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Hydro-TurbineApplications
Product Manual
HT2009.2
T H O R D O N B E A R I N G S I N C.
Table of Contents
A. Company Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
B. Thordon Hydro-Turbine Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 a) Product and Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2b) Thordon Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3c) Typical Bearing Abrasive Wear Rates . . . . . . . . . . . . . . . . . . . . . . . . .5d) General Material Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6e) Typical Bearing Wear Rate vs. Abrasive Content . . . . . . . . . . . . . . . .8f) Design and Installation Considerations . . . . . . . . . . . . . . . . . . . . . . .8g) Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9h) Thordon Bearing Sizing Calculation Program . . . . . . . . . . . . . . . . . .9
C. Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11a) Main Guide Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11b) Segmented Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11c) Wicket Gate and Operating Mechanism Bearings . . . . . . . . . . . . . . .12d) Wicket Gate Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12e) Servo-Motor and Servo-Link Bearings . . . . . . . . . . . . . . . . . . . . . . . .13f) Operating Ring Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13g) Pump Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13h) Control Gate Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14i) Butterfly Valve Trunnion Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . .14j) Screen Bearings and Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14k) Butterfly Valve Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14l) Servo-Motor and Other Hydraulic/Pneumatic Sealing Applications .15m) Seals for Wicket Gate, Operating Mechanism and Other Limited
Motion Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15n) Kaplan Runner Hub Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
D. Reference Stories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
E. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F. Typical Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Note: The information contained in this document is offered as part ofour service to customers. Thordon Bearings reserves the right to revise any information or specifications included in this document without priornotice.
1
COMPANY PROFILE
Thordon Bearings Inc., a member of the Thomson-Gordon Group of Burlington,Ontario, Canada, designs and manufactures a complete range of high performance,environmentally-friendly bearings and bearing systems. Recognized internationally forsuperior performance, Thordon solutions and products are specified extensively inmarine, offshore, pump, hydro-turbine and other many other industrial applications inover 70 countries throughout the world.
Utilizing proprietary polymers developed and manufactured by Thordon as the bearingsurface, Thordon bearing solutions deliver high reliability and long wear life, particularlyin tough, abrasive operating conditions. This high level of product performance resultsin decreased life cycle costs and increased mean time between failures for Thordon'scustomers. A team of experienced, in-house application design engineers providesinnovative bearing system designs to meet or exceed each customer's technicalrequirements. Thordon products and services are available worldwide through localdistributors whose factory-trained specialists consult with customers from theestablishment of bearing system specifications to ensuring the product is correctlyinstalled and commissioned in the field.
Since the turn of the century, Thordon Bearings' parent company, the Thomson-GordonGroup, a fourth generation family-owned business, has recognized the importance ofproviding industry with superior products, precision manufacturing and solid applicationengineering support. Thordon Bearings' own engineering and quality focus has earnedworldwide recognition from its many customers. Quality procedures are certified to ISO9001:2000 Quality System requirements.
Thordon bearings, and bearing systems, are the proven, cost-effective,environmentally-friendly, solution for rigorous and demanding journal bearingapplications.
SECTION B
PRODUCT AND CONFIGURATIONS
Thordon has developed two types of polymer bearings and several grades that allowselection of the optimal bearing for your unique application.
Elastomeric BearingsThordon Bearings introduced a proprietary, elastomeric, synthetic polymer alloy morethan 30 years ago originally for use as a sleeve bearing for vertical pump applications.The unique polymer structure yields basic properties more in line with those you couldexpect from a very high performance rubber if one existed. However, Thordon isharder - yet elastomeric, tough and resilient in nature, self-lubricating with a muchlower coefficient of friction and able to accommodate much higher specific pressuresthan rubber.
Thordon elastomeric bearing grades are not reinforced with layers of woven fabric,rather, it is a fully homogenous product with all properties consistent throughout theentire wall thickness of the bearing. Compared to other non-metallics such as phenoliclaminates, Thordon is somewhat softer and more compliant. As a result, under slightmisalignment conditions where edge loading is created, Thordon is able to deformslightly, allowing the load to be distributed over a larger area. The localized pressureon the bearing edge is significantly reduced. Due to its elastomeric nature, Thordon isalso able to withstand higher degrees of vibration and shock loading without incurringpermanent deformation or damage. Thordon offers three elastomeric grades and twoconfigurations
Continuous research over the years has resulted in development of four differentbearing-grade elastomer products - XL, SXL, HPSXL and GM2401. This allowsselection of an optimum solution based on matching product characteristics to thespecific application requirements.
ThorPlas® Thermoplastic BearingsThorPlas® is a new, proprietary, engineered thermoplastic bearing product recentlyintroduced by Thordon Bearings. While the Thordon range of high performanceelastomeric bearing products clearly offers superior performance in the applications inwhich they can be specified, there are technical limits, such as maximum temperaturesand pressures beyond which they cannot be used.
To address this issue, Thordon Bearings has introduced ThorPlas®, which significantlyexpands the range of applications where Thordon bearings can be specified, while stillmaintaining many of the recognized Thordon performance advantages.
2
3
PRODUCT AND CONFIGURATIONS (cont’d.)
