Simulation of a Turbine Assembly Design in an Existing Power Plant
A major hydroelectric equipment manufacturer engaged Lx Sim to perform Finite Element Analysis (FEA) on newly designed components for a turbine assembly. The goal was to ensure that these parts met the client’s technical criteria and complied with current hydroelectric industry standards, while validating their compatibility with components in a power plant built in 1930.
Challenges
- Validate the impact of adding new components on the existing infrastructure of the plant
- Assess fatigue resistance under various operating conditions, including accidental scenarios
Solutions
FEA Simulation
- Mechanical validation of the new components and identification of critical areas not meeting specifications
- Analysis of the effect of new parts on the stay ring, flanges, and guide vanes
- Evaluation of fatigue life for both new and existing components
Design Optimization
- Collaboration with the client to adjust geometry and enhance structural performance of the new parts
Results
Thanks to FEA simulation and design optimization:
- The new components were successfully integrated into an older structure without compromising safety
- A better understanding of component lifespan was achieved through fatigue data
- The design was efficiently optimized prior to manufacturing
This project demonstrates how numerical simulation can facilitate the integration of modern components into legacy infrastructure, offering rigorous validation and reliability-focused optimization.