Long-term inspection validates reliability of grease-free turbine bearing and water quality package installed at Columbia Basin Hydropower’s Russell D. Smith Power Station.
BURLINGTON, ONTARIO, CANADA — At a time when North America is investing heavily in the modernization of its water infrastructure, a hydro installation in Washington State is demonstrating the long-term payoff of environmentally responsible engineering. Eighteen years after installation, a Thordon COMPAC bearing and Water Quality Package (WQP) at the Russell D. Smith Power Station near Othello, WA. continues to operate with no measurable wear, no need for bearing replacement and minimal maintenance.
Commissioned in 1982, the Russell D. Smith powerhouse was the first of seven hydropower facilities designed to provide generation during spring, summer and fall, based on irrigation water demand throughout the Columbia Basin. Installed in 2007 by what was then the Grand Coulee Project Hydroelectric Authority (now Columbia Basin Hydropower), in conjunction with Seattle City Light, the Thordon solution replaced a grease-lubricated white metal bearing that demanded frequent replacement due to abrasive wear. The upgraded 400 mm (15.75 in) Thordon COMPAC turbine guide bearing supports a horizontal Tampella turbine. Thordon also supplied the WQP to deliver conditioned water at the correct flow, complete with a low-flow alarm.
“The original white metal bearings were vulnerable to abrasive wear, which is extremely common when creating power from irrigation feedwater. The COMPAC system was the perfect solution,” said Jason Perry, Thordon Sales Manager, North America.
Irrigation canal water is notoriously laden with contaminants and abrasives, which can have a devastating effect on bearings that aren’t capable of effectively handling particulates. Thordon’s water quality package, with its advanced Hydro-Cyclone Separation Unit, provides effective removal of abrasive particles in the water >100 microns without the need to replace costly filter cartridges.
Unlike white metal bearings, which depend on oil or grease lubrication and are highly sensitive to abrasive contaminants, Thordon’s COMPAC polymer bearing uses water as its only lubricant. With a unique smooth-bottom and grooved-top design, COMPAC bearings allow for the creation of a hydrodynamic film between the shaft and the bearing. When paired with a WQP, Thordon bearings deliver unmatched bearing performance and lifespan, even in the most challenging operating environments.
A recent inspection confirmed that - 18 years on - the originally installed COMPAC bearing continues to operate as designed. The system is regarded by Columbia Basin Hydropower as one of its most reliable and maintenance free turbines, which is a powerful testament to both the longevity and reliability of Thordon products. The spare guide bearing is still waiting patiently on site.
“This project is a great example of what clean, grease-free technology can deliver,” said Todd Terry, President of Pacific Marine Equipment, Thordon’s distributor for the Pacific Northwest. “It’s quiet, clean, efficient, and it has been working without interruption, offering the long-service performance that utilities look for when they evaluate technologies for aging assets.”
From dam operators to industrial pump engineers, Thordon’s grease-free bearings and seals are proving that longevity and sustainability can go hand in hand. The Russell D. Smith Project installation stands as a compelling example of what is possible when aging infrastructure is retrofitted with advanced modern materials.
Photo 1 (Left): Todd Terry of Pacific Marine Equipment (brown sleeves) and Scott Groves of Thordon Bearings (black pants) inspect the Thordon Water Quality Package at the 2008 startup.
Photo 2 (Right): Original Thordon Water Quality Package.