NEW TECHNOLOGY IN BEARINGS

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Christina Williamson
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1 NEW TECHNOLOGY IN BEARINGS

2 AGENDA FOR THE NEW TECHNOLOGY: PTFE-LINED THRUST BEARINGS INTRUDUCTION NORTH AMERICAN PTFE BEARING ENERGY KEEPERS ENENERGO ONTARIO POWER GENERATION PTFE a.k.a. TEFLON R BACKGROUND RESEARCH & DEVELOPMENT EXPERIENCE KERR HPP UNIT 3 PTFE REPLACEMENT QUESTIONS AND ANSWERS

3 INTRODUCTION

ENENERGO WAS FOUNDED IN 2004 BY THE DESIGN ENGINEERS THAT PRIOR TO ITS ESTABLISHING WORKED FOR UETM, A BIG GENERATOR MANUFACTURER COMPARABLE TO OUR GE.

4 ENENERGO WAS FOUNDED IN 2004 BY THE DESIGN ENGINEERS THAT PRIOR TO ITS ESTABLISHING WORKED FOR UETM, A BIG GENERATOR MANUFACTURER COMPARABLE TO OUR GE. THEIR ENGINEERS WERE PART OF THE R & D TEAM IN THE MID 1960 S THAT DEVELOPED THE PTFE BEARING. WITH THEIR EXTENSIVE KNOWLEDGE GAINED WAS A GOOD BASIS FOR THE FOUNDING OF THE ENENERGO COMPANY

6 North American PTFE Bearing, LLC FOUNDER/OWNER Kjell V. Nyqvist 105 W Horizon Circle BOISE, IDAHO OFFICE: MOBILE: ptfebearings@gmail.com Web: ptfehydro.com

ALFRED MOHINO SENIOR MECHANICAL ENGINEER INTRODUCED THE FIRST PTFE THRUST BEARING IN NORTH AMERICA IN 1999 ONTARIO POWER GENERATION OWNS 69 HYDROELECTRIC

7 ALFRED MOHINO SENIOR MECHANICAL ENGINEER INTRODUCED THE FIRST PTFE THRUST BEARING IN NORTH AMERICA IN 1999 ONTARIO POWER GENERATION OWNS 69 HYDROELECTRIC GENERATING STATIONS WITH AN INSTALLED CAPACITY OF 13,000 MW 69 OF WHICH 14 ARE OPERATING WITH PTFE THRUST BEARINGS FOR A TOTAL OF 40 PTFE THRUST BEARINGS

8 Manitou Falls 5 x 15 MVA G.S., Ontario, CANADA 5 units, 5 years, 150 rpm, 286 ton, 2.5 MPa (360 psi), 8 pads 1,415 cm2 (219.3 in2), no noticeable liner wear

9 Energy Keepers, Inc. Gary Peterson, PE Maintenance Manager Se lis Ksanka Ql ispe Project Works (Kerr Project #0005) A Corporation of the Confederated Salish and Kootenai Tribes Kerr Dam Road Polson, MT 59860

10 PolyTetraFlouroEthylene, PTFE Better known as TEFLON R On April 6, 1938, Dr. Roy J. Plunkett, DuPont, discovered a white, waxy solid when checking a frozen, compressed sample of tetraflouroethylene, a gas related to Freon R. TFE spontaneously polymerized into PTFE. Teflon R was registered as DuPont s trademark for PTFE in Prominent properties: Specific gravity 2.15 Tensile strength MPa 3,000-5,000 psi Elongation % Flexural Modulus 500 MPa 72,000 psi Folding Endurance >106 cycles Impact Strength 189 J/m 3.5 ftlb/in Hardness Shore D Friction Coefficient 0.1 <3 m/min <10 fpm Melting Point 327 o C 621 o F Max. Op. Temp. (20,000 h) 260 o C 500 o F Dielectric Constant 2.1 Resistivity >1018 ohm-cm

11 BACKGROUND

13 CONVENTIONAL WHITE METAL (BABBITT) LINED THRUST BEARINGS Main Cause of Mechanical Failures of Hydro Generators Thrust Bearings o Thermal Deformation, Crowning o Low Flexibility; Alignment Critical o High Susceptibility to Particles o Wipes One, Wipes All

