GRAPHI CARB PRODUCT Narol, Ahmedabad, Gujarat

Using Carbon Thrust Bearing in Sub Motor ( G10Z Grade Carbon ) Saves electricity upto 10% Increase Pump efficiency upto 5% Starts & runs the Pump even at low / fluctuating voltage Motor runs ar full RPM Gives upto 10% more output of water in LPM as compared to teflon / fibre Makes pump rotates freely & silently The motor does not get locked even offer prolonged rest Submersible motors are fitted with Hydrodynamic Self Adjusting Tilting Shoe Thrust Bearing to take the axial down thrust from the pump. These are a complex and clever part of a reliable submersible motor and probably not understood very well. Principle The Hydrodynamic Thrust Bearing transmits the rotating shaft's axial thrust load to the frame of the motor which is mechanically supported in the well. The axial Thrust load is transmitted through the bearing on a self renewing film of lubricant which is water in most motors. The pressure in the fluid film supports the load without the thrust disc or pivot shoes making contact. Theory Fluids tend to stick to most surfaces due to viscosity. and in the case of loose segments thrust bearing we rely on the fluid sticking to the surface on the rotating thrust disc. This fluid is then dragged between the thrust bearing disc and the face of the pivot shoe by centrifugal force and forms a wedge shaped film. This wedge shaped film is essential for the successful operation of the thrust bearing. When the bearing is operating correctly there is no contact between the disc and the face of the pivot shoe. The only time there is contact is when the motor is stopping or starting. This means there should be only negligible wear between the faces and no wear while the motor is operating.   Surface finish of the carbon thrust bearing disc is machined flat and exactly perpendicular to the shaft with negligible runout on the face. The surface is lapped to give a very smooth flat finish. The surface of the face of the pivot shoes is also ground and lapped to give a very smooth flat finish and in addition the height of each pivot shoe in a set is identical and the base of the pivot leg is spherical so that the pivot shoes are free to pivot and share the load quality Due to mechanical tolerances there will always be some variations in dimensions but in general they are tightly controlled. The Design of the thrust bearing allows the whole thrust bearing assembly to swivel on the thrust button which also allows the pivot shoes to share the load more evenly.

Carbon-graphite stoker bushes are used in travel grate of boilers for high temperature applications because metal bushes needs oil/grease lubrication, Oil/grease lubricants can start to melt, volatilize or carbonize above this temperature above about 350ºF (177ºC).. When this occurs, oil/grease-lubricated metallic bearings start to experience high friction, high wear, galling, vibration and even seizing. Moreover Metallic bearings can start to have problems of thermal expansions at high temperatures. High Temperature Application At high temperatures, plastic and composite bearings are subject to other problems such as softening, melting, deformation and may extrude out of the bearing area all together. Carbon graphite bearings are ideally suited for applications at elevated temperatures because they rely on graphite for their self-lubricating properties. These solid homogeneous bearing materials do not contain oil/grease lubricants and they do not rely on oil/grease for lubrication. Thus, bearings manufactured from these carbon graphite materials are not subject to the shortcomings associated with petroleum-based lubricants and metals at elevated temperatures. Because the carbon graphite matrix is very strong, it is not subject to the deformation, melting, or even softening that can occur with plastic bearings at these elevated temperatures. Room Temperature Or Cold Temperature Dry Running Applications Carbon-graphite bearings are also used for dry running at room temperature or cold temperatures. This occurs in applications where oil/grease lubricated metal bearings can not be used because: Oil/grease lubricants volatilize in vacuum At low temperatures, oil/grease lubricants can congeal, freeze, or solidify Oil/grease lubricants volatilize in vacuum At low temperatures, oil/grease lubricants can congeal, freeze, or solidify In environments containing abrasive dust which is attracted by oil/grease lubricants to form a paste that increases bearing wear. In high load, slow roll, start-stop equipment where oil/grease lubricants can be squeezed out of the rubbing surface and cause metal-to-metal contact.   Where the bearings need to conduct an electric current. In sanitary or clean conditions where oil/grease lubricants could leak out and destroy product such as food, textiles, pharmaceuticals, paper, etc. Salient Features Carbon and graphite materials exhibit the following characteristic properties. Due to these properties, carbon and graphite bearings are used in many applications such as high and low temperature technology. High wear resistance Good thermal conductivity Self lubricating low coefficient of friction Resistance to corrosion Excellent dimensional stability Low thermal expansion High fatigue resistance Dry running properties

