Case Study

Ameren Osage Hydroelectric Plant

Facing frequent shutdowns due to failing synthetic bearings, the Ameren Osage Hydroelectric Plant successfully returned to its original lignum vitae bearings, resulting in significant cost savings and minimized downtime. This historic plant now operates reliably, showcasing a return to proven technology for long-term performance.

Lignum Vitae bearings in use at Ameren

Background:

  • The Bagnell Dam was built in Missouri and Allis Chalmers designed the turbines at the 201-MW Osage plant which was completed in 1931.  
  • The original specifications included lignum vitae bearings.
  • Produces enough clean energy to serve more than 40,000 households annually
  • Bearings that had lasted for up to 10 years were experiencing rapid shaft runout, failing in as little as a few months and requiring frequent adjustments that led to costly shutdowns and expensive repairs.

Challenge:

  • Manage extensive premature wear of synthetic turbine guide bearings on original and more recently installed vertical turbines. 
  • The plant needed to find a reliable and proven long-term solution to avoid costly and ongoing shaft sleeve replacements. 
  • Design and build bearings for both old and new units
  • Engineer a durable solution that could withstand the extreme raw lake water conditions 
  • Maintain uptime at this important facility – and return the plant to its originally specified bearing material. 
Lignum Vitae bearings in use at Ameren

Solution:

  • Engineered durable, replacement guide bearings for original,1930s vertical water turbine, as well as newer turbines replaced in 2007
  • Rated speed:112.5 RPM
  • Net head of 90-100 ft with 32 MW output
  • Raw water-lubricated
  • Carbon guidewear surface
  • Cut onsite to adapt to dove-tail shape of bearing housing

Results:

  • Successful installation of single, four-segment water cooled/lubricated guidebearing
  • Running at 3-4 mils, well under 20-30 mil excessive limit, since 2013
  • Saved $250,000 in shaft replacement costs
  • Plant has reverted to 100% lignum vitae bearing material

Conclusion:

  • LVNA is able to replace Main Guide Bearings or any composite/phenolic bearing as well as well as Oil Filmed lead babbitt bearings in hydroelectric applications
  • The Ameran Osage plant is now able to minimize downtime for maintenance and the need to replace expensive equipment parts.

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Wood Grain texture taken from a Lignum Vitae tree