Reverse Engineering & Manufacturing of BB1 Split-Case Pump Components for a Major Refinery -

When OEM spares are obsolete and shutdown is near, a disciplined reverse-engineering (RE) workflow—on-site measurement, metallurgy, and API/ISO-aligned QA/QC—can bring assets back online on time.

Challenge

Legacy Worthington pump with no available OEM spares during a planned shutdown window.
No complete drawings; only worn samples were available.
High risk of extended downtime and significant production loss if parts were not delivered on time.

Our Approach

Pump casing prepared for reverse engineering on site — Pump casing inspected on site prior to measurement and documentation.

1) On-site dimensional capture

3D scanning + CMM for geometry and GD&T; datum strategy aligned to ASME Y14.5.
Interface mapping (fits, sealing faces, gasket surfaces).

Portable CMM/3D scanning workstation capturing geometry — Portable metrology workstation used to capture critical sections and profiles.

2) Material & manufacturing planning

Material verification (spectrometry, hardness, microstructure) to define equivalent metallurgy.
Process route selection: casting/forging → CNC → heat treatment → finishing.
Parametric CAD rebuild; tolerances set from service conditions.

Worn pump impeller prepared for reverse engineering and QA — Original impeller prepared for RE: critical blades and hub geometry documented.

3) Qualified fabrication under Nexa supervision

Each part assigned to a specialist subcontractor (casing / impeller / shaft), with Nexa providing end-to-end supervision and change control.
Manufacturing travelers, routing sheets, and revision control maintained throughout.

QA/QC & Testing

Acceptance criteria aligned with relevant API/ISO intents for rotating equipment:

Dimensional reports (CMM) with ISO 10360 traceability.
NDT: Dye Penetrant / MPI for critical sections.
Hydrostatic pressure test for casing and pressure-retaining parts.
Dynamic balance of rotating parts per ISO 21940.
Final Certificate of Conformance + material certificates + heat-treatment charts.

All documentation compiled into a hand-over dossier (drawings, CAD, ITP, CMM/NDT, CoC) to enable repeat orders at lower risk and lead time.

Results

On-time delivery within the shutdown window; unit restarted as scheduled.
Significant downtime risk avoided; asset life extended without OEM dependency.
Creation of a reusable digital thread (CAD + drawings + routings) for future spares.

Need help with obsolete spares?

We apply a measured, standards-aligned RE process for pumps, compressors, and valves. See our Reverse Engineering service or send an RFQ.