Dupont Vespel Cr-6100: Application and Installation Guide For Centrifugal Pump Stationary Wear Parts
Dupont Vespel Cr-6100: Application and Installation Guide For Centrifugal Pump Stationary Wear Parts
Dupont Vespel Cr-6100: Application and Installation Guide For Centrifugal Pump Stationary Wear Parts
APPLICATION AND INSTALLATION GUIDE FOR CENTRIFUGAL PUMP STATIONARY WEAR PARTS
Fluid processing industries have embraced the use of composite materials in pumps to reduce vibration, increase mechanical seal life and MTBR (mean time between repair), reduce the risk of seizure, increase efficiency, and reduce repair costs. API 610, 10th Edition (ISO standard 13709), the latest centrifugal pump standard from the American Petroleum Institute (API), recognizes the use of composites to achieve these benefits.
Background
The CR-6100 grade of DuPont Vespel parts and shapes is a composite material consisting of carbon fibers held in a Teflon fluorocarbon resin matrix (PFA/CF Reinforced Composite, 20 wt% random x-y oriented carbon-fiber). Vespel CR-6100 has been installed in thousands of pumps in refineries, chemical plants, power plants, and other fluid processing facilities since 1996. It has replaced metal and other composite materials used for pump wear rings, throat bushings, and line shaft bearings to help users increase pump reliability and performance. The properties of Vespel CR-6100 help to reduce the risk of pump seizure and allow internal rotating-to-stationary part clearances to be reduced by 50% or more.
been made from metal, which can gall and seize the pump under contacting or run-dry conditions, resulting in abrupt, highenergy pump failure. With metal wear rings, design clearance is increased to prevent failure, which has a negative effect on efficiency, suction conditions, and overall pump vibration. Vespel CR-6100 can be installed with reduced clearances, without increasing the risk of seizure while improving pump performance. (See Figure 1.)
Maintenance Benefits
For personnel who are repairing pumps, the easy installation of Vespel CR-6100 reduces repair time. This increases equipment availability for service and reduces the operational tensions of long-term equipment repair. Repair time is reduced because parts can be produced and fitted quickly. Vespel CR-6100 can be machined into parts with thin radial walls of 1/8 in (3.175 mm) (up to 10 in [125.4 cm] diameter) allowing application in nearly all pump configurations. The material properties of Vespel CR-6100 allow it to be machined at high speeds and feed rates with the use of standard machine tooling. It does not require heat-treating or hard facing like some metal wear materials. In addition, material selection is simplified as Vespel CR-6100 has near universal chemical compatibility and can run against metallic wear ring materials.
Reduced clearance increases pump reliability because wear rings act as hydrodynamic bearings within the pump--a phenomenon known as the Lomakin Effect. The radial force from the wear rings is a function of differential pressure, speed, the process fluid properties, and the inverse of the wear ring clearance. Therefore, reductions in wear ring clearance increase the hydraulic radial force on the rotor. In many pump types, this additional hydraulic force will have the effect of reducing overall pump vibration, reducing shaft deflection, and increasing the pump life. Reduced clearance also reduces internal pump re-circulation, which yields equivalent production flow at reduced horsepower (i.e., increased efficiency). Applied on large pumps or across a large population of equipment, substantial annual savings are possible. Alternatively, reduced clearance can increase the production capacity of existing equipment. A further benefit of reduced clearance is that the pump Net Positive Suction Head Required (NPSHR) may decrease by as much as 23 feet (60.9691.44 cm), often providing the margin required in tough applications.
