3D Scanning Hydropower Equipment With Trackscan-Sharp

Hydropower presents a sustainable and eco-friendly energy solution with the potential to vastly decrease our reliance on fossil fuels, thereby bolstering energy security. As such, the optimisation of hydropower equipment is critical in fully realising the benefits of this renewable energy sector.

The hydropower industry is experiencing a surge in growth, necessitating large-scale equipment that comes with substantial investment and elevated maintenance costs. For manufacturers within this industry, it’s imperative to bolster product dependability right from the design stage through to manufacturing. This not only mitigates costs, but also enhances operational efficiency. With our expertise in 3D engineering solutions, we are well-positioned to assist manufacturers in achieving these goals.

Hydropower machinery is constructed of large intricate components, which are subjected to a wide array of influences during the production and operational phases. These elements encompass vibrations, humidity fluctuations, temperature variations, and exposure too acidic and alkaline corrosion, among others. By ensuring the integrity and quality of these components, manufacturers can guarantee the longevity of the equipment, in addition to the efficient and stable functionality of the hydropower unit. This approach allows hydropower equipment manufacturers to fully optimise their returns.

Traditional methods of measurement, while reliable, do have their limitations. These include low productivity, a high demand for skilled personnel, and a time-consuming process. Additionally, these methods lack the ability to produce intuitive reports or supply exhaustive measurement data for subsequent analysis. This deficiency in data hampers the ability to provide comprehensive direction for future maintenance and repairs, as operators and engineers are unable to predict or gauge the operational status of the equipment without complete measurement data.

In contrast, advanced 3D scanning technology offers a variety of solutions for hydropower equipment manufacturers, spanning from product design, production and maintenance. Utilising TRACKSCAN-SHARP, Scantech’s state-of-the-art optical 3D laser scanner, operators can execute non-destructive testing (NDT) on equipment. This level of quality aids in prolonging the lifespan of hydropower systems, reducing potential losses and enhancing overall efficiency.

“The ability of TrackScan-Sharp to rapidly acquire 3D data of components with optical tracking, without the need for targets, is impressive. Its 6-metre tracking distance stands out when compared to conventional optical tracking systems. Given its substantial working volume, there’s less necessity for operators to frequently reposition the tracker to scan an entire component. Its portability and lightweight design make it easy to set up on site. Often, factory conditions can be challenging, but TrackScan-Sharp’s compact size and high adaptability to harsh environments make it suitable for on-site tasks. TrackScan-Sharp effectively meets our quality control requirements, aiding us in delivering superior products to our clients at a faster pace”.

The optical tracking system, equipped with a 25-megapixel industrial-grade camera and boasting a substantial 49 cubic metre tracking volume, offers high-definition, expansive measurements. Its ability to gather data from lengthy distances across a broad spectrum without the need for frequent tracker repositioning makes it perfectly suited for measuring large components. These include large hydraulic turbine blades, runners of pumped storage units, generator wire rods, among others.

The system amalgamates cutting-edge hardware and a robust algorithm to yield high-precision measurements across different tracking ranges: 0.049-mm volumetric accuracy for 10.4 m³ small-range tracking, 0.067-mm volumetric accuracy for 28.6m³ mid-range tracking, and 0.089-mm volumetric accuracy for 49.0m³ large-range tracking. It is adept at capturing the intricate details of various medium and large hydropower equipment components.

TrackScan-Sharp is capable of scanning an entire component without the need for any targets, eliminating the time spent on applying and removing them. Furthermore, it allows for simultaneous scanning of multiple parts, substantially enhancing measurement efficiency.

 Equipped with potent 3D software, TrackScan-Sharp has the capability to capture, analyse, and archive data in real-time. It can scan hydropower equipment components, process the resulting point clouds to produce colour maps, and store the 3D data for future archival purposes. TrackScan-Sharp provides an accurate evaluation of component conditions, facilitating the delivery of high-quality products.

Scantech’s blue laser 3D scanning  solutions have found extensive application in the energy engineering sector, including the inspection of hydraulic turbine guide vanes, turbine castings, oil and gas pipelines, wind power flanges, among others. These innovative technologies assist numerous large-scale energy corporations in achieving digital transformation and upgrades.