When compared to the Thordon elastomer-based products, ThorPlas® offers:
• increased strength and rigidity allowing maximum dynamic working pressures up to 31 MPa (4500 psi) in a full-form tubular configuration
• improved ability to operate at elevated temperatures up to 80°C (176°F) in water• improved chemical resistance in all major chemical categories• enhanced wear life in non-abrasive environments
In recent Powertech tests, ThorPlas® demonstrated exceptional wearperformance particularly in the dry tests. According to Powertech, there waslittle evidence of stress on the bearing material and no indication of damage tothe journal surfaces.
THORDON GRADES
ThorPlas® (Blue)
• thermoplastic material developed by Thordon specifically as a homogeneous high pressure bearing
• maximum dynamic working pressure to 31.0 MPa (4500 psi)• very low wear in non-abrasive environments • reasonable abrasion resistance - less than Thordon
elastomeric grades, but better than bronze, epoxy phenolics and many other non-metallic bearing materials
Thordon SXL (Off White)
• maximum dynamic working pressure to 10.0 MPa (1450 psi)in limited motion
• lower coefficient of friction (typically 0.10-0.20) than XL• higher dry PV (Pressure Velocity) rating than XL• higher resistance to abrasion than XL in wet applications;
good abrasion resistance operating dry• dry start-up capability as a vertical pump bearing• high resistance to shock loading and vibration
4
THORDON GRADES (cont’d.)
Thordon HPSXL (Grey)
• designed for higher pressure applications, as the bearing component in HPSXL TRAXL bearings (HPSXL bonded in a metallic shell)
• maximum dynamic working pressure to 15.0 MPa (2175 psi) in limited motion
• HPSXL TRAXL has maximum dynamic working pressure to 55.0 MPa (8000 psi) in limited motion
• lowest coefficient of friction (typically 0.06 - 0.12)• moderately abrasion resistant (lower abrasion resistance
than XL or SXL)• high resistance to shock loading and vibration
Thordon XL (Black)
• maximum dynamic working pressure to 5.5 MPa (800 psi) in limited motion
• low coefficient of friction (typically 0.20-0.25)• high resistance to abrasion in dry applications• high resistance to shock loading and vibration
Thordon GM2401/Composite (Yellow Shell, Black Wear Surface is GM2401)
• bearing formulated specifically for use in very abrasive environments
• used in rotating applications in abrasive water conditions such as pump and dredge bearings
• outstanding abrasion resistance - two or more times that of rubber
• significantly lower coefficient of friction than rubber • higher resilience and stiffness than rubber
THORDON GRADES (cont’d.)
Thorseal
• high performance elastomer hydraulic lip (cup) seal• highly abrasion resistant - use as a seal to exclude abrasives from limited motion bearings
• suitable for pressures from 0 to 100.0 MPa (0 - 15,000 psi)• recommended for reciprocating linear or limited motion rotary applications
• very tough - cut and tear resistant• low friction - self-lubricating• available in single lip or stacked ThorPak ("chevron" style)
5
TYPICAL BEARING ABRASIVE WEAR RATES
6
Recommended Thordon GradesLubrication /
Operating Pressure
Dry (sealed or minimal abrasives)
0-10 MPa (0-1450 psi) SXL ThorPlas
10-15 MPa (1450-2175 psi) HPSXL ThorPlas
15-31 MPa (2175-4500 psi) HPSXL TRAXL ThorPlas
31-55 MPa (4500-8000 psi) HPSXL TRAXL
Dry (abrasives present)
0-5.5 MPa (0-800 psi) XL SXL ThorPlas
5.5-10 MPa (800-1450 psi) SXL ThorPlas
10-15 MPa (1450-2175 psi) HPSXL ThorPlas
15-31 MPa (2175-4500 psi) ThorPlas
Wet (sealed or minimal abrasives)
0-10 MPa (0-1450 psi) SXL ThorPlas
10-15 MPa (1450-2175 psi) HPSXL ThorPlas10-15 MPa (1450-2175 psi) HPSXL ThorPlas
15-31 MPa (2175-4500 psi) HPSXL TRAXL ThorPlas
31-55 MPa (4500-8000 psi) HPSXL TRAXL
Wet (abrasives present)
0-3 MPa (0-500 psi) GM2401 SXL ThorPlas
3-10 MPa (500-1450 psi) SXL ThorPlas
10-15 MPa (1450-2175 psi) HPSXL ThorPlas
15-31 MPa (2175-4500 psi) ThorPlas
Note: The maximum pressures given for the various products are based on maximum dynamic
working pressures for intermittent, limited motion. For applications involving continuous
rotary motion, PV limits of the materials will significantly reduce the maximum
allowable pressures stated above.
This is a general guide for technical reference only. Critical applications that are close to
pressure or temperature limits, or subjected to non-standard environments should be
reviewed and approved by Thordon Engineering.