Table A: Vespel CR-6100 clearances compared to standard minimum API diametrical clearances Bore Diameter (in) 4.0015.000 5.0016.000 6.0017 .000 7 .0018.000 8.0019.000 Bore Diameter (mm) 101.6127 .0 127 .0152.4 152.4177 .8 177 .8203.2 203.2228.6 Vespel CR-6100 Clearance 0.007 in (0.187 mm) 0.008 in (0.203 mm) 0.009 in (0.2286 mm) 0.010 in (0.254 mm) 0.011 in (0.2794 mm) API Minimum Clearance 0.015 in (0.381 mm) 0.017 in (0.4381 mm) 0.018 in (0.4572 mm) 0.019 in (0.4826 mm) 0.020 in (0.508 mm)
Application Guide
DuPont Vespel CR-6100 is suitable for pump wear rings, throat bushings, and line shaft bearings. Figure 3. Orientation of material
NOMENCLATURE
Service Limits
Vespel CR-6100 can be used in temperatures from cryogenic up to 500F (260C). The low x-y plane thermal growth of Vespel CR-6100 allows close clearances to be maintained over the entire temperature range. (Figure 3 shows the orientation of the x-y plane and z direction.) Note that interference fits and axial clearance need to be adjusted with temperature. Best performance is achieved in non-abrasive services. Vespel CR-6100 has been installed with success in services with low concentrations of solids, however, performance may not be consistent due to many variables, which can cause premature wear. Pipe scale and other common debris in low concentrations are not typically a problem. Users should rely upon field experience and to apply appropriately. Figure 4. Installation of Vespel CR-6100 wear rings and throat bushing in typical overhung pump
Note: All fiber reinforcement is randomly oriented in the x-y plane.
Table B: Pump parts, which can be converted to Vespel CR-6100. Pump Type Overhung and Vertical Inline (API Pumps) Single stage between bearings Multi-stage horizontal Vespel CR-6100 Parts Stationary* wear rings and throat bushings Stationary wear rings and throat bushings Stationary wear rings, throat bushings, inter-stage bushings, and pressure reducing bushings Stationary wear rings, interstage bushings, line shaft bearings, and throat bushings
Throat Bushings
Mechanical seals generally require a flush with a close clearance throat bushing installed to control the fluid environment at the mechanical seal. The close clearance forms a barrier, which isolates the mechanical seal environment from the process fluid. Vespel CR-6100 throat bushings can used instead of specially fabricated, spring loaded, carbon bushings for close clearance applications. Vespel CR-6100 bushings are less expensive, easier to install, and more durable than the specialty bushings. Vespel CR-6100, installed with minimal clearance, improves the performance of several common seal flush plans used across the fluid processing industries.
Vertical
* Vespel CR-6100 should be mounted in compression, which in nearly all pumps will be the stationary, case and head rings.
Wear Rings
Vespel CR-6100 is used as the stationary wear rings in a wide
range of centrifugal pump types (Table B). For pumps in nonabrasive services under 500F (260C), Vespel CR-6100 can
be applied to reduce wear ring clearance, resulting in improved reliability and performance. Vespel CR-6100 can also be applied to services prone to off-design operation, minimizing the risk of seizing failures associated with metal wear rings and allowing the pump to continue in service after temporary run-dry conditions.
5
Installation Guide
Step 2: Select running clearance from Table 3
Appendix A, Table 3 shows recommended running clearance based on component diameter. Unlike materials with high coefficients of thermal expansion, the installed clearance of Vespel CR-6100 remains constant over the full application temperature range. This is because as temperature increases, stress in the material is relieved and the I.D. will increase at the same CTE as the material of the bore that it is pressed into. Temperature correction is only required when the impeller and case are different materials (which is true for all wear ring materials). Simply identify the I.D. of the Vespel CR-6100 component, and select the appropriate clearance from the table. DuPont Vespel CR-6100 pump components are easy to machine and install. Components are fitted into machined holders or directly into the pump casing, whichever is easier and more economical. Because Vespel CR-6100 can be installed with
Note: Where possible it is recommended to final machine the I.D. of the Vespel CR-6100 component after the press fit operation. This practice ensures the best possible accuracy, surface finish, and concentricity of the component bore. Note on Vertical Pumps: Many multi-stage vertical pumps are assembled in sections with pilot fits that may be larger than the recommended minimum clearance for Vespel CR-6100. In these situations, it is essential that the repair facility either install the Vespel CR-6100 line shaft bearings with additional clearance, or tighten the pilot fits between sections to ensure adequate rotor concentricity.
thin radial walls (Appendix A, Table 5) end-users often find that installing a Vespel CR-6100 sleeve inside an existing metal wear component is the easiest way to use the material. Whether the Vespel CR-6100 is installed as a sleeve or a solid component, it is essential for it to be installed with the correct interference fit, clearance, and end clearance for axial growth.
CR-6100 component. Before pressing, be sure that the metal bore has an adequate lead-in chamfer and all sharp corners have been removed. Many users also find the press operation easier if the leading edge of the Vespel CR-6100 wear ring has been machined with a 0.125 inch (3.175 mm) long, zero interference pilot fit.
