Putting the engineering into reverse engineering

Huw Rodway, Global Re-Engineering Manager at Celeros Flow Technology, explains how taking reverse engineering a stage further and re-engineering parts when repairing pumps can offer a wide range of benefits.

Working with older flow control equipment can present challenges. For example, it can be difficult to source replacement parts for equipment that has existed for many years. Sometimes, the pump manufacturer is unknown, no longer in business or unwilling to support aged products.

Ensuring that spare parts are available for servicing equipment is key. However, how much time and effort is invested in locating spare parts? How frustrating is it to find pumps are obsolete? Would the traditional approach of replacing the worn parts with identical parts solve any issues or allow for any performance or reliability improvements to be implemented as part of the repair?

Likewise, new replacement pumps can be an expensive solution, especially since it is not only the cost of a pump that needs to be considered. A plant may have a complex layout, and replacing associated pipework may not be practical.

Throughout a pump’s life, there may have been alterations in operating conditions, duty or the medium being pumped now differing from the original design requirements. Operating equipment outside its design parameters will accelerate and exacerbate wear, corrosion, cavitation, and erosion, resulting in pumps no longer performing as required and, ultimately, premature failure.

Going beyond simply replicating a part, a solution to addressing these challenges is ‘re-engineering’, but what exactly is involved?

Part replication and reverse engineering generate like-for-like parts, potentially without any engineering assessment. Whilst this may deliver a spare part, it does nothing to address the root cause of any failure or poor performance experienced and could replicate the exact failure mechanisms.

By contrast, re-engineering takes a holistic pump repair and maintenance approach. By using an existing part only as a template and incorporating engineering input, mating part analysis, component design optimisation, modern materials and manufacturing techniques, the enhanced solution can have an extended service life and lower total cost of ownership.

Re-engineered components are offered on multiple levels, with several benefits:

• Engineered replacement parts are a secure source of parts, particularly for obsolete items.

• Upgraded enhanced parts can be designed to last longer and solve recurring issues.

• Re-rated parts with altered hydraulic performance can realign a pump’s performance to current or future system requirements, extending its life.

• Upgraded and re-rated parts offer maximum life, performance, and benefit.

Therefore, whenever pumps require spare parts or repair, there is an opportunity to make changes, incorporating these additional benefits.

Engineered Replacement Parts

Perhaps the most apparent application of re-engineering is in being able to supply spare parts – particularly those that are no longer available or supported.

Re-engineering ensures a secure supply route for all future spares, giving long-term assurance.

If a pump is deemed obsolete, it is likely that a replacement pump would have a different footprint, making installing a new pump with different dimensions problematic. Re-engineering an obsolete pump’s internal components and casing allows these parts to be supplied as and when required. This mitigates the requirement to purchase a complete replacement pump, and allows the retention of the existing base plate, footprint and auxiliary equipment, thus saving significant expense and possible infrastructure changes. This is likely the fastest and most cost-effective solution.

The re-engineered parts can be designed to ensure replacement parts or sub-assemblies fit precisely with existing components. They can even be made compatible with a fleet of pumps, standardising parts to reduce inventory.

Upgraded And Enhanced Parts

What if the life of the components that require replacing could be increased? By reviewing the system and pump operations, carrying out route cause analysis of