Month: June 2021

Motor Control Center – Why do we use them, Types and Components

by vemcoblogs -

A Motor Control Center is an assembly that controls some or all of the electric motors in a central location. It consists of various components like starters, fuses and circuit-breakers. All of these play the corresponding function of starting, controlling and protecting the motors and are assembled in an integrated panel. MCCs are mostly found in large commercial and industrial buildings where these are used to control a large number of widely deployed electric motors in an efficient and easy way.

MCC Control Panel VEMC Make

An MCC panel consists of a Power Circuit, Control Circuit and Protection. The Power Circuit supplies electric power to the motors and the Control Circuit regulates the sequencing of the contactors and also operates the fans in auto or manual mode. Protection mechanisms like the thermal protection circuit in the panel ensure that the motors are protected from overheating and short-circuit. Contactors, overload relays to protect the motor, fuses and a disconnecting switch, used to isolate the motor circuit, are all parts of an elaborate design of an MCC.

There are different types of Motor Control Centers, based on the voltage supplied, the type of operation, and module division.

Based on the voltage supplied:

MCCs can be classified as Low Voltage and Medium Voltage. Low voltage MCCs are used for low voltage three-phase alternating current motors from 230V to less than 1000V. Medium-voltage MCCs on the other hand are used for large motors requiring around 1000V to 15000V.

Based on the type of operation:

  • Combination starter motor: This comprises of several main equipment such as Molded Case Circuit Breaker (MCCB), magnetic contactor, over-interference safety relay and control transformer.
  • Manual operation: This type of MCC is used to control a motor that has a maximum power of 10 HP. The starter is manually operated through an on-off switch which also acts as a safety device for overload interference.
  • Adjustable speed controller: This type of MCC enables the motors to change their speed by changing the voltage frequency on the motor.

Based on module division:

  • Fixed type: In this type of MCC, components like the starter, contactor, thermal overload and others are completely integrated with the frame.
  • Semi draw out type: In this type of control center, the voltage source section can be separated from the plug-in system so that if there is damage to one module, it can be removed without interfering with the other systems.
  • Fully draw out type: In this type of MCC, all the components can be removed in case of damage, and repaired outside the panel without interfering with the function of the other modules.

As one of the top MCC panel manufacturers, we would be happy to assist you in finding the best match based on your requirements. Feel free to get in touch with our experts on +91 98199 07445. One of India’s best solar companies with 72 years of market experience, VEMC provides end-to-end solar EPC services to its clients. VEMC is ISO 9001:2015 certified and is one of the most renowned control panel manufacturers in the market. Being one of the leading custom control panel manufacturers, our valued clients are provided with tailor-made solutions to fit all their needs.

Motor Control Center (MCC) Installation for Sewage Disposal at IIT Bombay

by vemcoblogs -

Located between the Powai and Vihar lakes of East Mumbai, IIT Bombay has a sprawling campus of about 550 acres. The green cover of the campus has been maintained over the years and gives the campus an idyllic appearance. The institution authorities have, in fact, been very keen on embodying and exemplifying a sustainable spirit towards education and research. Sewage disposal of this massive campus, with nearly 600 major buildings, had to be in line with the same spirit.

MCC Control Panel installed at IIT Powai

Challenge

The organisation was looking at a sewage disposal solution which combined the benefits of automatic operation as well as energy efficiency. The most important consideration was to reduce human intervention. The control panel had to be designed so as to avoid energy wastage and ensure the highest efficiency. Finally, an emergency alarm mechanism had to be installed for sudden spurts in sewage.

Our Solution

After a thorough feasibility study of the existing disposal system at the campus, we designed a motor control center (MCC) panel, considering the requirements of control, safety and efficiency. Detailed Single Line Diagrams and General Arrangement Drawings were discussed with the client. Components of the highest quality were used and a state-of-the-art graphical display was installed for tracking parameters such as voltage, current and frequency.

