Category Archives: M-161 babbitt impregnated carbon graphite

A Look At Pump Life Cycle Costs – Part 1: Maintenance

Typical Life-Cycle Cost For A Pump System Infographic

Typical Life-Cycle Cost For A Pump System

Most of us have seen a graph similar to the one above. Over the life of an engineered pump, the energy consumption and maintenance will account for the majority of the life cycle cost. So, if you can make your pumps more efficient and more reliable, you will save a lot of money.
Over the years, we have collected several groups of data to suggest how much money you can save from using composite materials in your pumps like Vespel® CR-6100Boulden B-Series, or Metcar® composites. The savings come from two areas–improved reliability and efficiency.

Improved Pump Reliability = Maintenance Savings

Improving pump MTBR has been a primary focus of Rotating Equipment Engineers for decades. Longer life means fewer repairs, lower chance of downtime, and lower risk of environmental or safety incidents. There is no doubt that more reliable pumps save money. The question related to composite materials is how much of an MTBR improvement should be expected from the upgrade?
To answer that question, we have several data sets:
  • Between the years 2004–2006, a refinery upgraded 61 “bad actor” pumps to Vespel® CR-6100. In the 3 years prior to the upgrades, this group of pumps would result in 20-30 repairs. In the 3 years after the upgrades, this group of pumps averaged fewer than 10 repairs per year.
  • Another plant looked at 11 vertical pumps for 5 years before and 5 years after upgrading the shaft bearings and found repairs had been reduced by 64%.
  • Several other data sets have shown dramatic improvements in the overall plant MTBR when the site included Vespel® CR-6100 into their pump reliability improvement program.

Average Pump Repair Cost

We can use the study of 61 pumps to estimate the annual savings. The average repair cost of an API pump is about $12,000. Prior to upgrading to Vespel® CR-6100, this site had between 20 and 30 repairs per year–$240,000 to $360,000 annually to repair this group of pumps. After the upgrades, with fewer than 10 repairs per year annual repair costs were less than $100,000. That is a savings of around $200,000 every year. The upgrades to composite materials easily paid for themselves several times over.

Conclusion: Upgrade Pump Parts To Composite Materials

In short, using quality composite materials like Vespel® CR-6100 with reduced clearance in your pumps will lead to a big increase in pump life and significant maintenance savings. Next month, we’ll discuss energy savings.
Until then, whatever the temperature, chemical, or operating conditions for your pump, it is likely that Boulden has a non-seizing, non-galling composite material to help you improve your pump reliability. Boulden has a large inventory of material in stock and we can supply raw material or finished parts with very short lead times. We can provide all of the technical support required for you to make the upgrade a success.
Contact us today and use your next repair as an opportunity to upgrade your pump.

 

Boulden Partners With Metcar To Distribute Carbon Graphite Parts

Boulden is excited to announce that it is now distributing Metcar’s  M-161 babbitt impregnated carbon graphite and M-310 nickel impregnated carbon graphite materials. Boulden has been serving the pump repair industry for decades with a range of composite materials. Our objective is to support plant engineers to improve the reliability, efficiency, and safety of their machines. The combination of Boulden’s service-minded mission and Metcar’s high-performing materials will be a valuable asset to the pump repair industry.

Reducing Pump Failure with Carbon Graphite Materials

The M-161 and M-310 material grades are critical to the reliable operation of countless pumps in the utilities, oil & gas, and petrochemical industries. Carbon graphite is self-lubricating, so it can run dry in certain conditions without the need for grease or oil lubrication. Since there is no metallic attraction between carbon graphite and metal running surfaces, these M-161 and M-310 materials are not prone to galling or seizing, which is a known failure mode of other types of bearings.
Boulden will be stocking M-161 and M-310 for fast delivery along with Boulden’s service and technical support. M-161 and M-310 add to Boulden’s complete range of composite materials which can cover applications from cryogenic to 1700 F (900 C).
Interested in these materials for your applications or if you would like more information, contact Boulden today!

About Metcar

Metallized Carbon Corporation has been supplying engineered carbon/graphite solutions for severe service lubrication to industrial customers worldwide since 1945. Under the trade name Metcar®, our unique family of solid, oil-free, self-lubricating materials have been under continuous development by Metallized Carbon Corporation for over seventy years. With over seven decades of application engineering experience and field expertise, corporate headquarters and manufacturing facilities in New York, along with manufacturing facilities in Singapore and Mexico, Metcar is strategically situated to provide the global market with the materials it needs to keep the world running.