Rotating Machinery Services (RMS), a global provider of engineering, repair, and maintenance solutions for turbomachinery, implemented a digital twin workflow using Prevu3D to improve the accuracy and efficiency of equipment replacement.

Facing increasing pressure to reduce downtime and ensure precision during complex machinery swaps, RMS leveraged 3D scanning, point cloud data, and virtual assembly to transform its maintenance process for critical rotating equipment.

The Challenge: Complex Equipment Replacement and Downtime Constraints

Replacing turbomachinery components—such as centrifugal compressors—requires extreme precision. Even minor misalignments can lead to costly delays, safety risks, and operational disruptions.

Before adopting a digital twin approach, RMS faced several challenges:

Limited visibility into as-built conditions of operating equipment
High dependency on manual measurements and field verification
Risk of misalignment during drop-in replacements
Inability to detect fit and clearance issues before shutdown
Tight maintenance windows with zero tolerance for error
Potential for unexpected rework during installation

These constraints made it difficult to guarantee a seamless replacement without impacting production timelines.

The Solution: Digital Twin and Virtual Assembly Workflow

RMS implemented a digital twin-driven maintenance workflow, combining real-time 3D scanning with Prevu3D’s RealityPlatform™ to simulate and validate equipment replacement before execution.

This approach enabled:

Accurate 3D visualization of existing and replacement equipment
Virtual overlay of components to identify discrepancies early
Data-driven decisions using precise metrology insights
Full validation of installation scenarios before downtime begins

Technology Deployed: 3D Scanning and RealityPlatform™

Live 3D scanning of operating equipment without interrupting production
High-precision scans of replacement machinery at RMS facilities
Upload and processing in RealityPlatform™
Conversion of point cloud data into high-fidelity 3D meshes
Core Capabilities

Virtual overlay of existing vs. replacement equipment

Measurement of critical geometries (nozzles, baseplates, alignments)
Integration with engineering workflows for rapid validation

Process: RMS Virtual Assembly Workflow

Step 1 – Capture Existing Equipment

Scan the compressor while in operation
Capture critical geometries without disrupting production

Step 2 – Scan Replacement Equipment

Digitally map the replacement blower at RMS facilities
Ensure high-accuracy reference for integration

Step 3 – Virtual Overlay and Assembly

Overlay replacement equipment onto existing scan data
Evaluate fit, alignment, and internal clearances in real time

Step 4 – Issue Detection and Mitigation

Identify mismatches (e.g., nozzle height differences)
Implement corrective actions such as:
Baseplate machining adjustments
Fabrication of transition components

The Results: Reduced Downtime and Increased Installation Accuracy

The digital twin workflow enabled RMS to significantly improve maintenance outcomes:

Operational Efficiency

Reduced maintenance downtime through pre-validated installation plans
Faster execution with fewer on-site adjustments

Accuracy and Precision

Early detection of alignment and clearance issues
Improved fit between existing systems and replacement equipment

Risk Mitigation

Elimination of unexpected installation conflicts
Reduced reliance on reactive problem-solving during shutdown

Collaboration and Decision-Making

Enhanced coordination between engineering, metrology, and field teams
Faster, data-driven decisions using 3D visualization tools

Engineering Impact: Data-Driven Maintenance for Critical Equipment

The adoption of digital twin technology allowed RMS to shift from reactive to proactive maintenance planning.

Key improvements include:

Ability to simulate equipment replacement scenarios in advance
Reduction in manual measurement errors
Improved reliability in high-stakes industrial environments
Standardization of repeatable, scalable maintenance workflows

With Prevu3D, we can overlay CAD models onto 3D scans, identifying critical misalignments before they escalate. This proactive approach has saved us and our clients significant time and resources.

-Matt Walker, Manager of Data Analysis and Training at Rotating Machinery Services

Conclusion: Transforming Turbomachinery Maintenance with Digital Twin

By integrating 3D scanning, virtual assembly, and digital twin technology, RMS established a more efficient and reliable approach to turbomachinery maintenance.

This methodology sets a new benchmark for:

Precision in equipment replacement processes
Minimization of downtime and operational risk
Scalable adoption of data-driven engineering workflows

about The client

RMS

Founded in 1998, Rotating Machinery Services (RMS) was established with a clear vision: to redefine the aftermarket turbomachinery business. RMS provides turbomachinery operators with unmatched service, combining robust engineering expertise, technical excellence, and long-standing relationships. This dedication is supported by competitive pricing and responsive lead times, making RMS a trusted partner in the industry.

about us

Prevu3D

Prevu3D, a Montreal-based tech company founded in 2017, is dedicated to leveraging the physical world to drive work efficiency and innovation. Our intuitive software solution bridges reality to the digital world, offering the most accurate representation of facilities for engineering, maintenance and operational needs.