GENERAL MATERIAL SELECTION GUIDE FOR VARIOUSAPPLICATION PARAMETERS
7
MATERIAL SELECTION GUIDE FOR PUMPBEARING APPLICATIONS
Thordon Grades
Parameter Thordon XL Thordon SXL
Thordon
Composite
(GM2401)
ThorPlas
Description Elastomeric
Polymer Alloy
Elastomeric
Polymer Alloy
Elastomeric
Polymer Alloy
Engineered
Thermoplastic
Temperature Limit 60°C (140°F) 60°C (140°F) 60°C (140°F) 80°C (176°F)
Suitable for Dry Start Up NO YES** NO YES**
Resistance to Acids Limited Limited Limited Fair to Good
Resistance to Alkalies Limited Limited Limited Fair to Good
Suitable for Hydrocarbons YES YES YES YES
Abrasion Resistance Good Better Best Acceptable
Shaft Sleeve Material Bronze,
Stainless Steel
Bronze,
Stainless Steel
Ni-Cr-B
Recommended
Bronze,
Stainless Steel
Lubrication Water, Seawater,
Most Fluids (pH 5 10)
Water, Seawater,
Most Fluids (pH 5 10)
Water, Seawater,
Most Fluids (pH 5 10)
Water, Most Fluids
(pH 3 11) exceptMost Fluids (pH 5-10) Most Fluids (pH 5-10) Most Fluids (pH 5-10) (pH 3-11) except
Chlorinated Solvents
and Strong Acids
and Bases
Remarks Good balance
between abrasion
resistance and low
friction
Lowest friction;
Suitable for dry start-
up; Good abrasion
resistance
For use in highly
abrasive operating
environments
Good choice for low
abrasion applications
and for use at
temperatures and in
chemical solutions
unsuitable for Thordon
elastomers
** For dry start up times longer than 30 seconds, please contact Thordon Engineering for grade selection
Note: For Nuclear use, Quality Control certificates including certified test reports can be supplied. Thordon Bearings Inc.
operates under the provision of 10 CFR21.
This is a general guide for technical reference only. Critical applications that are close to
pressure or temperature limits, or subjected to non-standard environments should be
reviewed and approved by Thordon Engineering.
8
Increasing Abrasive Content
Clean Water Abrasive Water
Incr
easi
ng W
ear
XLSXLCOMPOSITERUBBER
TYPICAL BEARING WEAR RATE VS. WATER ABRASIVE CONTENT
DESIGN AND INSTALLATION CONSIDERATIONSBefore choosing a Thordon grade for an application, the following criteria must beconsidered:• speeds (rpm) • process temperature (pumps)• type of lubrication • pH levels (pumps)• pressures • Thordon has produced a Bearing Sizing• amount of abrasives • Calculation computer program to assist • degree of impact loading designers in the calculations required to• ambient temperatures (maximum/minimum) correctly size Thordon bearings• special ambient conditions (e.g. intermittent (see sample output above)
exposure to high temperature steam cleaning) • Thordon engineers can help in designing• media temperature (pumps) bearing solutions and drawings can be
provided
9
TECHNICAL SUPPORT
Thordon Bearings recognizes the importance of superior products, precision manufacturingand application engineering support. Thordon Bearings in-house engineers work closelywith customers to provide innovative bearing system designs that meet or exceed thetechnical requirements of the application. Full engineering drawings are generated asnecessary. Thordon has many years of experience with numerous industrial applications invirtually all industries and offers technical support during machining and installation.
Geared to provide quick response to customer needs, Thordon Bearings understands theimportance of quick delivery and reduced downtime. Standard size bearings are stocked atthe factory and by Thordon distributors around the world. Special sizes or designs can bemachined to the exact requirements of the customer and delivered quickly throughout theworld.
THORDON BEARING SIZING PROGRAM
The Thordon Bearing Sizing Calculation Program is provided to assist designers in thecalculations required to correctly size Thordon bearings. The program input parametersinclude shaft RPM, interference or bond fit, type of lubrication, type of service, load onbearing, etc. Output parameters include machined bearing sizes and tolerances,amount of interference, bore closure amount, min. installed clearance, runningclearance, etc. An example of the Thordon Bearing Sizing Calculation Program outputis attached.
Designed to operate on a PC (personal computer), the software operates in the Windows operating system. The program is in a color, menu-based format so thatentries can be made with a minimum of effort. Outputs can be printed and inputs canbe saved to a file. Contact Thordon or your distributor to obtain a copy of the programor visit our website at http://www.thordonbearings.com.
SAMPLE OUTPUT
10
11
APPLICATIONS
Application: Main Guide BearingsRecommended Grades: SXL and GM2401
Thordon Bearings recommends two bearinggrades for use in water-lubricated turbine mainguide bearings. Thordon SXL offers the lowestcoefficient of friction, superior adhesive wearperformance and good resistance to wearresulting from third particle abrasion. GM2401is specially formulated to provide optimal wearresistance in abrasive-laden water conditions,routinely outwearing rubber bearings by a factorof two or more, yet still exhibiting a significantlylower coefficient of friction compared to rubber.
Thordon can be specified as an upgrade forrubber or other non-metallic bearings in existing water-lubricated bearing systems oras a complete conversion from sealed oil or grease lubricated systems to pollution-freewater lubrication. Although elastomeric in nature, Thordon bearings, particularily SXLare stiffer than rubber and capable of supporting higher loading. A high degree ofresilience, however, is still maintained and running clearances similar to rubber arepossible.
Thordon main guide bearings are usually supplied factory-bonded into split bearinghousings, or on larger diameter shafts, onto multiple segment blocks. Thordonbearings can also be supplied in stave configuration if required.
