Vessel returned to service within dry-docking schedule
Shaft restored without replacement
OEM dimensional tolerances and alignment maintained
Project Snapshot
A tanker vessel experienced a critical failure of its ERV-32 cargo oil pump turbine, requiring immediate restoration to maintain operational capability.
Inspection revealed severe deterioration across multiple turbine components, including extensive corrosion, worn rotating parts, damaged gears and blades, and shaft bending. All critical components were found beyond repair.
Because of the turbine’s operational importance and the obsolescence and unavailability of spare parts, KIMI undertook the challenging task of manufacturing through reverse engineering all required components to fully restore the turbine to operational condition.
Challenge
Due to the turbine’s age, the availability of OEM documentation was limited and insufficient to support the manufacturing process. One of the major challenges was that all dimensional verification had to be performed based on worn and damaged components rather than detailed engineering drawings or original blueprints.
Despite these limitations, KIMI’s engineers undertook the challenge of redesigning and manufacturing the required parts through advanced reverse engineering, utilizing detailed 3D scanning, precision measurements, and extensive engineering know-how to accurately reproduce the components and restore full operational capability.
Complex Manufacturing & Engineering Challenges
Wear, bending, and corrosion on shafts and discs
Damage and scoring on gear teeth and grooves
Damaged rotating and stationary blades
Destroyed bearings and labyrinth seals
Limited OEM documentation availability
Strict repair and delivery schedule
Steam Turbine Manufacturing Process
INITIAL INSPECTION & CONDITION ASSESSMENT
Detailed inspection, dimensional verification, and operational evaluation of all turbine components to define the repair shame for restoration.
REVERSE ENGINEERING & 3D SCANNING
Advanced 3D scanning and digital modeling applied to reproduce damaged or obsolete components with high dimensional accuracy.
METALLURGICAL ANALYSIS & MATERIAL IDENTIFICATION
Material samples analyzed in KIMI’s metallurgical lab to identify material specifications and manufacturing requirements.
CNC MANUFACTURING & COMPONENT MANUFACTURING
Critical turbine components manufactured using multi-axis high-precision CNC machining centers.
ASSEMBLY & DYNAMIC BALANCING
The turbine rotor assembly dynamically balanced to ensure smooth operation, stability, and vibration control.
ONBOARD INSTALLATION & TESTING
The newly manufactured turbine installed onboard and successfully commissioned under full-load operating conditions.
Achievements
✔ Obsolete components manufactured without OEM documentation
✔ Major turbine components successfully manufactured and assembled
✔ OEM-level dimensional accuracy achieved through reverse engineering
✔ Full-load onboard commissioning successfully completed
✔ Cargo pump turbine fully restored to operational condition in less than 9 weeks
Why rely on KIMI
Advanced reverse engineering, 3D scanning, and multi-axis CNC manufacturing capabilities for obsolete equipment under strict maritime industry timeframes, fully integrated within one workshop.
Advanced reverse engineering capability for obsolete and non-supported marine components
High-precision 3D scanning and multi-axis CNC manufacturing capabilities
Fast-response manufacturing for critical marine equipment under strict maritime industry timeframes
ESYD-accredited quality control laboratory