3D eliminates that risk at the source by verifying existing conditions before anything is fabricated.
From Tie-In Verification to Full TA Coordination
OnSite3D works across the refining and petrochemical project lifecycle — from pre-TA conditions capture to post-TA as-built closeout.
As-Built Capture & Digital Twin
High-accuracy 3D laser scanning of existing process facilities — distillation columns, heat exchangers, piping racks, structural steel, and critical tie-in points. Results hosted on WebShare and available to your engineering and maintenance teams from Day 1.
Scan-to-Fabrication
Point cloud registered against the design model, deviations flagged before fabrication. Replacement piping, structural components, and process tie-ins fabricated in our RoboFab facility — ABSA AQP certified. Laser QA before every piece ships.
Virtual Assemblies & 4D Simulation
Digital fit-up validation before the TA window opens. Rigging paths, equipment installation sequencing, access and clearance validation — resolved in the model so field execution proceeds without improvisation.
Turnaround & STO Support
Pre-TA conditions capture and scope validation, in-TA dimensional support for tie-in issues, and post-TA as-built capture to close the record for the next maintenance cycle.
94.36%
Spool in-tolerance on laser QA (CN-1001)
98%
Off-site prefabrication achieved (Acid Gas Injection Upgrade)
48 hrs
Planning estimate turnaround
75–80%
Proposal award rate
$10M+
Cost of one day of extended refinery downtime
ABSA AQP
Certified — CS, SS, Monel, Inconel
Services Built for Refining and Petrochemical Execution
Every OnSite3D service that matters for petrochem brownfield work, in one connected workflow.
3D Laser Scanning
Engineering-grade point cloud of existing process facilities — distillation columns, heat exchangers, piping, structural, tie-in points.
As-Built & Digital Twin
WebShare-hosted facility model — verified record of actual plant conditions, accessible to engineering and maintenance.
Scan-to-Fabrication
Spools fabricated from verified scan data — ABSA AQP certified, laser QA’d, first-time fit-up by design.
Virtual Assemblies & 4D Simulation
Pre-TA fit-up validation, rigging studies, sequencing, clearance checks.
Turnaround & STO Support
Pre-TA capture, in-TA dimensional support, post-TA as-built.
Brownfield Engineering & MRO
CWPs and modification packages from verified scan data — ABSA AQP stamp.
Why Refining and Petrochemical Teams Choose OS3D
Outage Window Discipline
OnSite3D’s workflow is built around the constraint that makes refinery and petrochemical work unforgiving: the TA window is fixed, the cost of overrun is immediate, and field rework is not an acceptable contingency. Verified conditions and pre-validated fit-up are the baseline, not the aspiration.
Difficult Environment Scanning
Refineries and petrochemical facilities present unique scanning challenges — live process units, overhead pipe racks, heat exchanger bundles, and confined process areas. Our scan teams capture what engineering needs for fabrication.
Fabrication to Certified Tolerances
ABSA AQP certified across CS, SS, Monel, and Inconel. Laser QA on every spool before it leaves our shop. 94.36% in-tolerance documented on CN-1001. The quality record follows the deliverable.
One Vendor from Scan to Installed
Scan, VDC, engineering, and fabrication under one contract. No handoff chain between a survey firm, a drafter, and a fab shop. When something needs to change, there’s one phone number.
Western Canada and US Gulf Coast
OnSite3D serves refining and petrochemical operators from Calgary and Houston. Western Canada — oil sands upgraders, SAGD facilities, and Prairie refineries — is our anchor market. The US Gulf Coast petrochemical corridor is an active and growing part of our regional footprint.
Tell Us Your Scope
Send us the unit, the tie-in, and the TA window. We’ll come back within 48 hours with a planning estimate — what we’d scan, how we’d coordinate it, and what we’d fabricate.
No commitment. No generic proposal. A real answer for your refinery or petrochem project.
Calgary, AB
587.325.9996 — Western Canada: refinery process units, petrochemical facilities, brownfield capital modifications
Houston, TX
US Gulf Coast — petrochemical, gas processing, refinery
Eastern Canada
Active project corridor — scan mobilization and fabrication delivery