Lubrication of sliding bearings for hydropower applications

Abstract: The term "sliding bearing" refers to types of bearing where two conformal surfaces (usually the stationary bearing and a moving shaft) slide relative to one another with load distributed directly across the interface. A suitable lubricant may be employed to reduce the friction between these two surfaces. In "fluid film" bearings, this lubricant builds up a layer of sufficient thickness such that the two surfaces are completely separated. Examples include journal and thrust bearings and shaft bushings. Unlike ball or roller bearings which have a limited lifespan, sliding bearings have, at least in theory, an indefinite operational lifespan. As long as an oil film of sufficient thickness is maintained and contamination is avoided, the bearing may continue to do its job indefinitely. However, more and more onerous demands are being placed on such bearings and their associated methods of lubrication in order to maximise performance in terms of efficiency and load carrying capacity, for example in hydroelectricity generators and turbines. Given the sensitivity of operating any form of mechanical equipment in the vicinity of watercourses, often the source of drinking water for major population centres, the hydropower industry has a duty of responsibility in ensuring that as much as possible is done to minimise the risk of contamination of the water or damage to flora and fauna. Two aims - increased output, decreased environmental impact - are currently the major driving forces behind Research and Development in the hydroelectric power generation industry. Looking at these from a tribological (friction and lubrication) point of view, three areas of particular interest can be identified. These are: 1) How can the load carrying capacity of thrust bearings be increased whilst at the same time improving performance within existing dimensional constraints? 2) What is the influence on bearings of transient events (rapid changes in speed or loading) and what impact do they have on the machinery components? 3) How does the use of Environmentally Adapted Lubricants (as opposed to mineral oils) influence friction and wear etc, specifically with reference to shaft bushings, and what is the impact of fluid ageing (oxidation) on their performance? Each of these three points has been studied in the course of the work carried out for this thesis.