Steam Turbine Design Engineer (Casings & Hoods Engineering)

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- Design and develop steam turbine casings (HP, IP, LP) and exhaust hoods, including both horizontal and vertical split configurations.

- Define design specifications considering steam pressure, temperature, mechanical loading, and thermal cycling.

- Create casting-friendly designs suitable for foundry manufacturing, ensuring structural integrity and inspectability.

- Design flange joints, bolting layouts, alignment features, and gasket interfaces to ensure pressure containment and ease of assembly.

- Integrate design provisions for instrumentation and controls, including thermowells, drain piping, pressure tappings, and casing relief devices.

- Perform thermal and structural analysis using FEA tools to assess wall thickness, thermal gradients, and stress distribution.

- Evaluate casing behavior under steady-state and transient conditions, including startup, shutdown, and emergency load rejection.

- Design exhaust hoods with appropriate flow paths, structural support, and drain management features.

- Ensure casing configurations support rotor clearances, steam sealing, and accommodate controlled thermal expansion.

- Coordinate with controls engineering to define monitoring points and interlocks related to casing metal temperature and drain conditions.

- Incorporate safety and operational features such as overpressure protection, pressure relief, and proper casing drainage.

- Select suitable materials (e.g., steel castings, chrome-moly alloys) based on design criteria, thermal properties, and operating environment.

- Support casting simulations, heat treatment processes, and manufacturing inspections (NDT, hydrotesting).

- Define tolerances and fit-up conditions to ensure accurate assembly and reliable rotor-casing alignment.

- Develop 3D models, 2D manufacturing drawings, and BOMs using CAD and PLM systems (NX, Creo, Teamcenter).

- Interface with turbine rotor, bearing pedestal, piping, and insulation teams to ensure integrated system design.

- Assist field engineering during installation, alignment, commissioning, and troubleshooting of casing-related issues.

Participate in root cause analysis for casing failures such as distortion, cracking, or leakage in operational turbines