Engineering

Reverse engineering, modification and life extension

As installations age, operating periods often exceed the original design life or process conditions change significantly. At that stage, operators are typically faced with a critical decision: full replacement or reuse and upgrading of existing equipment.

Delta Controls specializes in reverse engineering, modification and second-life upgrading of valves, actuators, pressure systems and related equipment. In many cases, reuse and targeted improvement are not only technically feasible, but also the most cost-effective and least disruptive solution.

By applying reverse engineering, Delta Controls enables true like-for-like replacement or controlled optimization, allowing existing equipment to be restored, improved or adapted without major modifications to the surrounding installation. This avoids costly piping changes, foundation work or interface adjustments and minimizes downtime and project risk.

Our engineering capabilities are particularly valuable for legacy and obsolete OEM equipment, where original documentation or manufacturer support is no longer available.

Like-for-like engineering for legacy equipment

Delta Controls has extensive experience with brand-independent reverse engineering and like-for-like reproduction of components from both current and older manufacturers, including legacy valve and actuator designs.

Using detailed inspections, dimensional measurements, material analysis and performance assessment, we:

• Reconstruct original designs and tolerances
• Reproduce components to original specifications
• Implement targeted improvements where beneficial
• Ensure full compatibility with existing installations

This approach allows operators to extend asset life, maintain compliance and reliability, and avoid unnecessary system redesign.

Computational fluid dynamics (CFD)

Understanding fluid flow, heat transfer and pressure behavior is essential when designing or modifying equipment for demanding process conditions. Delta Controls applies Computational fluid dynamics (CFD) to analyze and optimize valve designs, pressure systems and flow paths.

CFD calculations are based on numerical methods, often combined with finite element analysis (FEA), enabling accurate simulation of real operating conditions.

Typical CFD outputs include:

• Pressure distribution
• Velocity profiles
• Temperature distribution
• Visualization of flow paths and streamlines

Both two-dimensional and three-dimensional models can be analyzed, covering:

• Laminar and turbulent flow
• Compressible and incompressible media
• Subsonic, transonic and supersonic conditions
• Steady-state and transient flow
• Heat transfer through conduction, convection or combined mechanisms

The results can be directly applied in structural and thermal stress calculations to validate mechanical integrity under real process loads.

Engineering of pressure systems and gas utilities

Delta Controls provides full engineering support for gas utilities, hydraulic and pneumatic pressure systems, from concept and calculation through detailed design and validation.

Our engineering scope includes:

• System design and layout
• Strength and fatigue calculations (FEA)
• Flow and thermal analysis (CFD)
• Design verification for safety and compliance
• Engineering support for manufacturing, testing and commissioning

By combining engineering with in-house manufacturing, refurbishment and testing, we ensure that designs are practical, manufacturable and field-proven.

Engineering with practical impact

Delta Controls engineering is not theoretical. Every design, calculation or modification is aimed at:

• Extending service life
• Improving safety and reliability
• Reducing downtime and maintenance costs
• Avoiding unnecessary replacement or installation changes

Our engineers work closely with maintenance teams, production engineers and operators to deliver solutions that perform in real-world conditions.