India’s Kaleshwaram Lift Irrigation Scheme (KLIS) stands as a monumental achievement in water management, tackling one of the country’s most critical challenges—water scarcity. Spanning 500 km and connecting 13 districts, this irrigation scheme is the largest multi-stage lift irrigation project in the world. To sustain such a massive infrastructure, reliable and high-performing equipment is crucial, and the turbine pumps used to lift water play an essential role in keeping the system operational. 

Among the vital components of these turbine pumps are the axial shaft seals—which manage water and pressurized air leakage, preventing potential damage and flooding within the plant. This blog post delves into how Thordon SXL seals were selected to address the unique challenges faced by the pumps at Kaleshwaram, ensuring a long-lasting and efficient operation. 

To meet these challenges, Thordon Bearings Inc., in partnership with Soneji Engineering Pvt. Ltd. (SEPL), provided a state-of-the-art solution with the Thordon SXL axial shaft seal assemblies. A total of 24 large-diameter seal assemblies were supplied for KLIS’s turbine pumps, along with a water filtration system to ensure that the seals remained free from debris. 

The decision to use Thordon SXL seals was based on their superior performance in demanding applications. Thordon SXL seals offer several advantages over traditional materials: 

The project was commissioned by Bharat Heavy Electrical Limited (BHEL), one of India’s leading heavy equipment manufacturers, and SEPL was tasked with delivering a complete package, from supply to installation and commissioning. By December 2023, SEPL had supplied all 24 Thordon SXL seals, with eight seals installed and one successfully commissioned and tested. 

This first installation has already proven successful, with leakage rates well within acceptable limits and no signs of early wear or degradation. The robust performance of these seals gives the project’s operators confidence that the SXL seals will continue to perform reliably for years to come. 

SEPL’s success in delivering the Thordon SXL axial seals for KLIS opens the door to future opportunities. The positive results from this project are likely to lead to additional inquiries for related components, such as guide vane bushes and seals for other hydro equipment used across India. As the Thordon SXL seals continue to demonstrate their value in demanding environments like KLIS, the potential for further expansion into other hydro projects is strong. 

The Kaleshwaram Lift Irrigation Scheme is a critical piece of infrastructure for India, and ensuring the reliability of its turbine pumps is essential to its success. By choosing Thordon SXL axial shaft seals, KLIS has adopted a cutting-edge solution that balances durability, performance, and cost-effectiveness. These seals are not only keeping water where it belongs but also ensuring that the pumps continue to operate smoothly under challenging conditions. 

If you’re looking to enhance the performance and longevity of your hydraulic systems with high-quality axial seals, Millstream Engineering is your trusted partner. Drawing from our experience with large-scale projects like the Kaleshwaram Lift Irrigation Scheme, we understand the unique challenges that harsh environments and large turbine systems can present. Our team specializes in designing and supplying robust sealing solutions, like Thordon SXL seals, which have proven effective in managing abrasive wear, controlling leakage, and maintaining long service life under extreme conditions.