Application: Segmented Shaft SealsRecommended Grade: SXL
Thordon SXL radial and axial segmentedshaft seals provide extended wear lifecompared to carbon graphite-based seals,particularily when abrasives are present.There is absolutely no risk of damaging atough SXL seal during installation and overalllife cycle costs are significantly reduced.Thordon segmented shaft seals are suppliedmolded to size to suit the shaft diameter.
12
Application: Wicket Gate and Operating Mechanism BearingsRecommended Grades: HPSXL, HPSXL TRAXL and ThorPlas®
Thordon HPSXL TRAXL, or on some smallermachines HPSXL full form bearings are suitablefor the lower pressures encountered, arerecommended for use in wicket gate and linkagebearing systems. HPSXL, an enhanced elastomerproduct introduced by Thordon more than fiveyears ago, offers even better friction and wearperformance operating either wet or dry than SXLTRAXL. HPSXL TRAXL achieved a top leveloverall rating in the Powertech simulation tests forwicket gate and operating linkage bearings.
Thordon ThorPlas® is also well suited for wicketgate and linkage bearing applications. Anengineered thermoplastic, ThorPlas® can beinstalled as a full-form product and does notrequire a bronze shell that HPSXL requires tomeet the specific pressure requirements of thisapplication. Also successfully tested byPowertech, ThorPlas® demonstrated very lowwear and acceptable friction levels. Where thereis a preference for a full form bearing, ThorPlas®
is the clear choice for performance and value.
Both HPSXL and ThorPlas® are easily machined and can be supplied either finished tofinal sizes provided by the customer, or with overbuild to facilitate line boring afterinstallation to correct the misalignment and dimensional consistencies oftenencountered during turbine rehabilitation.
Application: Wicket Gate Thrust BearingsRecommended Grade: HPSXL
Thordon HPSXL gate thrust collar bearings eliminate theneed for grease required by conventional designs.Elastomeric HPSXL's inherent resilience and lowcoefficient of friction ensures smooth gate operation withno stick slip. Thordon's designs typically incorporate thethrust bearing into the upper head cover bearing bypolymerizing HPSXL onto a flange on the upper bearing,however separate thrust bearings can also be supplied.
13
Application: Servo-Motor and Servo-Link BearingsRecommended Grades: HPSXL TRAXL and ThorPlas®
HPSXL TRAXL bearings are recommended for theservo-motor and servo-link bearing positions.Elastomeric HPSXL is able to accommodate the minormisalignment that often occurs at these bearinglocations and grease lubrication can be eliminated.
ThorPlas® is also a good bearing choice for thesebearing positions. Self-lubricating and capable of beinginstalled as a full form tube, ThorPlas® also performs wellunder the edge loading that can occur due to minormisalignment.
Application: Operating Ring Wear PadsRecommended Grades: SXL and HPSXL
Thordon SXL and HPSXL vertical and horizontal operatingring wear pads offer smooth, grease-free operation andhigh abrasion resistance. Usually supplied molded to sizecomplete with stainless steel inserts for mechanicalfastening, Thordon wear pads can also be bonded inposition using a Thordon-approved adhesive.
Application: Pump BearingsRecommended Grades: SXL, XL, GM2401 and ThorPlas®
Non-polluting Thordon water-lubricated pump bearings offerdry-start capabilities, long wear life, low friction and superiorresistance to abrasive wear. Available in four grades, Thordonpump bearings can be selected to optimize specificperformance requirements. From Thordon Composite for highlyabrasion resistant bottom bowl bearings to Thordon SXL fordry-start upper bearings to ThorPlas® for higher temperatureapplications, Thordon pump bearings outperform rubberbearings by a factor of two or more in abrasive conditions. Notlimited by shelf life or a range of standard production sizes,Thordon pump bearings facilitate quick turn-around andreduced maintenance inventories. Costly sleeve or shaftreplacement can often be avoided by machining a pre-groovedThordon tube to the exact non-standard dimensions required.A separate Pump Bearing Product Manual is available.
14
Application: Control Gate BearingsRecommended Grade: HPSXL
Supplied in ball and socket, or bushing and padconfigurations to suit all types of control gateapplications, Thordon HPSXL bearings with theirlow coefficient of friction operate smoothly andeasily without grease lubrication. Abrasion resistantand resilient, Thordon bearings provide long wearlife and are not damaged by the impact loadingresulting from frequent operation.
Application: Butterfly Valve Trunnion BearingsRecommended Grades: HPSXL TRAXL and ThorPlas®
Thordon HPSXL TRAXL valve trunnionbearings operate smoothly and easily withoutgrease lubrication. ThorPlas® bearings alsooperate well when specified in this application.
Application: Screen Bearings and Wear PadsRecommended Grades: SXL, HPSXL and ThorPlas®
Resilient, and highly resistant to abrasion, ThordonSXL is the obvious choice for the shaft bearings andwear pads used in travelling and stationary screens.Non-corroding Thordon bearings offer extended wearlife while eliminating the maintenance and pollutionconcerns associated with grease lubrication. In somedesigns and locations where pressures may exceedthe limit for SXL, HPSXL or, if necessary, ThorPlas®
are the recommended options due to their higherpressure capabilities.
