Advanced 3D digitization for two ENI industrial sites
INTRODUCTION
3Units has developed accurate digital models to support the management of two strategically important industrial plants.
This large-scale project, commissioned by ENI, involved the creation of two separate Digital Twins for the San Donato Milanese and Ferrara sites. The objective was to equip the energy group with an advanced tool for process optimization, predictive maintenance, and asset management.
The project presented a significant challenge: digitizing extensive and complex areas using next-generation 3D surveying technologies, while ensuring maximum data accuracy and reliability. It required deep technical expertise, a rigorous methodological approach, and a strong understanding of industrial operations.
STEP 1
Laser scanning
and 3D digitization
The first step involved conducting a full as-built laser scan — both static and mobile — of the Bolgiano co-generation plant in San Donato Milanese. The survey covered approximately 4,000 m², including both interior and exterior areas with diverse environments such as engine oil tanks, the UREA storage zone, the TLR pump building, the water treatment facility, and the superheated water accumulators.
High-precision 3D data was captured using Z+F 5016 terrestrial laser scanners and Leica HDS7000 scanners with pulse-based technology. This was combined with a SLAM (Simultaneous Localization and Mapping) mobile mapping system featuring dual LiDAR sensors and four color cameras — enabling rapid and accurate digitization of the entire facility. The integrated approach resulted in a color virtual tour and a detailed 3D point cloud. All equipment was also photographed to link visual context with 3D data, and the complete dataset was processed and delivered through an interactive online platform for client access.
STEP 2
3D Modeling from point cloud
The next phase involved the 3D modeling of two distinct areas within the Ferrara petrochemical complex, covering a total surface area of approximately 28,000 m². Using data provided by ENI, detailed three-dimensional models were developed with the support of four specialized software platforms. All visible elements within the point clouds were modeled, including beams, columns, stairs, railings, tanks, reactors, pumps, ducts, and piping.
The resulting model — delivered together with 2D floor plans and elevations — offers a comprehensive 1:100 scale representation of the entire reprocessed area. It serves as a valuable tool for the planning, operation, and management of the industrial facility.
Total surface area
Industrial sites
Production areas
Modelling software used
CONCLUSIONS
Digital Twins: dynamic tools for operational excellence
The collaboration with ENI showcases 3Units’ ability to deliver comprehensive, customized 3D digitization solutions for highly complex industrial facilities. By integrating advanced surveying and modeling technologies, 3Units developed valuable digital models to support operational planning at both the San Donato Milanese and Ferrara plants.
These 3D models are not just digital replicas — they are dynamic tools that provide ENI with deep insight into its assets. Their functionality enables more efficient maintenance planning, reduced equipment downtime, and significant improvements in workplace safety.
