Bearing technology and energy supply systems for hydropower plants

Machine components used in hydropower generation must function reliably and continuously, as failures due to material wear and frequent maintenance can have a negative impact on energy yield. igus offers customised solutions from prototype to high-volume production that improve the technology of your wave power plants, turbines or rake cleaners. Our plain and spherical bearings, lead screws and energy supply systems have many advantages: They are suitable for use under water, dirt and UV-resistant, quiet and low vibration and fit into tight installation spaces thanks to their compact design. Our dry-tech bearing technology made from tribo-optimised plastics is characterised by extremely low friction coefficients and a long, predictable service life and is 100% lubrication-free and maintenance-free.

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Screening plant, rake cleaner

In order for hydropower plants to produce electricity reliably, the flow of water to the turbine must be guaranteed at all times. Any floating debris that collects on the protective screens of the water supply must therefore be removed regularly. This task is performed by screen cleaning systems, for example mobile horizontal/crosswise cleaners. As an alternative to trailing cables/festoons and busbar systems, we offer low-maintenance energy chain systems to reliably supply the travelling carriage with energy, in particular the basic flizz system, our standard for rake cleaners and scrapers.

basic flizz energy supply system

Cost-effective complete system consisting of energy chain, chainflex cables and stainless steel housing
Protection against weather and dirt exposure
Low-maintenance, for travels up to 100m

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Water turbines

In Kaplan and Francis turbines, the water flow to the rotor blades and thus the turbine output can be regulated with the aid of adjustable, pivoting guide vanes. The adjustment mechanism consists of adjustment rings on the outside of the housing, which act on the rotary axes of the guide vanes via articulated levers. We offer the right plain bearings and rod ends for this purpose, which are robust, maintenance-free and corrosion-free.

Turbine detail, igubal KBRM, iglidur G plain bearing

Plain and spherical bearings

Lubrication-free flanged bushings made of the all-round material iglidur G or iglidur H especially for underwater applications
Rod ends igubal KBRM: corrosion-free, suitable for liquid media, with robust, long fibre-reinforced polymer spherical ball

Wave energy converter

Point absorber

Buoys anchored to the seabed with an integrated generator that converts the kinetic energy into electrical energy as the waves move up and down: point absorbers are considered a particularly promising wave energy converter technology. To guide the movement of the floating body and stabilise it even under adverse conditions, robust, maintenance-free linear guides are required, which we offer alongside sliding plates and compact, lightweight energy chains for safe cable guidance.

Bearing technology and e-chain

Bar stock plates made of iglidur JB: highly wear-resistant with a low coefficient of friction
Heavy-duty lead screw nut dryspin JGRM + high helix lead screw dryspin stainless steel AISI 304 with right-hand thread
Pillow block drylin RJUM + round shaft EEWM in stainless steel AISI 420C
Energy chain Series E4.1: light, robust, modular

Oscillating wave converters

An OWSC (Oscillating Wave Surge Converter) utilises the amplified liquid particle movement of waves in the near-shore zone. The conversion principle is based on a horizontal (more rarely vertical) pendulum movement of a flap that drives a high-pressure fluid in a secondary hydraulic system by means of a piston. We have the right plain bearings for the outer bearing points and for guiding the piston - high-strength, media-resistant and, as always, lubrication-free and maintenance-free.

Plain bearings

For guiding the piston:
Sleeve bearings iglidur H370 for high loads, with very good wear resistance under water
For fixing the water column and the main pivoting movement:
High-strength wound slide bearings igutex X1 or igutex TX2, very wear-resistant under extreme loads

Plain bearings

For guidance of the piston:
Sleeve bearings iglidur Q for high loads, wear-resistant on many shafts
For supporting the main axis:
High-strength wound slide bearings igutex X1 or igutex TX2, very wear-resistant under extreme loads

Seawater pump

The wave energy converter (WEC) "Searaser" is a pump consisting of two floats arranged one above the other and connected by a piston. As the waves rise and fall, seawater is pumped to a higher level on land so that it can be stored in large ponds and generate electricity with a turbine and generator when required. To guide the pump piston, we offer suitable plain bearings with particularly high wear resistance for underwater applications.

Plain bearings

Cylindrical bushings iglidur UW: extremely wear-resistant underwater endurance runner, the first choice for pump applications

Attenuator

This is another way to generate electricity from wave movements: with a long, modular series of floats connected via lever arms to a chain of electric generators. Placed in the direction of the waves, a serpentine movement is created as soon as the waves pass under the floats, and the levers drive the generators. We recommend our heavy-duty underwater plain bearings with flange for the many bearing points on both sides of the levers.

Plain bearings

Flanged bearing iglidur H370 for high loads, with very good wear resistance under water

Success stories

Safe energy supply even in high swells

The point absorbers from CorPower Ocean are lightweight, compact and cope well with storms thanks to the new "Wavespring Phase Control Technology". A cascade gearbox that drives a power generator converts the buoy's up-and-down movement into rotational movement. Two E4.1 series e-chains together with chainflex servo, power and control cables ensure safe energy supply within the buoy.

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Plain bearings for long-life wave energy converters

For Rotary Wave's WEC, the designers were looking for bearings that were extremely resilient and suitable for the harsh seawater environment. The surface pressures achieved are around 50MPa, the maximum speed amounts to 10rpm. The decision was made in favour of iglidur Z plain bearings. They help achieve significantly better results than, for example, sintered plain bearings with a bronze surface.

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First plastic WEC reliably moved with iglidur

PolyGen's wave energy converter is the world's first WEC to be made predominantly of plastic. For the bearing points on the axes of the flaps, bearings were needed that could withstand the high mechanical loads and corrosive salt water for as long as possible. The perfect solution was found at igus: iglidur flanged bushings made of the material H370, specially developed for the wet area.

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Uninterruptible power transmission at the tidal turbine

The company Tocardo was looking for a way to guide the cables safely from the turbine to the converter in the control cabinet and thus achieve the longest possible service life for the system. igus provided the perfect solution with E4/4 e-chains: they are corrosion-resistant, completely resistant to persistently damp environments, easy to install, and quick to open if a cable needs to be replaced.

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Tidal turbine moving safely on rough seas

The OpenHydro tidal turbine generates green electricity in the North Sea. The generator can be moved down 20 metres if necessary, which means that the cables are mostly below the water surface. A metal chain was not suitable for the harsh conditions at sea. The operator therefore relies on ourE4/4 plastic energy chain, which ensures maintenance-free operation of the turbine.

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basic flizz and Schlossmühle hydroelectric power station

Saves space and maintenance costs: basic flizz system on the rake cleaner

The H-cleaner from Muhr, a global specialist for these systems, uses a proven standard for the energy supply to the carriage: the basic flizz system. Completely installed in just 1.5 hours at the Rochlitz hydroelectric power station, the compact system safely moves the cables up to 15 metres. Although well hidden, the energy chain is easily accessible for maintenance or when new cables need to be added.

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