Application: Butterfly Valve SealsRecommended Grade: Thorseal
Highly abrasive resistant, tough, and compliant,Thorseal butterfly valve seals offer extended wearlife and are resistant to damage resulting from debrisbecoming lodged in the valve during operation.
15
Application: Servo-Motor and Other Hydraulic/Pneumatic Sealing ApplicationsRecommended Grade: Thorseal
In servo-motor and other hydraulic/pneumatic sealingapplications, high performance, tough, Thorseal lip self-lubricating polymer lip seals offer positive sealing up to 100MPa (15,000 psi). Thorseals provide long wear life with noneed for periodic adjustments; resist tearing and extrusion;and as a result of their internal lubricants, operate with lessdrag and reduced cylinder wear. Thorseals are not onlyavailable in a wide range of standard sizes but can also bequickly machined to custom size requirements up to 1.5m(60") in diameter.
Application: Seals for Wicket Gate, Operating Mechanism and other Limited Motion Bearings
Recommended Grade: Thorseal
To prevent contamination of wicket gate, or other hard-to-reach, bearings by abrasive laden waters; or operatingmechanism bearings by corrosion residue or othercontaminants, seals are recommended. High qualityThorseal lip seals are formulated from a tough, high-strength polymer impregnated with internal lubricants andare supplied as an integral part of the bearing design.
Application: Kaplan Runner Hub SealsRecommended Grade: Thorseal
Taking advantage of tough, long-wearing Thorsealpolymer lip seals, an enhanced sealing design has beendeveloped for Kaplan runner blade hubs. Essentially, twospecially designed Thorseal single ring U-cup seals arelocked together to function as a monolithic double-actingseal and fitted back to back in the blade shaft stuffingbox. The outer seal lip prevents ingress of water into thehub contaminating the lubricating oil and the inner sealprevents oil from leaking out of the hub into theenvironment. This design is easy to install, resists distortion during blade re-positioningand the modified lip design insures positive sealing under conditions of significantlymore blade droop than conventional packing. Shaft wear is reduced due to the frictionand wear reducing additives in the polymer and the seals can be supplied split for easyin-situ replacement.
REFERENCE STORIES
MORE POLYMER SHAFT SEALS ORDEREDB Y C H I N E S E T U R B I N E I N D U S T R Y
Dongfang Electrical Machinery Co.,Ltd (part of Dongfang Electric Corp.)and Harbin Electric Machinery Co.,Ltd. have recently placed additionalorders for Thordon SXL elastomericpolymer segmented turbine shaftseals bringing the total on order oralready installed in 2005, to six sets.The shaft seals sold by ProcoInternational Co. Ltd., Thordon'sexclusive Distributor in China,are/will be installed at the Kangyang,Sanbanxi, Xiafu, Baishan and Nalanpower plants in China and the TekezeHydropower Plant in Ethiopia. Sealing large hydro turbine shafts
from 400mm up to 2000+mm (16 upto 80 in.) diameter can be amaintenance challenge for powerplant operators. Typically, turbineseals consist of two or three sets ofstacked segmented carbon rings thatcan be difficult to install withoutbreakage and can be subject torelatively short life if misaligned orsubjected to abrasives.
Since its first shaft seal installation in1982 at the Manapouri Power Station
in New Zealand, Thordon Bearingshas compiled a history of segmentedshaft seal installations. In 2003,Thordon embarked on a program tofurther optimize it's segmented shaftseal design utilizing its proprietarySXL material. SXL is formulatedusing a tough elastomeric syntheticpolymer alloy offering ease ofinstallation, high natural abrasionresistance and good sealingperformance.
SXL Segmented Shaft Seal
Customer Power Plant/Dam CountrySeal Type
Turbine/ Pump RPM
Shaft Diameter
(mm)
Shaft Diameter (inches)
Install Date
Itaipu Binacional Itaipu Brazil Axial 3770 mm 148.43 Oct. 2005Dongfang Electric Machinery Co., Ltd Nalan China Axial Francis 892mm 35.12 Oct. 2005Harbin Electric Machinery Co., Ltd. Baishan China Radial Pump Turbine 200 1015 mm 39.96 Aug. 2005Harbin Electric Machinery Co., Ltd. Xiafu China Radial Francis 107 1170 mm 46.06 Apr. 2005Harbin Electric Machinery Co., Ltd. Sanbanxi China Axial Francis 166 1532 mm 60.31 Mar. 2005Dongfang Electrical Machinery Co. Ltd. Tekeze Hydropow er Plant Ethopia Radial 1160 mm 45.67 Mar. 2005Dongfang Electrical Machinery Co. Ltd. Tekeze Hydropow er Plant Ethopia Radial Francis 300 1160 mm 45.67 Mar. 2005Harbin Electric Machinery Co., Ltd. Kangyang China Axial Horizontal 125 970 mm 38.19 Mar. 2005Meridian Energy Manapouri Pow er Station New Zealand Radial 910 mm 35.83 Jan. 2005Infraserv Hochst Germany 2060 mm 81.10 Oct. 2004Harbin Electric Machinery Co., Ltd. Nirji China Radial Francis 107 1170mm 46.06 Jun. 2004Harbin