Carbon graphite materials are used extensively for vanes , rotors and end plates in rotary vane pumps pumping both liquids and gases. Carbon graphite vanes can withstand the rubbing of the vane tip against the housing bore and the rubbing of the side of the vane against the slots in the rotor. Carbon Graphite rotors are light in weight to save energy and can also withstand the rubbing of the vane against the end plates.   Carbon graphite vanes , rotors and end plates are used for pumping liquids with poor lubrication properties (low viscosity) such as water. gasoline and beverages. They are also used for pumping strong chemicals that attack metals.   Carbon Graphite Vanes , rotors and end plates are also used to pump gases such as air , vacuum , combustion products and gasoline vapors.   Graphic Products supplies carbon graphite vanes , rotor , and end plates to rotary pump and compressor manufacture and rebuilders. The Vanes , rotors , and end plates can be supplied to customer prints and specifications.   Chemically resistant Compatibility with foods & beverages (FDA) (if PTFE Impregnated) Dimensionally Stability High Strength to weigh ratio impermeability (pressure tight) Light Weight (low centrifugal force) Low wear rate running in gas atmospheres Low wear rate running in low viscosity liquids Dry Running Applications Auto anti smog pumps Chemical Pumps Gasoline vapor pick up pumps Oil free air pumps Paint spray pumps Pumps for automobile locking devices Rotary Compressors for fresh air (breathable air) Vacuum Pumps for aircraft gyroscopes Vacuum Pumps for milking machines    

at high temperatures plastic and composite bearings are subject to other problems such as softening , melting , deformation and may extrude out of the bearing area all together. Because the carbon graphite matrix is very strong.it is not subject to the deformation , melting or even softening that can occur with plastic bearings at these elevated temperatures the temperature resistance in an oxidizing atmosphere can be specified as 400o c maximum for g10 bearing qualities.in a non - oxidizing atmosphere the temperature resistance is determined by the final graphitizing treatment of each individual grade ( e.g. Upper application limit for graphite is approximately 3000o c ). Temperature resistance is also affected by various impregantions. In the case of resin impregnation the maximum operating temperature is 180o c for lead impregantion 200o c and antimony impregnation 500o c