DP
Step 5: Locking
Installed with the proper interference fit, field experience indicates additional mechanical locking devices in Vespel CR-6100 wear rings are not required. However, differential pressure should be pushing the Vespel CR-6100 against a shoulder (Figure 6, A) to prevent axial movement of the Vespel CR-6100 component. For applications with no differential pressure, radial pins can be used for retention (Figure 6, B). Typically a shoulder 0.12 inch (3.048 mm) minimum thick is provided to prevent the stationary wear ring from becoming dislodged axially from the holder due to differential pressure. The radial wall thickness of the holder typically is 0.125 in (3.175 mm) minimum. For applications where differential pressures are very high ( >250 psig [>1.73 MPa] per stage), or the pump has other unique characteristics, the solution should be engineered to fit. Contact your local DuPont Vespel CR-6100 representative for additional support.
A
Differential Pressure
B
No Differential Pressure
Appendix A
Table 1A: Carbon Steel Case/HeadEnglish Units CTE = 6.5 x 106 in/in/F These are recommended installation interference fits. Pump Operating Temperature, F Bore Diameter (in) 0.0011.000 1.0012.000 2.0013.000 3.0014.000 4.0015.000 5.0016.000 6.0017 .000 7 .0018.000 8.0019.000 9.00110.000 10.00111.000 11.00112.000 12.00113.000 13.00114.000 14.00115.000 15.00116.000 At or below Ambient 0.004 0.005 0.007 0.008 0.010 0.012 0.014 0.016 0.018 0.020 0.022 0.024 0.026 0.028 0.030 0.032 100 0.004 0.005 0.007 0.008 0.011 0.013 0.015 0.017 0.019 0.021 0.023 0.026 0.028 0.030 0.032 0.034 150 0.004 0.006 0.008 0.009 0.012 0.014 0.016 0.019 0.021 0.024 0.026 0.028 0.031 0.033 0.035 0.038 200 0.004 0.006 0.009 0.010 0.013 0.015 0.018 0.021 0.023 0.026 0.028 0.031 0.034 0.036 0.039 0.041 250 0.004 0.006 0.009 0.011 0.014 0.017 0.019 0.022 0.025 0.028 0.031 0.034 0.037 0.039 0.042 0.045 300 0.005 0.007 0.010 0.012 0.015 0.018 0.021 0.024 0.027 0.030 0.033 0.036 0.040 0.043 0.046 0.048 350 0.005 0.007 0.010 0.013 0.016 0.019 0.023 0.026 0.029 0.033 0.036 0.039 0.042 0.046 0.049 0.052 400 0.005 0.007 0.011 0.013 0.017 0.021 0.024 0.028 0.031 0.035 0.038 0.042 0.045 0.049 0.052 0.056 450 0.005 0.008 0.011 0.014 0.018 0.022 0.026 0.029 0.033 0.037 0.041 0.045 0.048 0.052 0.056 0.059 500 0.005 0.008 0.012 0.015 0.019 0.023 0.027 0.031 0.035 0.039 0.043 0.047 0.051 0.056 0.059 0.063
Table 1B: Carbon Steel Case/HeadSI Units CTE = 11.8 x 106 cm/cm/C These are recommended installation interference fits. Pump Operating Temperature, C Bore Diameter (mm) 0.025.4 25.450.8 50.876.2 76.2101.6 101.6127 .0 127 .0152.4 152.4177 .8 177 .8203.2 203.2228.6 228.6254.0 254.0279.4 279.4304.8 304.8330.2 330.2355.6 355.6381.0 381.0406.4 At or below Ambient 0.102 0.127 0.178 0.203 0.254 0.305 0.356 0.406 0.457 0.508 0.559 0.610 0.660 0.711 0.762 0.813 38 0.102 0.127 0.178 0.203 0.279 0.330 0.381 0.432 0.483 0.533 0.584 0.660 0.711 0.762 0.813 0.864 66 0.102 0.152 0.203 0.229 0.305 0.356 0.406 0.483 0.533 0.610 0.660 0.711 0.787 0.838 0.889 0.965 93 0.102 0.152 0.229 0.254 0.330 0.381 0.457 0.533 0.584 0.660 0.711 