Electric Machinery Co., Ltd. Etan China Radial Kaplan 22.5 2380 mm 93.70 Nov. 2003Dongfang Electrical Machinery Co. Ltd. Fenshuijiang China Radial Horizontal 166 720 mm 28.35 Jul. 2003Harbin Electric Machinery Co., Ltd. Gongboxia Pow er Station China Axial Francis 1820 mm 71.65 Mar. 2003California Department of Water Resources San Luis Dam U.S.A. Radial 940 mm 37.01 Mar. 2003China Pow er Complete Equipment Co., Ltd Gongboxia Pow er Station China Axial Francis 1820 mm 71.65 Feb. 2003Harbin Electric Machinery Co., Ltd. Huilong Pow er Plant China Radial Pump Turbine 750 620 mm 24.41 Feb. 2003US Bureau of Reclamation U.S.A. Radial Toshiba Turbine 792 mm 31.18 Jan. 2003Harbin Electric Machinery Co., Ltd. Banglang China Axial Francis 892mm 35.12 May. 2002Harbin Electric Machinery Co., Ltd. Kalun II China Axial Francis 1526mm 60.08 Jan. 2001Mighty River Pow er Maraetai Pow er Station New Zealand Radial 635 mm 25.00 Jul. 1999Snohomish Co. P.U.D., Washington Henry M. Jackson Project U.S.A. Axial Francis Turbine Nov. 1998Northern Wasco Co. P.U.D., Oregon McNary Dam U.S.A. Radial 650 mm 25.59 Aug. 1998LA Dept. of Water Pow er (LADWP) U.S.A. Radial 499 mm 19.65 Sep. 1997Genesis Pow er Rangipo Pow er Station New Zealand Radial 644 mm 25.35 Dec. 1996Seattle City Light, Washington Centralia City Light Pow er Plant U.S.A. Radial 400 337 mm 13.27 May. 1996Central Arizona Water Conservation Distri Havasu, Colorado River U.S.A. Radial Hitachi pump 514 1067 mm 42.01 Jul. 1995Mighty River Pow er Aratiatia Pow er Station New Zealand Radial 755 mm 29.72 Jan. 1992Hydro Quebec Beauharnois Generating Station Canada Radial 1022 mm 40.24 Aug. 1988US Bureau of Reclamation Grand Coulee Dam U.S.A. Radial Toshiba Turbine 792 mm 31.18 Mar. 1988Meridian Energy Manapouri Pow er Station New Zealand Radial 910 mm 35.83 Jan. 1982
SXL Segmented Shaft Seal References
REFERENCE STORIES
GREASE FREE THORPLAS® FOR KAPLANRUNNER BLADE BUSHINGS
it provides a smooth, quiet, stableoperation in demanding applications suchas wicket gate trunnion bearings.”
The material has good thermal stability(minimal to no changes due totemperature) and low water absorption(minimal to no changes due to exposure towater), which allow for tighter installedclearances, Muschta says. Furthermore, shesays it is easy and safe to machine becauseit produces no hazardous dust and releasesno dangerous byproducts.
Alabama Electric's Thomasson says thefact that the bearing is self-lubricating wasthe most important characteristic in itsselection. “The runner location is not easilyaccessed,” he says. “You have to stop theunit, put down headgates or stoplogs,dewater the pit, and climb in there. Andeven then it's still not easy to get to thebearings. It was not designed to belubricated.
He also appreciates the environmentallyfriendly nature of ThorPlas®. “If you usedone with grease and the seal failed, youcould contaminate the stream,” he says.
Thomasson cited ease of installation asanother key factor in choosing the Thordonproduct. According to Muschta, theproduct is installed using a “freeze fit” or“shrink fit” method. “Due to its coefficientof thermal expansion, ThorPlas® willcontract or shrink somewhat when cooled,”she says. “You can then place the bearinginto the housing by slipping it or lightlypressing it in.”
Thomasson reports no problems so far.“The bushings are easy to work with,” hesays. “And in the year they have been inuse at the plant, they have been troublefree.”
"From Hydro Review, June 2006, Copyright HCI Publications,
www.hcipub.com, Excerpted with permission."
NW
Alabama Electric installed ThorPlas® runnerblade trunnion bushings for their Kaplanturbine
In April 2005, operators at AlabamaElectric Cooperative's 3-MW Gantthydroelectric plant on the ConecuhRiver in Alabama, U.S.A., decided toreplace the four runner blade trunnionbushings in the vertical Kaplan turbineof Unit 4. The bushings reduce frictionwhen the runner blade pitch variesaccording to head and flow.
The powerhouse originally containedthree vertical Francis turbines. In 1984,Alabama Electric replaced Units 1 and 2with a single 2-MW vertical Kaplan unit(Unit 4). Unit 3 remains in service.
For Unit 4, Alabama Electric selected abushing manufactured by ThordonBearings. The bushing is the company'snew ThorPlas®, a grease and oil-freeengineered (i.e., non-elastomer)thermoplastic bearing.
“We chose the Thordon bushing becausewe have been using a Thordon turbinemain guide bearing without anyproblems since 1984,” says WesThomasson, a mechanical engineer inthe central generation section ofAlabama Electric.
ThorPlas® is a crystalline, premiumgrade, homogeneous, engineeredthermoplastic bushing that is self-lubricating and can accept operationpressures up to 31 MPa (4,500 psi)without the need for metal backing, saysIngrid A. Muschta, P.Eng., ProductManager for Thordon.