Working of the MCC panel 

The working logic formed the core of our sewage disposal solution. The sewage tank was calibrated with markers of 20%, 40%, 60%, and 80%, and all pumps were to be OFF with sewage levels below the 20% (Low) mark. As soon as the sewage fluid would rise above the 40% (High) mark, Pump #1 would start and stop only when the fluid levels dropped below the 20% mark. In case the fluid levels rose above the 60% mark (Very High), Pump #2 would start and run alongside Pump #1. If the fluid levels crossed the 80% (Very Very High) mark, Pump #3 would start and run alongside pumps #1 and #2. An alarm would also go off as soon as the fluid level crossed the 80% mark. As the level of sewage fluid dropped through the markers, the pumps would stop running, one at a time, in the first in first out (FIFO) mode. Finally, with the sewage fluid dropping below the 20% (Low) mark, all pumps would stop and the cycle of running the pumps would change to ensure equal usage of all pump sets.

The Impact

This working logic ensured the proportionate usage of pumps in response to the volume of sewage in the tank and also used all the pump sets equally, to avoid wear and tear of only one or a few pumps.

For any assistance that you might need, feel free to contact us on +91 98199 07445. With 72 years of market experience, VEMC provides end-to-end EPC services to its clients. VEMC is ISO 9001:2015 certified and CRISIL MSE-1 rated, and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

How Solar Operation and Maintenance Can Optimize Your System Performance

by vemcoblogs -

As solar plants get older, they need operation and maintenance to maximize output. It not only enhances the lifespan of the solar plant but also deals with failures and defects. Solar system owners are increasingly concerned about the longevity of their systems and are paying attention to the critical role of operation and maintenance. The frequency and degree of maintenance of solar systems depend upon the installation type, system configuration and location of the setup. 

Here’s how solar operation and maintenance services can increase the performance of your solar power system.

  1. Performance monitoring: It is important that your solar power system works at its peak efficiency and maintains high output levels at all times. To gauge the performance of the system, continuous real-time monitoring is needed. The foremost task involves establishing a performance baseline against which various parameters are continuously compared, followed by steps to mitigate deviations. This helps to keep any shortfall in performance under check and subsequently plan the necessary corrective action.
  1. Preventive maintenance:  To avoid direct and indirect costs related to sudden system breakdown, a timely inspection of components and devices is necessary. Cables, inverter, combiner boxes, photovoltaic panels and remote monitoring devices must be in good working condition. Preventive maintenance includes, but is not limited to, adjustments, cleaning, lubrication, repairs and replacements. Timely preventive checks and actions help the system maintain top levels of performance and also anticipate any possibility of a breakdown.
  1. Corrective maintenance: Despite all the efforts at performance monitoring and preventive maintenance, a system breakdown could be encountered. For situations like these, a comprehensive plan of action has to be ready. Corrective maintenance involves activities performed in order to restore a PV plant system, equipment or component to its original working condition. These include reporting, diagnosing, troubleshooting and providing repair or replacement to restore the system to fully operational status. In some cases, involving a Defect Liability Period (DLP), backup parts may be needed to keep the system running while the equipment is sent back to the vendor for a warranty claim. Although a certain amount of corrective maintenance will be required at some point during the long lifespan of a solar power system, it can be lessened through proactive preventive maintenance and performance monitoring, thus calling for a holistic approach towards operation and maintenance.

The long lifespan of photovoltaic systems necessitates the management of maintenance and breakdown costs over a long time horizon. While the installers usually brief the customers on details of maintenance checks to be carried out at regular intervals, the safest and most effective maintenance service can be provided by solar professionals conversant with system components and their safety procedures.

For further information on any aspect of solar energy, feel free to contact us on +91 98199 07445. We would be happy to assist you in finding the best match based on your requirements. With 72 years of market experience, VEMC provides end-to-end EPC services to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. 

