HYDRO SOLUTIONS
About Our Hydro Solutions
Engineered Solutions for Hydro Power Generation
For over three decades, SEPL has supported hydroelectric projects through advanced bearing systems, sealing technologies, precision-engineered components, and field engineering services.
Combining globally proven Thordon technology with in-house engineering, machining, assembly, and commissioning capabilities, we help hydro operators improve reliability, reduce maintenance requirements, and transition towards environmentally responsible water-lubricated systems.
Thordon Applications
Critical Hydro Turbine Applications
Thordon technologies are engineered to perform in the most demanding hydro turbine environments, delivering long service life, reduced maintenance, and environmentally responsible operation.
Turbine Guide Bearing
Water-Lubricated Turbine Guide Bearings
For over four decades, Thordon water-lubricated turbine guide bearings have helped hydro operators improve reliability, reduce maintenance, and eliminate the environmental risks associated with conventional oil-lubricated systems.For over four decades, Thordon has delivered water-lubricated turbine guide bearing solutions for both new hydro projects and rehabilitation programs worldwide. Engineered to operate without oil or grease, Thordon guide bearings combine exceptional abrasion resistance, low friction, and long service life while supporting environmentally responsible hydro power generation.
Whether integrated into a new turbine design or installed as part of an oil-to-water conversion project, Thordon guide bearings can be supplied as complete engineered solutions including bearing design, shaft sleeves, water conditioning systems, sealing systems, and condition monitoring packages.
Key Advantages of Thordon Turbine Guide Bearings :
- Oil & grease-free operation
- Long wear life
- Reduced lifecycle costs
- High abrasion resistance
- Easy installation & replacement
- Complete engineered package support
Guide Vane Bush
Grease-Free Guide Vane Technology
ThorPlas-Blue guide vane bushes eliminate the maintenance burden and environmental risks associated with conventional greased systems. Designed for low-friction operation and exceptional wear resistance, they provide reliable long-term performance in demanding hydro turbine applications.
Key Advantages of Guide Vane Bush Bearings :
- Self-lubricating operation
- No stick-slip effect
- Corrosion resistant
- Long wear life
- Easy machining & installation
- Reduced maintenance requirements
Segmented Shaft Seals
Advanced Turbine Shaft Sealing Systems
Designed specifically for hydro turbine applications, Thordon SXL segmented shaft seals provide a robust alternative to traditional carbon graphite and phenolic sealing systems. Available in both radial and axial configurations, they offer reliable sealing performance in clean and abrasive water environments while reducing leakage and lifecycle costs.
Key Advantages of Segmented Shaft Seals :
- High abrasion resistance
- Reduced leakage
- Easy installation & replacement
- Tolerance to shaft misalignment
- Suitable for clean & abrasive water
- Direct-fit replacement for existing seals
Applications :
- Radial Shaft Seals – For standard hydro applications and moderate sealing pressures.
- Axial Shaft Seals – For large turbine shafts and higher sealing pressures.
Thorseal Cup Seals
Hydraulic & Contamination Control Sealing Solutions
Thorseal cup seals are engineered to protect critical hydro turbine components from abrasive contamination while delivering reliable hydraulic sealing performance. Manufactured from Thordon's proprietary self-lubricating polymer, they provide exceptional wear resistance, low friction, and long-term reliability.
Key Benefits :
- High-pressure sealing capability
- Low friction performance
- Excellent abrasion resistance
- Self-lubricating design
- Resistant to tearing & extrusion
- Available in custom configurations
Typical Applications :
- Guide vane systems
- Servo motors
- Kaplan hubs
- Turbine brake systems
- Hydraulic actuators
Other Applications
Additional Hydro Applications
Beyond primary bearing and sealing applications, Thordon technologies are also used in a wide range of auxiliary hydro turbine components where low friction, wear resistance, and lubrication- free operation are essential.MIV Trunnion Bushes
- Kaplan Runner Hub Bearings
- Operating Ring Wear Pads
- Spherical Linkage Bearings
- Servo-Link Bearings
Conversion To Water-lubricated Systems
Transforming Hydro Power Through Water-Lubricated Technology
Many hydroelectric facilities continue to rely on oil-lubricated systems that increase maintenance requirements, operating costs, and environmental risks. SEPL helps operators transition to advanced water-lubricated bearing and sealing systems that improve reliability while eliminating the risk of oil contamination.