“ThorPlas® has demonstratedexceptional wear and abrasion resistanceand has one of the lowest wear ratesamong nearly all rigid polymers, “saysMuschta. “Due to its ratio of static todynamic co-efficient of friction, it doesnot exhibit any stick slip effect. Instead,
REFERENCE STORIES
MAINTENANCE AT INCO GENERATING PLANT NOLONGER FRAZZLED BY DOWNTIME CONCERNS
Frazzle ice is created when long periods ofextremely cold weather, typically in the -35°Crange, turn river water into a giant Slushie®.This isn't uncommon on The Spanish River inNorthern Ontario, Canada, home of three IncoHydropower Generating Stations. Frazzle ice isa regular occurrence almost every spring,pounding into the intakes and causing pumpsthat provide water to the turbines to ice up andshut down.
"When this occurs," says Claude Mailloux,Planner/Supervisor for Inco, "there is a risk thatthe turbine may run dry." As a result, the mainguide bearings may overheat and need to beremoved, inspected and reinstalled again.
Easier said than done. Until, that is, Inco beganto use Thordon SXL.
Powering A Century Of GrowthThe Spanish Riverways has an important dualrole in Northern Ontario. It is one of the mostbreathtaking recreational waterways in theProvince, attracting tourists worldwide. It isalso the source of hydroelectric power that fuelsthe region's vast pulp and paper and nickelmining industries. Inco taps this tributary withgenerating plants located in Big Eddy, HighFalls and Nairn Falls.
For most of the operational history of theseplants, wood called lignum vitae was used as themain guide bearing. But as the rare source ofthis hard and oily timber - the guayacum tree -became even rarer, Inco was forced to look foralternatives.
"They originally switched over to phenolicbearings," said Lorne Thornton, President ofPioneer Power Industries, a long-time
Thordon Bearings distributor, "But these camewith maintenance headaches and otherconcerns."
The problem was, the river water contains ahigh level of particulates, making it abrasive. Asa result, the phenolic bearings would wearrapidly and need to be changed approximatelyevery two to three years. This was not a quickprocess. In fact, because of the hands-on leadchinking that was involved, the turnaround timeto remove and install the bearings was up tofour months.
"To make matters worse," says Thornton, "thephenolic bearings would constantly needadjusting to maintain performance, which onlyadded to the workload and expense."Clearly, Inco needed a better solution. And theyfound it, in Thordon SXL.
A Track Record That Speaks For ItselfProven in demanding hydroelectric applicationsaround the globe, Thordon SXL has become theindustry standard. An elastomeric polymer, thebearing features grease-free operation,remarkably low wear and exceptionalperformance in dirty water conditions. It's thebearing of choice for water lubricated mainshafts and pumps in both rehabilitation and newturbine projects.
"Inco not only wanted to lower maintenancecosts, but they also wanted to eliminate leadchinking. Thordon SXL was the answer to bothof these issues," says Thornton.
To reduce downtime in the future, Thornton andthe engineers at Thordon Bearingsrecommended a stave configuration. Thishelped reduce the time it would take to remove,
service and reinstall the bearings from thecurrent standard of three to four months to justa few days!
The new bearings were installed in Unit #3 (oneof three turbines in total) at the Nairn Falls plantin 1999. After excellent performance over thenext 24 months, SXL was installed in the othertwo units.
"So far, Thordon has lasted twice as long as theprevious phenolic bearing," says Mailloux."And the longer lifespan has kept labour andmaterials costs down while expanding uptime."Bearing performance is monitored continuouslyand has being running within acceptableparameters for more than five years. "This isremarkable considering the rough operatingconditions and the fact that the turbines arenearly one hundred years old!"
Getting Frazzled Once AgainThen mother nature struck. In January 2004,frazzle ice once again formed on The SpanishRiver. During this inclimate period, Unit #2started and stopped five times, each timerunning dry. The fear was that the bearingwould be burnt and require immediatechangeout, something that would be expectedfrom a phenolic material. It wasn't. In fact, afterinspection, Thordon SXL was only mildlyscuffed.
"And the good news is," says Thornton, "Inco'smaintenance staff was able to clean theexfoliated material from the water grooves andreinstall the bearing in the same day."
This allowed Inco to keep this unit on line forthe upcoming spring run-off period and have aplanned outage in the summer for the changeoutof the bearing during the low water flow period.
Reliability was an important factor in the
Star Lake Hydro Partnership’s decision
to replace the Star Lake Generating
Station’s turbine guide bearing. The 18-
MW facility — owned by a partnership
of Abitibi-Consolidated Inc. (51 percent)
and Enel North America, Inc. (49
percent) — runs about 98 percent of the
time, shutting down for scheduled
maintenance for only six to seven days a
year.
As manager of the Star Lake Generating
Station in southwestern
Newfoundland, Canada, Robert
Conlon wanted to replace a water-
lubricated, hydrostatic turbine guide
bearing in a vertical Francis unit that
required a complex high pressure
filtered water supply. This filtration
system was very costly to maintain
and a previous hydrostatic bearing
failure during initial startup had
required the replacement of both the
turbine shaft and the bearing, which
meant a month-long and costly
outage.