Mechanical Seal Ring Materials require high strength and a relatively high modulus of elasticity to with stand deformation at the interface. Carbon-graphite seal materials provide the strength and rigidity which are especially important in high pressure , high vacuum , high temperature and zero leakage mechanical end-face seals. High thermal conductivity is essential in removing heat from the interface.   Pure carbon graphite is strictly speaking a ceramic material , but in the form that it is used for seals it will usually be impregnated with other materials that are provided to variously improve the sealing. By reducing porosity , wear performance or strength is increased. it is widely used , not only as one of the face pair on the vast majority of mechanical seals , but also found as the most popular material for segmented circumferential seals and for piston rings in dry or marginally lubricated conditions.   Impregnation of Carbon - Graphite Seals   Impregnation of carbon seals can be done with a variety of materials to control permeability. in addition to thermoset resins , other types of impregnants include thermoplastics , metals and inorganic salts or glasses. The temperature limit of the impregnant places an upper limit on the operating temperature of the carbon parts.   Metals such as antimony , silver , copper , nickel and babbitt can improve the strength , thermal conductivity , and tribological characteristics of the materials. Impregnants made of inorganic salts usually phosphate or borate - and glasses are used in high temperature applications. Carbons impregnated with soluble salts must be handled carefully to avoid exudation , especially under humid conditions , but loss of impregnant rarely affects any physical property of a seal other than permeability. Mechanical seal primary rings can be supplied as per customer drawings and specifications. The rings can be supplied plain , shrink fitted or cemented in metal retaining rings. Mechanical seal rings can also be supplied with the sealing face lapped flat to one helium light light band.   Guidelines for the installation & Design of Carbon Seal Rings   Solid Carbon Rings : Normally the seal rings are used in solid form machined from suitable size of carbon blank. The Shape and size of the rings vary according to the design of mechanical seals which are designed for its respective operating conditions. Since carbon - graphite are stable at high temperature , majority of the seal ring designs consitute solid rings. Cold Pressing : For a cold press fit in steel , where the application is lower than 100o C steel housings made to H7 bore tolerance are normally recommended. if the housing material has a higher coefficient of thermal expansion than steel the temperature limitation is normally lower. When pressing bearing into its housing a mandrel with collar whose diameter is approximately three tolerances be low the drilling tolerance of the carbon bearings as supplied should be used to press the bearings in. the bore diminishes by 70 - 80% of the pressing over dimension according to the quality and dimension of the housing. Shrinking : We Recommend shrinking carbon seal rings directly into the metal housing which are to be used at operational temperatures of over 100o C. To shrink in the bearings , experience has shown that the tolerance overlap should be in the range corresponding H7 / x8...z8. The selected Heating temperature for mounting must be sufficiently high to allow the cold bearings to be easily inserted. On shrinking the carbon bearing bore diminishes by approximately 80...100% of the shrinking overdimension. in the case of the above mentioned shrink fits H7 / x8...z8 this diminishes according to the wall thickness ratio. in order to keep to exact tolerances it is advisable to machine the bearing bore to size after shrinking. Adhesives : Adhesives are only suitable for bearings which are subject to low temperatures ( up to 200o C ). Bonding to the housing with commercially available adhesives is possible.for higher temperatures , thermal setting adhesives should be used. Suitable Counter Face Materials Suitable :Plain Steel , alloyed steel (Chrome Steel) , Hard Metal , Ceramic & glass. Suitable under certain conditions :Nonferrous heavy metal , chrome nickel steel , chromium plate materials. Unsuitable :Aluminium and its alloys.

Professional power tools place the highest demands on electric motors. Carbon Brushes of this equipments are compelled to work under difficult situations such as : High Current Densities vibration Dust Formation High Rotational Speeds Exposure to weather conditions etc. G35 Grade Carbon Block is specially made to work under such conditions. Carbon Brushes made from G35 Grade carbon blocks have shown excellent performance in this field. in additional to research and development , it is the right materials choice combined with superior process technology in our mixing plant with our modern production technology which ensures the high quality of our products.   Carbon Brushes made of G35 grade carbon blocks experience a long operating life and high operational reliability. In addition to Long life , Carbon Brushes made from G35 also possesses extra qualities such as : Not to damage Commutator Lower Level of radio interference To endure vibration , impact and in some cases even electric brakes work   With G35 Grade excellent test results have been achieved with small and large angle grinders. some of the noteworthy results seen are : Remarkable increase in lifetime of brush and commutator Low commutator wear Lower operating temperatures Low RFI

Graphicarb Products offers machinable , resin impregnated , carbon-graphite blanks for companies that need to machine mechanical seal primary rings , radial bearings , thrust bearing , case wear rings , vanes for pumps and other mechanicaparts in house. Standard cylinders and blocks are available in GRADE G10Z & G6Z (resin impregnated) Grades G10B (babbitt impregnated) , G10C (copper impregnated) , G10A (antimony impregnated) The machinable , resin impregnated blanks are made from fine-grained , high strength , carbon-graphite that is fully impregnated with chemically resistant , thermal setting resin. The material has excellent lubricating qualities when running in low viscosity liquids in the temperature range from -30 to +180o C. The blanks are readily machinable with conventional tungsten carbide or diamond tools. Mechanical seal rings , bearings , and vanes machined from these blanks are impervious to high-pressure liquids. The material is dimensionally stable so that mechanical seal ring faces can be polished to one helium light band flatness is retained indefinitely. The material is chemically resistant to almost all liquids except extremely strong , oxidizing acids and alkalis. Standard Rod Sizes Wide range of standard cylinder sizes are available to cover mechanical seal rings and bearing sizes. We also supply rods of carbon-graphite impregnated with resin. The rod diameters range from 1" to 6". Different standard lengths are available and upon maximum length of 80 mm. We also supply the material impregnated after machining partly for critical applications.