Abstract
Custom design and manufacturing projects require careful planning, precise execution, and a keen eye for detail with a bit of creativity sprinkled on top. In the realm of babbitt bearings for the hydroelectric industry, this process becomes even more critical. In this case study, we will take you through the steps involved in our company’s approach to a custom design and manufacturing job. From the initial site visit to the final commissioning, we leave no stone unturned to ensure the highest quality and reliability for our clients.
Context
New issues can arise when you demand more from your machine than it can handle. A 100-year-old double overhung Pelton hydroelectric unit suffered continuous bearing wipes due to extreme shaft bending and misalignment. Pioneer analyzed the issue and designed and manufactured an entirely new bearing system—a pair of 25” diameter pivoted journal/thrust bearings. Pioneer’s turn-key upgrade now allows this hydroelectric unit to produce reliable clean power at its full potential. This is just one project of a plethora of hydro related solutions we’ve provided.
The Initial Site Visit
Ideally, every major project begins with an in-person visit to the site. This crucial step allows our team to understand the specific requirements, challenges, and unique environmental factors associated with the installation. By conducting a thorough assessment, we gather essential information, including measurements, photos & video, that shape the subsequent stages of the project. With a long history of traveling to customer sites, it was another routine effort to send multiple personnel on-site. When there is a systemic bearing issue, it’s always best to see the situation first hand to fully understand the problem.
Information Acquisition
Once the site visit is complete, our team engages in a comprehensive information acquisition process. This step involves collaborating closely with the client to gather all relevant data, such as operating conditions, historical data, load requirements, and performance expectations. Clear and open communication is key during this phase to ensure a shared understanding of project goals.
Design & Modeling
Armed with the gathered information, our experienced design engineers commence the design and modeling phase. Using cutting-edge software tools, they develop detailed 3D models and simulations, considering factors like bearing geometry, material selection, lubrication systems, and structural integrity. This step allows us to visualize and refine the design before moving to the manufacturing phase. Some of the software Pioneer used in this project include: Inventor/ANSYS, OpenFOAM CFD, DyRoBes – RODYN, JURNBR (ARMD), & MAXBRG3D, and our renowned GENMAT™.
Manufacturing
Once the design is approved, we begin the manufacturing process. It starts with the raw forging being cast with a small layer of babbitt/ Our skilled machinists work meticulously to machine the babbitt bearings with precision and attention to detail. We utilize state-of-the-art machinery and follow strict quality control protocols to ensure that each component meets our rigorous standards.
Factory Acceptance Test (FAT) Inspections
With a project this large in scope it was no surprise that the customer required numerous hold points and FAT inspections. While the timing of these inspections might have been troublesome for other outfits as it was in the middle of pandemic restrictions, Pioneer Motor Bearing has been conducting remote/virtual inspections for years—even with our nuclear customers.
Installation Support
With the completion of the manufacturing component finished and the FAT signed off on, Pioneer then traveled back to the customer site some 2.5 years after the initial inquiry. Pioneer provided oversight on and training on the installation of the new bearing system. The installation was so unique that our design engineer invented a new slip-in harness/carriage system to delicately rotate in the slinger ring lower halves.
Commissioning
The commissioning phase marks the final stage of the project. Our team conducts a series of rigorous tests and inspections to validate the performance of the babbitt bearings. We monitor key parameters, such as temperature, vibration, and load capacity, to ensure that the bearings operate optimally. By thoroughly documenting the commissioning process, we provide our clients with a comprehensive report that validates the successful completion of the project.
Conclusion
The journey of a custom babbitt bearing design and manufacturing job encompasses several crucial steps, each essential to delivering a high-quality product. From the initial site visit to the final commissioning, our company remains committed to excellence and customer satisfaction. By employing a meticulous approach, leveraging advanced technology, and collaborating closely with our clients, we ensure that our babbitt bearings meet the highest standards of performance and reliability in the hydroelectric industry. This particular 100-year-old hydro plant looks like it’ll have another successful century of clean power generation.
If you have problems with your hydro thrust or journal/guide bearings please reach out to us so we can help solve your problems.
