Industrial Equipment Measurements and Product Development — Integrated Steel Plant, India
Capturing complete geometry and engineering data from legacy industrial machinery with no surviving design records, and developing replacement products from it.
Industrial equipment at integrated steel plants is often sourced from multiple countries — Germany, Russia, the USA, Sweden — and operated for decades with minimal documentation. When components fail or need replacement, the original drawings are rarely available. This project required capturing complete engineering data from complex machinery with no existing design records.
The engineering challenge
The equipment in question had been in continuous operation for several decades. Original engineering drawings were unavailable, and the components required precise dimensional capture to enable replacement part manufacturing.
Working in an active steel plant environment adds another layer of complexity — access windows are limited, conditions are demanding, and the accuracy requirements allow no margin for error.
What we did
Using portable measurement equipment, our team captured the complete geometry of the components on-site. The data was processed and converted into parametric CAD models and GD&T annotated manufacturing drawings — providing the plant with usable engineering data for the first time.
Measurement was conducted across equipment sourced from multiple international origins — requiring interpretation of mixed standards, documentation gaps, and decades of in-service modifications.
Outcome
Engineering Deliverables
- Complete CAD models developed from physical measurement data — no original drawings required
- Manufacturing drawings released and replacement parts/assemblies developed for machineries
- Engineering data captured from equipment sourced across Germany, Russia, USA, and Sweden
- Complete support extended until the products are manufactured