Page 0036

ENERGYCASE STUDIES

36

3D Scanning technology from

Steinbichler has been used to aid

decommissioning, and provide cost and

schedule savings, for Sellafield Ltd.

Sellafield embraced new technology to

design and reverse engineer a new 40

tonne flask lid for safe transportation of

radioactive sludge. Using a Steinbichler

Blue Light Comet L3D Scanner and

Photogrammetry, another GTMA member,

Central Scanning Ltd, created a 3D vector

model to underpin the new lid design.

Sellafield said: "The 3D scan is being used

to design the new lid and has resulted

in highly significant cost savings. It was carried out in less than a week; a fraction

of

the normal six months to manufacture such

a component using traditional tooling or a

metrology rig."

Sellafield welcomed the 3D technology to

simplify and de-risk the lid design process,

adding "all traditional metrology methods

available would have added complexity and

cost, and not necessarily de-risked the

process to the same extent as the 3D Scan."

• Steinbichler UK is a worldwide leading

supplier of optical measuring and testing

technology including laser scanning, automatic surface inspection and shearography.

Central Scanning's services include 3D

scanning, system sales, inspection reverse

engineering and 3D printing services.

www.steinbichler.co.uk

www.central-scanning.co.uk

STEINBICHLER UK / CENTRAL SCANNING

3D TECHNOLOGY SAVES TIME AND

MONEY FOR SELLAFIELD

Verisurf Software helps power companies reverse

engineer steam turbine

rotor assemblies to support new and

improved bladding. Among those to

benefit have been Southern California

Edison, GE, Alstom, Siemens, Mitsubishi

and Toshiba.

They have all used Verisurf Software to create

'as built' CAD models of existing rotor

assemblies. But why go to all that trouble

you might ask? The reason is that after 130

years, steam turbines are still a wonderful

and powerful design generating about 90%

of the electrical power in the United States.

Most global steam turbine power plants in

use today were built over 60 years ago,

long before CAD and advanced surface and

fluid analysis. So when plants are taken

offline for maintenance, repair and overhaul,

there is an opportunity today to upgrade

turbine rotors with more efficient blades

able to generate 8-15% more power.

Turbine housings are extremely large castings and the rotor

assemblies have tight tolerances,

which makes the design and integration

of improved blades tricky. The fact

that drawings and detailed plans for the

original rotor assemblies do not exist makes

it necessary to produce a detailed 'as built'

dimensional CAD model of the entire rotor -

coupling face, shaft, bearings, steam seals

and bladding area.

Southern California Edison created Edison

ESI in 1987 specifically to support the

metrology requirements of its nuclear and

conventional electric power generating plants.

As metrology software and supporting digital capture

devices evolved, Edison EDI

standardised on Verisurf Software as their

application of choice.

Turban rotor assembly tolerances are

extremely tight and errors can be catastrophic.

A typical turban fan can rotate at

3,600 RPM. At this speed the blade tips

are turning at close to mach speed. All

components, including coupling face, bearings and shaft must match the rotor

exactly.

Verisurf Reverse Software was selected for its

power, flexibility and ease of use. It is capable

of processing scan or probe data to produce

usable 2D or 3D manufacturing models.

www.verisurf.com

VERISURF UK

HOW TO GENERATE 15% MORE POWER

Probe data collection

in progress on main

rotor assembly -

Verisurf Software helps

give more power.

Index

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