Category Archives: Metcar M-310

A Look at Life Cycle Costs – Part 3: Unplanned Events

Typical Life-Cycle Cost For A Pump System Infographic

Typical Life-Cycle Cost For A Pump System

Today we take a final look at the above graph. We have already looked at Energy and Maintenance costs. Today we look at Operating, Environmental, and Downtime Costs.

When you upgrade pumps with composite materials like Vespel® CR-6100, Boulden B-Series, or Metcar® composites, you eliminate the metal-to-metal contact points in the pump, which essentially eliminates the risk of pump seizure. The pump is far more likely to survive running dry at start-up or during off-design events.

Benefits of Upgrading Pumps With Composite Materials

These are hidden bonuses to upgrading your pumps with composite materials. High quality composite materials act like a safety net in your pump, and sometimes, the savings from this benefit pay for all of the composite upgrades your company will ever do. Consider the following case studies:

Case Study: Condensate Return Pumps

Many years ago, a refinery upgraded the vertical pump shaft bearings in one of their 3 condensate return pumps to Vespel® CR-6100. The other two pumps had their original bronze bearings. The pumps were located in the hot well of a condensing steam turbine. The turbine was driving a critical compressor in one of the refinery process units.

Something happened which changed the pressure in the hot well and the pumps started operating in a vacuum intermittently for 9 hours. The two pumps with bronze bushings seized and had to be removed from service. The pump with Vespel® CR-6100 survived and allowed the process unit to continue operating. An upgrade which cost about $2000 likely saved the refinery millions.

Case Study: Potassium Carbonate Pumps

Plant operators heard a loud noise coming from a hot potassium carbonate pump. They were concerned because if potassium carbonate is released into the atmosphere, it creates a respiratory hazard. They shut down the pump and switched to the spare.

When the pump arrived in the shop, they found a piece of metal had broken from a valve and lodged in the pump impeller. Fortunately, during the previous repair, the maintenance shop had upgraded the pump to Vespel® CR-6100 case rings. During the incident, the pump did not seize, the seals didn’t leak, and a potentially major incident was likely avoided. A $3000 upgrade to the wear rings likely saved hundreds of thousands of dollars.

Case Study: Hydrocracker Charge Pump

Improved efficiency can also translate into increased production. A refinery upgraded their 9-stage hydrocracker charge pump, operating at 6400 rpm to Vespel® CR-6100 wear rings with reduced clearance. This $25,000 upgrade increased unit throughput by 4% creating millions of additional revenue for the refinery over the life of the installation.

Pump Impeller with Vespel CR-6100 wear rings

Conclusion

Upgrading your pumps to composite materials reduces pump life cycle costs by making your pumps safer, easier to operate, more reliable and more efficient. When unexpected events occur or where you can increase throughput, a single installation can save you millions of dollars.

Take a look at the pumps coming into your workshop. Use the repair as an opportunity to make the pump better by upgrading to composite wear parts. Boulden has the material you need in stock and can deliver raw material or machined parts with very short lead times. Get in touch with us today!

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.