Types Of Solar Panels And The Best Fit For Your Commercial Needs

by vemcoblogs -

One of the foremost choices to make when it comes to procuring a solar system is with regards to the type of solar panel you wish to install. There are broadly three types of solar panels available and each differs from the other in terms of cost, efficiency and aesthetics.

Monocrystalline Panels

This type of panel gets its name from the fact that each cell in the panel has a single crystal of silicon which allows free movement of electrons through the cell, taking its efficiency upto 20% and more. High efficiency means lesser requirement for space and hence, these panels are best suited for residential use as space can be managed efficiently. Monocrystalline panels contain either 60 or 72 cells, depending on the size of the panel. The silicon cells are in the shape of black squares with their corners cut off, giving the panels a deep black aesthetic look.

Polycrystalline Panels

Multiple crystals go into making each cell in these panels which restrict the free flow of electrons through the cell. Their efficiency ranges between 15% and 17% but with increasing innovation in technology, this is expected to improve. Compared to Monocrystalline panels, these panels require more space and therefore, may be slightly challenging to accommodate in a residential setting. These panels also contain 60 or 72 cells but multiple crystals give them a marbled blue appearance, which may not be aesthetically pleasing. However, Polycrystalline panels are more affordable which, despite factors like space and efficiency, has enabled the product to make galloping strides even in the residential market segment in recent years.

Thin Film Solar Panels

These panels are solid black in colour and do not have any silicon cell outlines. Being lightweight and flexible, these are easy to carry and install. Thin-Film panels are the least energy-efficient (10-13% range) and are only suitable for large establishments like industries and utility solar projects with ample space. Being extremely cost-effective due to low energy efficiency and ease of installation makes these panels all the more suited for large-scale commercial establishments. These have a very short life expectancy and require frequent replacement. Depending on the material they’re made of, these panels can be both blue and black.


If you need some assistance to decide on the solar panel that suits your needs the best, feel free to contact us on +91 98199 07445. We would we happy to assist you in finding the best match based on your requirements. As one of India’s best solar companies, having 72 years of market experience, VEMC provides end-to-end Solar EPC services to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Our sub-brand VEMCO Solar (Check out our solar story) is a market leader in solar system solutions — be it solar plant erection, procurement, commissioning, solar metering system, or electrical connections. At VEMCO Solar, our valued clients are provided with customised solar services solutions to fit all their needs.

Different Types of Ground-Mount Solar Racking Systems

by vemcoblogs -

Traditional ground-mounted solar systems are set up by anchoring panels in the ground. These panels hold a large number of stacked panels. But as there are different types of foundations, anchoring to the ground is the most challenging part of these installations. 

In case of clear soil with no debris, steel beams are simply driven into the soil and the racking system is attached to these beams. However, in situations where the soil is not visible and the ground is littered with boulders, anchor systems may be used, in which, helical piles and ground screws are driven into the debris.

Let’s take a look at the different types of ground-mounted solar systems. 

Regular Ground-Mount System: This is a conventional setup in which the photovoltaic panels are held in place by racks or frames that are attached to ground-based mounting support. The mounting support may comprise of pole-mounts that are driven into the ground or embedded in concrete. Alternatively, foundation mounts such as concrete slabs or poured footings may be used.

Capped Landfill: This is an innovation in the solar sector wherein the ground-mounted systems are not fitted into the landfill grounds but are instead ballasted on it, just like they are on flat roofs. This is probably the best utilization of the surface of these otherwise abandoned landfills and brownfields. This kind of setup uses concrete and cast-in blocks to hold the system in place.

Tracking systems: To enhance energy output, tracking systems may be used. These are motorized ground-mounts that track the sun throughout the day exposing the panels to sunlight at all times. Single-axis tracking systems span the panels on long rows and only move them from east to west. Dual-axis tracking systems separate out tables of panels and follow the sun on a circular path. The latter ensures higher energy output. Trackers may be centralized, which have a single motor to move many rows of panels; or distributed, which have multiple motors to move the rows.

