Technical Case Study: 3D Terrestrial Laser Scanning of Fuel and Water Storage Tanks

Project Summary

Client: Newmont Corporation

Location: Lihir Island, Papua New Guinea

Asset: Large Above-Ground Fuel Storage Tanks

Scope: Geometric deformation analysis (banding and peaking) using terrestrial laser scanning

Technology: High-resolution terrestrial LiDAR scanners (millimetre accuracy)

Background and Objectives

Newmont’s Lihir Island operation includes several critical above-ground fuel storage tanks subjected to continuous thermal cycling, internal pressure, and environmental stress. Over time, these factors can lead to banding (circumferential shell distortion) and peaking (localized vertical deformation at weld seams).

The primary objective of the survey was to:

• Capture high-density, full-surface geometry of the tank shells and roofs.

• Quantitatively assess banding and peaking deviations against design tolerances.

• Generate a digital baseline model for future integrity comparison and maintenance planning.

Methodology

Nurosight Robotics deployed terrestrial laser scanning (TLS) to obtain a complete three-dimensional point-cloud model of each tank.

Scanning Process:

• Multi-station scans were performed around the tank perimeter and upper catwalks.

• Each scan captured millions of XYZ points with sub-centimetre precision.

• Data was registered and aligned into a unified coordinate system using georeferenced targets.

• The merged point cloud was processed to extract vertical and circumferential cross-sections at 1° increments.

Analysis Workflow:

• Shell curvature and roundness profiles were computed from the point cloud using industry-standard analysis software.

• Banding was identified through periodic variations in shell radius along circumferential lines.

• Peaking was assessed through localized angular discontinuities at vertical weld seams.

Results and Deliverables

Data Output:

• Point-cloud resolution: < 5 mm spacing over the tank shell.

• Vertical deviation profiles (± 1 mm accuracy).

• Circumferential roundness plots for each shell course.

• Colour-mapped deformation models highlighting banding and peaking zones.

Engineering Insights:

• Quantified banding amplitude within acceptable API 653 tolerances for most shell courses.

• Detected minor peaking anomalies near vertical weld seams on the upper course.

• Provided baseline digital geometry for long-term comparative monitoring.

All findings were compiled into a comprehensive engineering report, including 3D models, sectional plots, and tabulated deviation statistics for each measured course.

Advantages Over Conventional Techniques

Parameter	Manual Survey	Terrestrial Laser Scanning
Measurement Density	Discrete points (≈ 10–20)	Millions of points (continuous surface)
Accuracy	± 10 mm	± 2–3 mm
Inspection Time	Several days per tank	1 day per tank
Safety	Requires working at height	Non-contact, ground-based
Repeatability	Low	High (digital dataset archived)

TLS provided a non-intrusive, data-rich, and repeatable inspection approach that significantly improved diagnostic accuracy and long-term asset traceability.

Conclusion

The application of terrestrial laser scanning at Newmont Lihir successfully demonstrated the capability of modern LiDAR systems to detect banding and peaking deformations in large-diameter fuel storage tanks.

By integrating 3D geometric analysis into asset integrity management, Nurosight Robotics enabled the client to:

• Verify tank condition quantitatively, not visually.

• Establish digital baselines for lifecycle monitoring.

• Reduce inspection duration and eliminate safety exposure.

  
  

This project validates the role of TLS as a key tool in structural integrity assessment and predictive maintenance planning within the mining and energy sectors.