14 RESEARCH & DEVELOPMENT

15 AIRCRAFT APPLICATION TRANSFER CHALLENGE 1 Low Elasticity Module Bonding to Steel

16 TECHNICAL SPECIFICATION & INSTRUCTIONS FOR INSTALLATION & CONTENT: 1. Purpose 2. Technical Data OPERATION 3. Product Description 4. Preparation Before Installation 5. Installation 6. Operation and Maintenance 7. Instructions for Transportation and Storage

18 SOLUTION Joint Russian Team Figured out How to Bond the PTFE to the Metal Base by Impregnating a Wire Mesh with the PTFE which was then soldered to the Metal Base

19 REWARD Highest Award in Science and Technology, Russia, 1985 Vladimir P. Loshkarev, Chief Design Engineer, UETM (Now EnEnergo), was Awarded the USSR State Prize for development of hydro units thrust bearings with PTFE coated segments 38 Years Operation More than 800 Delivered

20 CHALLENGE 2 First Commercial Application, 1978 Ust-Ilim, 18 x 282.5MVA, 125rpm, 1,650ton (3,637,623 lbs), 16pads, 6.3MPa ( psi)

23 The below cross section of a PTFE-lined thrust shoe shows pre-drilled and NPT threaded hole for insertion of a temperature sensor Also notice the slot through the friction surface metal flex PTFE composite above the sensors tip transferring the oil film temperature

24 Below Plan and Section Drawings shows the Wear Marks that are typically provided with 2 or 4 shoes of the set s PTFE friction surfaces Depth of wear marks are 0.05, 0.1, 0.15, and 0.2 mm

25 Complex and complicated design for this Babbitt bearing is to minimize the risk of deformation and wipe can be made simpler with the insulated properties of the PTFE- lined thrust bearing.

26 This shows the replacement PTFE-lined thrust bearing shoe that replaced the previous shown complex design. All PTFE shoes are made to the exact fitting dimensions as the old Babbitt thrust bearing shoe s for easy replacement installation.

27 EXPERIENCE

28 LONGEVITY OF PTFE-LINED THRUST BEARING To establish a wear rate of PTFE-lined thrust bearings one would have to go back to its infancy when the first such bearings were put into commercial operation in 1978 at the Ust-Ilim hydropower plant. These liners have 1.5 mm of wearable thickness. Protracting from actual wear rates, the longevity is expected to be between 40 to 70 years.

29 Of course, the wear rate depends on different operating conditions. Below are listed a few hydropower plants with different operating conditions and parameters to indicate measured wear rates so far. After twenty (20) years of operation at the 18 x 283 MVA Ust-Ilim HPP on the Angara River in Russia the wear of the 16 segment thrust bearing with a total load of 103 metric ton was 0.3 mm (0.012 in.).

30 9 units, 15 years, 200 rpm, 1,720 ton, 6.0 MPa (867.6 psi), 12 pads 2,350 cm 2 (364.3 in 2 ), 0.32 mm (0.013 in) liner wear

31 Zagorsk Pumped Storage Plant

32 The thrust bearings at the Zagorsk Pumped Storage Plant north of Moscow with six units each rated 236 MVA, 150 rpm, axial thrust 1,460 ton, without HPOL, and 1,200 starts annually were inspected after fourteen years uninterrupted operation and found in excellent condition with 0.2 mm wear (0.008 in).

commercial operation since 2003 4 x 278MVA, 214.

33 Mean velocity: 24.9m/s (81.7fps) TEHRI HYDROELECTRIC PROJECT INDIA First delivery in 2001 In commercial operation since x 278MVA, 214.3rpm, Total thrust load: 1,500ton (3,306,930lbs) Number of pads: 12 Pad area: 2,190cm 2 (339.5sqi) Specific load: 5.8MPa (812.1psi)

36 KERR HPP UNIT 3 PTFE REPLACEMENT

37 QUESTIONS/ ANSWERS

38 North American PTFE Bearing, LLC FOUNDER/OWNER AND GENERAL MANAGER Kjell V. Nyqvist 105 W Horizon Circle BOISE, IDAHO OFFICE: MOBILE: ptfebearings@gmail.com Web: PTFEHYDRO.COM

Thrust Bearing PTFE Re-Design for Pump Storage Generator Case Study

Thrust Bearing PTFE Re-Design for Pump Storage Generator Case Study Paper by: Mike Dupuis, President of Hydro Tech Inc., Canada Tim Maricic, Senior Engineer Specialist of Ontario Power Generation, Canada