Lignum Vitae Water-Lubricated Bearings

Background:

• Albany Engineering Corporation’s Upper Machanicsville Hydroelectric plant began operating on the Hudson River in 1897.
• It is one of the first and oldest 3-phase AC power stations still in operation in North America using original equipment.
• Bearings engineered with lignum vitae performed for 50 years without issues.

Challenge:

Changes to shaft configurations and eventual transition of all bearings to newer, composite materials created ongoing issues with vibration, damaged and broken shafts and misalignment problems.

Solution:

• The Mechanicsville plant team worked with Lignum Vitae North America (Lignum Vitae N.A.) to research original design tolerances, dimensions and alignment
• Long-term project to return all of the plant’s 66 water-lubricated bearings back to the original design specifications – lignum vitae – to ensure the continued viability of this important run-of-river facility.
• Reconfigure and repair shafts to address vibration and poor performance in dirty river water
• Address lack of filtration and secondary water feeding tobearing•
• Install vibration sensors on units•
• Return all units to original design specifications

Results:

• Bearings replaced with lignum vitae material
• Work on final unit began in 2019
• Limited bearing wear in 10 years since replacement project began
• Annual preventative maintenance includes bolt tightening, dewatering; restores operation within hours
• Reduced maintenance costs generated return on investment within 2 years