Workshop & on-site 7–30 days

Precision Reverse Engineering

3D Scanning to Production Drawing: Eliminating OEM Dependency

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5kW–60MW

Turbine Range Covered

0.001mm

CMM Measurement Resolution

100%

PMI Material Verified

GD&T

Full Tolerance Drawings

Why Our Engineers

When an OEM stops supporting a machine, a simple worn rotor or broken diaphragm can force a plant shutdown for months. Our reverse engineering process recreates the exact material, geometry, and heat treatment specification, with full manufacturing drawings, so any competent machine shop can manufacture the part.

Overview

When OEM drawings are unavailable, the OEM is no longer active, or lead times are measured in years, Keshav Enterprises can reverse-engineer any turbine component from 5 kW to 60 MW to a full production-ready drawing set. Our process uses 3D laser scanners, CMM coordinate measuring machines, and XRF PMI material identification (the same tools used by major OEM engineering teams) to generate complete manufacturing drawings with all tolerances, surface finishes, heat treatment sequences, and material specifications. We have successfully reverse-engineered rotors, diaphragms, nozzle blocks, labyrinth seals, bearings, governors, and steam path components for Triveni, Siemens, BHEL, DLF-Skoda, Belliss, and Maxwatt turbines.

Our Process

Component Receipt & Initial Assessment

Safe receipt of the worn or original reference component. Initial visual inspection, cleaning, and comprehensive photography. Assessment of damage, wear zones, and critical measurement surfaces to determine the optimal measurement strategy and datum scheme before any measurement begins.

PMI Material Identification

Positive Material Identification using XRF (X-ray fluorescence) analyser on multiple locations to identify exact alloy composition. Hardness testing (Rockwell, Brinell, Vickers) to determine heat treatment condition. Material grade confirmed and matched to nearest current standard before measurement begins, with no guessing on alloy.

3D Laser Scanning & CMM Measurement

Full 3D scan of component exterior using portable laser scanner: point cloud accuracy to 0.05 mm. Critical internal dimensions and tolerances (bore, keyway, spline, thread form, pitch, and lead) measured on CMM with 0.001 mm resolution. Datum scheme established from functional bearing surfaces.

Engineering Drawing Generation

CAD model developed from scan data and CMM measurements. Full 2D manufacturing drawing produced with: all linear and angular dimensions, GD&T tolerances (concentricity, cylindricity, parallelism, roundness, runout), surface finish callouts (Ra values in μm), thread form and class standards, and a complete datum reference frame.

Heat Treatment & Surface Treatment Specification

Full machining sequence defined: pre-machining stress relief, rough machining, normalising or hardening, pre-final and final machining stages. Heat treatment conditions specified with temperature (°C), soak time, quench medium, and target hardness. Surface treatment specs: nitriding depth, case hardness, carburising, or hard chrome plating as required.

Material Procurement & Manufacturing

Material procured against PMI-identified specification with EN 10204 Type 3.1 mill certificate. CNC machining executed through each defined stage with in-process dimensional inspection at each stage. All inspection data recorded in a manufacturing data pack.

Final Inspection & Delivery

Complete dimensional inspection report against the engineering drawing. PMI re-verification on the finished component confirms correct alloy was used throughout. Surface finish measurement. Hardness testing on critical surfaces. Full traceability documentation pack supplied with every component.