Consumers Energy Tippy Dam Bearing Rehabilitation
Services Provided
- Full-service mechanical rehabilitation and field services
- Fabrication and supply of replacement components
- Turbine guide bearing refurbishment with new Lignum Vitae staves
- Upper and lower generator bearing re-babbitting
- Ultrasonic bond testing
- Thrust bearing system upgrade to PTFE design
- Precision machining of thrust runner plate
- Thrust block and turbine shaft repairs
- Full unit reassembly and precision alignment
Project Overview
Hydro Tech USA executed a comprehensive bearing system rehabilitation and alignment project for Consumers Energy at the Tippy Dam hydro facility.
The scope included full replacement and refurbishment of critical turbine and generator bearings, beginning with restoration of the turbine guide bearing. This included shell inspection, coating, and installation of new Lignum Vitae staves machined to final dimensions.
The upper and lower generator bearings were fully re-babbitted, followed by precision machining and ultrasonic bond testing to verify integrity and performance.
In addition, the existing thrust bearing system was upgraded from a traditional Kingsbury design to a modern PTFE configuration to improve efficiency and long-term reliability. Supporting work included precision machining of the thrust runner plate, repairs to the thrust block, and turbine shaft restoration to recover proper fit and concentricity.
Following the mechanical upgrades, Hydro Tech USA completed full unit reassembly and precision alignment, returning the unit to service with improved operating performance and long-term reliability.