0.787 0.864 0.914 0.991 1.041 121 0.102 0.152 0.229 0.279 0.356 0.432 0.483 0.559 0.635 0.711 0.787 0.864 0.940 0.991 1.067 1.143 149 0.127 0.178 0.254 0.305 0.381 0.457 0.533 0.610 0.686 0.762 0.838 0.914 1.016 1.092 1.168 1.219 177 0.127 0.178 0.254 0.330 0.406 0.483 0.584 0.660 0.737 0.838 0.914 0.991 1.067 1.168 1.245 1.321 204 0.127 0.178 0.279 0.330 0.432 0.533 0.610 0.711 0.787 0.889 0.965 1.067 1.143 1.245 1.321 1.422 232 0.127 0.203 0.279 0.356 0.457 0.559 0.660 0.737 0.838 0.940 1.041 1.143 1.219 1.321 1.422 1.499 260 0.127 0.203 0.305 0.381 0.483 0.584 0.686 0.787 0.889 0.991 1.092 1.194 1.295 1.422 1.499 1.600
9
Table 2A: 300 Series Stainless Case/HeadEnglish Units CTE = 9.60 x 106 in/in/F These are recommended installation interference fits. Pump Operating Temperature, F Bore Diameter (in) 0.0011.000 1.0012.000 2.0013.000 3.0014.000 4.0015.000 5.0016.000 6.0017 .000 7 .0018.000 8.0019.000 9.00110.000 10.00111.000 11.00112.000 12.00113.000 13.00114.000 14.00115.000 15.00116.000 At or below Ambient 0.004 0.005 0.007 0.008 0.010 0.012 0.014 0.016 0.018 0.020 0.022 0.024 0.026 0.028 0.030 0.032 100 0.004 0.005 0.008 0.009 0.011 0.013 0.016 0.018 0.020 0.022 0.024 0.027 0.029 0.031 0.033 0.036 150 0.004 0.006 0.009 0.010 0.013 0.015 0.018 0.021 0.023 0.026 0.029 0.031 0.034 0.036 0.039 0.042 200 0.005 0.007 0.010 0.012 0.015 0.018 0.021 0.024 0.027 0.030 0.033 0.036 0.039 0.042 0.046 0.048 250 0.005 0.007 0.011 0.013 0.016 0.020 0.023 0.027 0.030 0.033 0.037 0.040 0.044 0.047 0.050 0.056 300 0.005 0.008 0.011 0.014 0.018 0.022 0.026 0.029 0.033 0.037 0.041 0.045 0.048 0.052 0.056 0.060 350 0.005 0.008 0.012 0.016 0.020 0.024 0.028 0.032 0.037 0.041 0.045 0.049 0.053 0.057 0.061 0.066 400 0.005 0.009 0.013 0.017 0.022 0.026 0.031 0.035 0.040 0.044 0.049 0.054 0.058 0.063 0.067 0.072 450 0.005 0.009 0.014 0.018 0.023 0.028 0.033 0.038 0.043 0.048 0.053 0.058 0.063 0.068 0.072 0.078 500 0.006 0.010 0.015 0.020 0.025 0.030 0.036 0.041 0.047 0.052 0.057 0.063 0.068 0.073 0.078 0.084
Table 2B: 300 Series Stainless Case/HeadSI Units CTE = 17.4 x 106 cm/cm/C These are recommended installation interference fits. Pump Operating Temperature, C Bore Diameter (mm) 0.025.4 25.450.8 50.876.2 76.2101.6 101.6127 .0 127 .0152.4 152.4177 .8 177 .8203.2 203.2228.6 228.6254.0 254.0279.4 279.4304.8 304.8330.2 330.2355.6 355.6381.0 381.0406.4
10
At or below Ambient 0.102 0.127 0.178 0.203 0.254 0.305 0.356 0.406 0.457 0.508 0.559 0.610 0.660 0.711 0.762 0.813
38 0.102 0.127 0.203 0.229 0.279 0.330 0.406 0.457 0.508 0.559 0.610 0.686 0.737 0.787 0.838 0.914
66 0.102 0.152 0.229 0.254 0.330 0.381 0.457 0.533 0.584 0.660 0.737 0.787 0.864 0.914 0.991 1.067
93 0.127 0.178 0.254 0.305 0.381 0.457 0.533 0.610 0.686 0.762 0.838 0.914 0.991 1.067 1.168 1.219
121 0.127 0.178 0.279 0.330 0.406 0.508 0.584 0.686 0.762 0.838 0.940 1.016 1.118 1.194 1.270 1.422
149 0.127 0.203 0.279 0.356 0.457 0.559 0.660 0.737 0.838 0.940 1.041 1.143 1.219 1.321 1.422 1.524
177 0.127 0.203 0.305 0.406 0.508 0.610 0.711 0.813 0.940 1.041 1.143 1.245 1.346 1.448 1.549 1.676
