Case Study
Reverse Engineering to Fabrication — Existing Plant Equipment
Reverse EngineeringConfidential Details Removed
Problem / Requirement
An operating petrochemical plant needed to replace a corroded structural-mechanical component for which no original engineering drawings or material records existed. The original equipment manufacturer was no longer trading, and no equivalent spare was commercially available. The plant required the replacement component to be fully engineered, stress-verified and supported by fabrication drawings within a constrained maintenance window to minimise production downtime.
Engineering Scope
Site visit and systematic field measurement of the existing component using calibrated measurement tools and photogrammetry
Dimensional reconciliation — identification of manufacturing tolerances versus in-service deformation
Material identification: visual examination, hardness testing reference and spectroscopic analysis cross-check to confirm alloy grade
3-D parametric model creation from measured data, with critical interface dimensions locked to plant mating features
Stress analysis of the replacement component under operating, upset and maintenance load cases per applicable code
Identification and resolution of any dimensional or material upgrades needed to meet current design standards
Production of complete fabrication drawings: part drawings, weld details, dimensional tolerance callouts and surface finish requirements
Material specification and procurement data sheet for the replacement component
Deliverables
Field Measurement Record and Dimensional Survey ReportMaterial Identification and Grade Confirmation Report3-D CAD Model (STEP/IGES format)Stress Analysis Calculation ReportFabrication Drawing Set — Part Drawings and Assembly (×6 sheets)Weld Detail and NDE Requirement DrawingMaterial and Procurement Data SheetDimensional Inspection Check Sheet for Fabricator QC
Client Value Delivered
Fabrication drawings delivered within ten working days of the site visit, meeting the plant maintenance window target
Material identification confirmed an equivalent modern grade was available as standard stock, avoiding a long-lead custom casting
Stress analysis demonstrated the replacement could use a slightly increased wall thickness for improved corrosion life with no change to external interface dimensions
Dimensional inspection check sheet enabled the fabricator's QC team to sign off the part before despatch, preventing a costly re-make
The 3-D model and drawings were archived as the permanent record, ensuring future replacements can be ordered directly without another site survey
Standards Referenced
ASME BPVC Sec. VIII Div.1 (pressure parts reference)ASME B31.3 (piping component interface)AWS D1.1 (structural weld design)ASTM A105 / A182 (forged component material reference)ASME Y14.5-2018 (GD&T tolerancing)ISO 9013 (thermal cutting tolerances)SNT-TC-1A (NDE personnel qualification reference)
Software Used
SolidWorks 2023 (3-D reverse modelling)ANSYS Mechanical 2024 R1 (stress analysis)AutoCAD 2024 (2-D fabrication drawings)Microsoft Excel (dimensional comparison, load calculations)Bluebeam Revu (field mark-up and drawing review)
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