Benefits :
- Eliminate oil leakage risks
- Lower lifecycle costs
- Improve reliability
- Reduce maintenance requirements
- Increase equipment accessibility
- Support sustainability objectives
Conversion Process :
- Site Assessment
- System Design
- Manufacturing
- Installation
- Commissioning
- Ongoing Support
Why Water-Lubricated Technology?
Comparing conventional oil systems with modern water-lubricated solutions.
Conventional Oil Systems
Water-Lubricated Systems
Complete Assemblies
Complete Bearing & Shaft Seal Assemblies
SEPL delivers fully engineered shaft seal and bearing assemblies for hydroelectric, lift irrigation, and pump storage projects. From design to commissioning, every stage is managed in-house for consistent quality, faster delivery, and long-term reliability.
Our Expertise:
- Custom design and engineering
- Precision manufacturing
- Assembly and fit up
- On-site installation
- Testing and commissioning
With all processes under one roof, SEPL provides end-to-end system compatibility and dependable performance — making us a trusted partner in complex hydro projects.
Bearing housings
Radial seal assembly
Axial shaft seal assembly
Guide bearing assembly
Water Filtration Systems
Reliable Water Supply for Reliable Bearings & Seals
The performance and longevity of any water-lubricated bearing or sealing system depends on the quality of water supplied to it. Our Water Filtration Systems are specifically engineered to deliver clean, conditioned water for cooling, lubrication, and abrasive particle removal, ensuring predictable wear behaviour and maximum component life.
Designed for hydro turbine guide bearings and shaft seal systems, these packages integrate filtration, monitoring, pressure regulation, and automated controls into a single engineered solution tailored to site conditions.
Key Benefits:
- Removes abrasive particles
- Improves bearing & seal life
- Maintains stable hydrodynamic lubrication
- Reduces maintenance interventions
- Enhances turbine reliability
Advanced Features:
- Automatic monitoring & alarms
- PLC & HMI integration
- Remote monitoring capability
- Single & duplex configurations
- Automated operation
- Flow & pressure management
Functional Spares & Components
Precision Engineered Hydro Components
SEPL manufactures a wide range of hydro turbine components engineered to deliver dimensional accuracy, wear resistance, and long-term operational reliability. Every component is designed to integrate seamlessly into critical hydro systems.
Rotating & Runner Components:
- Shaft Sleeve
- Kaplan Runner Blades
Sealing Components:
- Seal Housing
- Maintenance Seal
- Labyrinth Seals
Hydraulic & Flow Components:
- Guide Vanes
- Guide Vane Housing
- Nozzle Assembly (Pelton)
- Draft Tube Cone
Bearing & Wear Components:
- Main Guide Bearing Housing
- Bush Bearings
- Wear Rings
- Lantern Rings
- Seal Rings
- Mating Plate
- Pressure Plate
- Self-Lubricating Bush
- Self-Lubricating Strip
- Oil Header Bush
Actuation & Control Components:
- Cylinder Housing
- Oversize Oil Piston
Every component is manufactured to exacting standards, ensuring seamless integration, long service life, and dependable performance in critical hydro applications.
Special Non- Ferrous Parts
Special Steel Parts
Guide vane bush housings
Maintenance Seal
Shaft Sleeve
Bush Bearing
Services
Lifecycle Engineering Services
At SEPL, our engagement extends beyond product delivery. We offer a comprehensive range of hydro turbine services, delivered on-site and in-house, to ensure reliable operation, optimal performance, and extended service life of critical components. Our experienced team combines field expertise with advanced engineering tools to support projects from assessment through commissioning.
Inspection
Dismantling
Coating
Relining
Refurbishment
Measurement
Maintenance Support
Reverse Engineering
Installation & Commissioning
Why SEPL For Hydro Projects?
Your Trusted Partner for Hydro Engineering Solutions
Combining globally proven Thordon technology with over three decades of hydro industry experience, SEPL delivers complete engineering solutions that maximise reliability, reduce maintenance, and support sustainable hydro power generation.
Highlights:
- 30+ Years Experience
- Exclusive Thordon Partner
- In-House Engineering Expertise
- Complete Assembly Solutions
- Water-Lubricated System Specialists
- Pan-India Service Support
Contact Our Hydro Specialists
Let's Discuss Your Hydro Application
Whether you're planning a new hydro project, upgrading an existing turbine, or evaluating water-lubricated technologies,
our engineering team can help identify the right solution for your requirements.