From Buckets to Breakthroughs: Innovative Sealing Solutions in Hydropower
At Progressive Sealing Inc., we thrive on solving our customers’ toughest challenges. Recently, we partnered with a hydropower customer in Western Canada who operates turbines commissioned in the early 1900s. Yes, these turbines are more than a century old — and still running. But as with all aging equipment, unique challenges come with time.
The Challenge: Oil Leaks in a Century-Old Turbine
The customer approached us with a problem: oil was leaking so badly from the turbine that it had to be collected in a bucket. Not only was this inefficient, but it also created safety, environmental, and maintenance concerns. Their simple but urgent question to our team was:
“Do you have anything for this?”
The Solution: Engineering Meets Innovation
Instead of a quick patch, our Technical Specialist designed a custom solution that combined modern sealing technology with innovative engineering design.
The final system included:
Custom 3D-printed housing: Built in-house with an internal honeycomb design for strength and reduced weight.
A.W. Chesterton Company Matrix Seal: Engineered to fit a 16” shaft, providing reliable sealing performance.
Oil recapture system: A clever design that redirects excess oil through a hose into an existing pipe fitting, recycling it back into the turbine.
This transformed a messy, leak-prone setup into a clean, sustainable system built for long-term reliability.
The Results: Sustainable Performance
Since implementation in 2023, the new system has been running successfully with no major issues. The results were so positive that the customer has now rolled out the solution across three turbines, each one running smoothly.
By capturing and recycling excess oil, the system not only improves efficiency but also reduces environmental impact. This project is a strong example of how sustainable solutions can extend the life of aging infrastructure.
Why It Matters
Hydropower remains one of the most important renewable energy sources in Canada. Many facilities still rely on older turbines and equipment, which can create maintenance challenges. At Progressive Sealing Inc., we help operators bridge the gap between historic infrastructure and modern demands by delivering solutions that are:
Sustainable: Reducing waste and environmental risk.
Cost-effective: Minimizing downtime and repair costs.
Innovative: Combining advanced sealing technology with creative engineering.
Our Commitment to Hydropower
This project reflects our passion for innovation and problem-solving. By pairing advanced tools like 3D printing with trusted sealing technologies from A.W. Chesterton Company, we are helping hydro facilities maximize the performance of equipment that has been serving communities for generations.
At Progressive Sealing Inc., we believe that no challenge is too old — or too complex — to find a modern solution.
