Challenge

Hydropower systems rely on wicket gates to regulate water flow and control turbine performance efficiently. In this case, a turbine wicket gate at the Warsak facility required digital reconstruction for inspection, refurbishment planning, and academic study. The component did not have updated engineering documentation, including CAD models or detailed drawings. Additionally, the complex curved profiles and wear over time made conventional measurement methods unreliable. The objective was to capture the complete geometry using high-precision 3D scanning, develop an accurate CAD model through reverse engineering, and generate engineering documentation suitable for maintenance, analysis, and educational reverse engineering applications.

Solution

A structured 3D scanning and reverse engineering workflow was implemented to accurately digitize and reconstruct the wicket gate.

• The wicket gate was scanned using a high-precision 3D scanning system to capture detailed surface geometry.
• Surface reconstruction converted scan data into smooth and accurate CAD geometry.

The digital model can be used for reverse engineering training and hydropower system studies.