“The second water-lubricated, metal
turbine guide bearing has performed
fine for four years,” says Conlon.
“However, we were concerned of the
consequences if this bearing failed at full
load. The result could be an unexpected
failure destroying the bearing, damaging
the shaft and possibly damaging the
generator.”
Those fears were eliminated, however,
when the hydrostatic metal bearing was
replaced with a water-lubricated,
Thordon SXL turbine guide bearing
operating in hydrodynamic conditions.
For water lubricated metal bearings such
as the one at Star Lake, the fluid film
must be consistent between the shaft and
the bearing. If abrasives are present in
the lubricating water, the fluid film may
be disrupted and the bearing will fail.
The water supplied to water lubricated
metal bearings has to be extremely clean
(contaminants removed to 25-30
microns).
Thordon SXL bearings allow a larger
diametrical clearance between the shaft
and the bearing surface and require more
water than the metal bearing. The water
flow requirements to the SXL bearing
surface for cooling purposes are 0.15
litres/minute per mm (1 U.S.
gallon/minute per inch) of shaft diameter
at standard clearances. However, the
water filtering requirements are not as
stringent for SXL bearings, because
wear life is not seriously effected with
water contaminants up to 150 to 200
microns.
Thordon SXL is an elastomeric polymer
bearing material with a 25-year history
of long-life performance in water
lubricated main shaft guide bearings. “It
was certainly the right choice for us,”
says Conlon. “Even if the Thordon SXL
bearing were to fail, it would not fail
suddenly and unexpectedly. The most
that would happen is that the Thordon
material would wear a little bit.”
Before making the commitment to
purchase the Thordon SXL bearing, the
Star Lake Hydro Partnership researched
the product extensively. This included
checking references in North America
and Europe. “Satisfied with the
experience of others,” says Conlon, “the
order was eventually placed for two
bearings (one plus a spare) in July
2003”.
Rapid installation reducesdowntime
Normally, the turbine shaft has to be
dismantled to install a solid journal
bearing. Disassembly and re-
assembly is an arduous process. In
addition, the whole unit has to be
realigned as a part of the process.
Working with Thordon’s engineers,
however, the decision was made to
design and fabricate the bearing in
two halves. “We simply took the two
halves and bolted them together
around the shaft,” says Conlon.
“Once the Thordon bearing was in
place, it was positioned with a
constant annulus around the shaft.”
Before removing the old bearing, the
turbine runner had been wedged in
position so that the turbine shaft was
centered on the old bearing. As a result,
no time-consuming realignment was
necessary.
The Thordon bearing was so simple to
install, in fact, that the outage lasted just
six days, which Conlon observed, “was a
large saving in time and money.”
Confident that the Thordon SXL bearing
will not fail unexpectedly, the Star Lake
Hydro Partnership is comfortable that
they have made a major improvement in
Station reliability. The Thordon SXL
bearing is performing as anticipated.NW
THORDON SXL GUIDE BEARING ELIMINATESRISK AT THE STAR LAKE GENERATING STATION
Thordon SXL Main Guide Bearing ready for installation at Star Lake
REFERENCE STORIES
REFERENCE STORIES
21
REFERENCE STORIES
22
REFERENCE STORIES
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02,
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3225 Mainway Drive, Burlington, Ontario L7M 1A6 Canada Tel: +1.905.335.1440 Fax: +1.905.335.4033
www.ThordonBearings.com
Supply and Service: Geared toprovide quick response tocustomer needs, ThordonBearings understands theimportance of quick delivery andreduced down time. Thordonproducts can be designed,produced to the exactrequirements of the customer andshipped quickly.
Distribution: With Thordonbearings specified all around theworld, an extensive distributionnetwork has been established inover 70 countries. Inventories ofcommon bearing sizes are stockedby local Thordon Distributors andare backed up by large regionaland head office Thordon stocks.
Application Engineering:Thordon Bearing’s engineers workclosely with customers to provideinnovative bearing system designsthat meet or exceed the technicalrequirements of the application.
Manufacturing: Thordon’s modernpolymer processing facility isstaffed with experienced anddedicated employees. Bearings upto 2.2 m (86") in diameter havebeen supplied and bearings up to1.5 m (60") O.D. have beenmachined in-house.Quality: Thordon Bearings Inc. is aCanadian company manufacturing to ISO 9001:2000 Quality Systemrequirements. With over 30 yearsexperience in elastomeric bearingdesign, application engineering
and manufacturing, Thordonbearings are recognizedworldwide for both quality andperformance.
Research and Development:Thordon bearings are beingcontinuously tested by our BearingTest Facility. The Facility evaluatesnew designs and applicationsbefore they are put into service.Ongoing testing not only allows fordesign refinements, but ensuresquality and performance afterinstallation. Our polymer laboratoryevaluates new and modifiedpolymers in a continuing quest toimprove Thordon bearingperformance and search for newploymer bearing solutions. to ord.
CUSTOMER FOCUSED TO SUPPORT YOUR IMMEDIATE AND FUTURE NEEDS
T H O R D O N B E A R I N G S I N C.
ZERO POLLUTION | HIGH PERFORMANCE | BEARING SYSTEMS