|Today we continue our look at the above graph. Last week we looked at maintenance costs. Today, we look at energy consumption.
When you upgrade pumps with composite materials like Vespel® CR-6100, Boulden B-Series, or Metcar® composites, you can reduce the energy consumption. Reducing the energy consumption of the pump creates continuous and long lasting savings.
Higher Pump Efficiency = Energy Savings
Composite materials reduce the operating cost of a pump through increased efficiency. Because composite materials do not seize, the clearance at the main wear parts – wear rings, throttle bushings, center bushings, balance drums–can be reduced. These parts separate areas of high pressure and low pressure within the pump and reducing the clearance reduces the internal recirculation across these parts.
The target for this upgrade should be the higher power pumps in the plant, as the payout tends to increase with pump power. Multi-stage horizontal pumps tend to offer the best return on investment because they produce high pressure and the recirculation across many internal components has a significant impact on pump efficiency.
Average Energy Savings Of A Pump Running Full Time
Over the years, many boiler feed pumps, charge pumps, and product shipping pumps have been upgraded to Vespel® CR-6100. It is typical for the efficiency gain from reducing clearance in these pumps to fall within the range of 3-5% compared to the “as new” condition of the pump. So, if you have a 1000 HP (750 kW) pump running full time, the energy savings will likely be in the range of $20,000 – $30,000 per year. If we assume an 8 year run at higher efficiency, savings will accumulate to around $200,000.
Conclusion – Using High-Quality Composite Materials Help With Energy Savings
In short, using quality composite materials like Vespel® CR-6100 with reduced clearance in your high energy pumps will pay for itself quite easily on energy savings alone. Next month, we’ll discuss some special situations where you can save even more money.
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 efficiency and 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.