204 0.127 0.229 0.330 0.432 0.559 0.660 0.787 0.889 1.016 1.118 1.245 1.372 1.473 1.600 1.702 1.829
232 0.127 0.229 0.356 0.457 0.584 0.711 0.838 0.965 1.092 1.219 1.346 1.473 1.600 1.727 1.829 1.981
260 0.152 0.254 0.381 0.508 0.635 0.762 0.914 1.041 1.194 1.321 1.448 1.600 1.727 1.854 1.981 2.134
Table 3A: Recommended Running Clearance English Units Bore Diameter (in) 0.0011.000 1.0012.000 2.0013.000 3.0014.000 4.0015.000 5.0016.000 6.0017 .000 7 .0018.000 8.0019.000 9.00110.000 10.00111.000 11.00112.000 12.00113.000 13.00114.000 14.00115.000 15.00116.000 Diametrical Clearance (in) 0.004 0.004 0.005 0.006 0.007 0.008 0.009 0.010 0.011 0.012 0.013 0.014 0.015 0.015 0.016 0.016
Table 3B: Recommended Running ClearanceSI Units Bore Diameter (mm) 0.025.4 25.450.8 50.876.2 76.2101.6 101.6127 .0 127 .0152.4 152.4177 .8 177 .8203.2 203.2228.6 228.6254.0 254.0279.4 279.4304.8 304.8330.2 330.2355.6 355.6381.0 381.0406.4 Diametrical Clearance (mm) 0.102 0.102 0.127 0.152 0.178 0.203 0.229 0.254 0.279 0.305 0.330 0.356 0.368 0.381 0.394 0.406
Table 4A: Axial End ClearanceEnglish Units Process Temperature, F 100 50 0 50 100 150 200 250 300 350 400 450 500 Axial Growth at Temperature in inches per inch (based on 68F ambient temperature) 0.030 0.020 0.012 0.003 0.006 0.015 0.024 0.033 0.042 0.054 0.067 0.092 0.118
Table 4B: Axial End ClearanceSI Units Process Temperature, C 73 46 18 10 38 66 93 121 149 177 204 232 260 Axial Growth at Temperature in mm per mm of axial length (based on 20C ambient temperature) 0.030 0.020 0.012 0.003 0.006 0.015 0.024 0.033 0.042 0.054 0.067 0.092 0.118
Table 5A: Minimum Wall ThicknessEnglish Units Bore Diameter (in) 0.0002.000 2.0014.000 >4.000 Minimum Wall Thickness (in) 0.062 0.087 0.125
Table 5B: Minimum Wall ThicknessSI Units Bore Diameter (mm) 0.050.8 50.8101.6 >101.6 Minimum Wall Thickness (mm) 1.575 2.210 3.175
11
The data listed here fall within the normal range of properties, but they should not be used to establish specification limits nor used alone as the basis of design. The DuPont Company assumes no obligations or liability for any advice furnished or for any results obtained with respect to this information. All such advice is given and accepted at the buyers risk. The disclosure of information herein is not a license to operate under, or a recommendation to infringe, any patent of DuPont or others. Since DuPont cannot anticipate all variations in actual enduse conditions, DuPont makes no warranties and assumes no liability in connection with any use of this information. CAUTION: This product is not permitted to be sold for use in medical applications involving any implantation in the human body or where contact with internal body fluids or tissues will equal or exceed 24 hours. For applications involving contact of less than 24 hours, see DuPont Medical Caution Statement H-50102 or contact your DuPont sales representative.
Copyright 2008 DuPont. The DuPont Oval Logo, DuPont, The miracles of science, Teflon, and Vespel are registered trademarks or trademarks of E. I. du Pont de Nemours and Company or its affiliates. All rights reserved. K-16392-3 (05/08) Printed in the U.S.A.