CASE STUDY

Stainless Spacer Solutions for Hydropower Infrastructure

We recently partnered with a maintenance lead at a regional hydropower plant. They were dealing with a recurring nightmare in their turbine housing. For this facility, the weak point was a set of mounting spacers that simply couldn’t handle the pressure.

The Problem: Vibration and the "Seize" Effect

The facility was struggling with a turbine unit that was “eating” bearings far faster than it should. When the crew pulled the assembly apart, the issue was obvious: the original spacers had become a pitted, rusted mess. Constant exposure to fast-moving, aerated water had triggered galvanic corrosion.

Because the spacers had degraded unevenly, the turbine components were no longer sitting perfectly flush. This tiny misalignment created a harmonic vibration that was rattling the entire drive train. The team was stuck in a cycle of “patch and repair,” losing days of power generation every time they had to shut down to fix the vibration issues. They reached out to us because they needed a spacer that wouldn’t just sit in the water, but actually survive it.

How Profab Machine Solved the Challenge

After looking at the flow rates and the specific water chemistry of the site, we choosed the project to 316L Stainless Steel. The “L” stands for low carbon, which is critical for preventing corrosion at the weld points and grain boundaries in underwater environments.

To stop the vibration, we didn’t just machine these—we surface-ground them.

We adjusted the internal bore to allow for a “slide-fit” over the mounting studs. This ensures that even after years of submersion, the stainless spacers won’t seize, making future maintenance much faster and safer for the crew.

The Result: A "Quiet" Turbine and Consistent Power

Since the swap to our custom hydropower spacers, the facility lead reports that the turbine is running quieter than it has in years. By investing in a higher grade of stainless, the plant has effectively ended the cycle of emergency shutdowns. It’s a classic example of how a small, precision-made part can protect a multi-million dollar piece of infrastructure.

Built In Stainless Steel, Trusted In Demanding Environments

Every case starts with a real mechanical challenge. Talk to Profab Machine to begin your project.

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Stainless Spacer Solutions for Hydropower Infrastructure

The Problem: Vibration and the "Seize" Effect

How Profab Machine Solved the Challenge

The Result: A "Quiet" Turbine and Consistent Power

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