Carports and canopies: These are tall ground-mounts, erected mostly in parking lots of schools, universities and large business establishments. Interestingly, these can also be equipped with electric vehicle charging stations to plug in the vehicles parked underneath them.

Floating solar systems: Although not mounted to the ground, floating systems function exactly like panels positioned on a flat roof. These could be assembled on land and can float on water, with the addition of more panels. These are secured to shore mounts or floating anchors. Floating systems can help land and real estate, and are becoming increasingly popular in Asia and parts of Europe.
For more information on various types of solar racking systems, feel free to contact us on +91 98199 07445. We would we happy to assist you in finding the best match, based on your requirements. With 72 years of market experience, VEMC provides end-to-end EPC services to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Our sub-brand VEMCO Solar is a market leader in solar solutions — be it solar plant erection, procurement, commissioning, net metering, or electrical connections. At VEMCO Solar, our valued clients are provided with customized plans to fit all their needs.

Our Solar Story: Installation of 360 kW Plant at MCGM Engineering Hub, Worli

by vemcoblogs -

Mumbai, the city that never sleeps, is a bustling metropolis. The Municipal Corporation of Greater Mumbai (MCGM) is responsible for the smooth running of key aspects of the city’s infrastructure like sewage lines, water supply system, roads, and garbage collection system. All this planning and execution is done at the MCGM Engineering Hub, Worli, which is home to chief engineers and senior executives of MCGM.

Challenge

Providing maximum working comfort to the staff who ensure such high levels of productivity on a regular basis is the top priority for the state-of-the-art facility. Ergo, it’s no surprise that electricity consumption at the building would run up to 2-3 lakh units every monthly, on average. This put a huge financial liability on the building maintenance department and added to MCGM’s overall carbon footprint.

Our Solution

VEMC’s undertaking of this massive project included the construction of a renewable energy system to produce onsite electricity. The idea was to set up a 360 kW solar plant and include a solar net metering connection with the support of BEST Undertaking. Prior to execution, VEMC created a detailed pre-feasibility study to ensure the viability of installing a rooftop solar project for a 25-year operational period. Everything from civil and structural stability to financial savings were explored in the study. Finally, detailed electrical single line diagrams (SLDs), shadow analysis reports, and structural design layouts for the solar modules were presented to the MCGM before proceeding to execution.

Execution

  1. Durability: To ensure a sturdy build, aluminium solar module mounting structures with 3-5 mm thick sections and 12-15 micron anodising, were crafted. Their durable and corrosion-resistant nature was perfect for the planned 25 years of the project. The plant was also designed to withstand wind speeds of up to 150 kmph and it has already been tested against two cyclones, with the speed of approximately 114 kmph, indicating that our design was accurate.
  2. Solar modules: With high efficiency and cost savings being major considerations, polycrystalline cells were chosen for the solar modules. As many as 1,075 modules were procured from reputed Indian manufacturers.
  3. Cables: On the direct current (DC) side, tinned copper cables were used for their resistance to UV and direct sunlight exposure. And for the alternating current (AC) side, armoured type cables were used to provide sufficient mechanical protection when hung or routed through their pathways. Module interconnection cables housed inside cable trays were installed on the roof with optimum clearance from the rooftop to avoid corrosion.
  4. Earthing: While early streamer emission (ESE) lightning arrestors were used, 10-feet deep chemical earthing pits were created for any possible current leakage in the system. This earthing system is completely maintenance-free and has a minimum lifetime of 10-15 years.
  5. Inverters: High-quality inverters from top brands were procured. Not only did they offer 5-year warranties, but they were also tested for IP65 protection and outdoor duty operation in the sun. All the inverters used abide by the International Electrotechnical Commission (IEC) standards required by the Ministry of New and Renewable Energy (MNRE), Government of India, and have surge protection devices (SPDs) and built-in fuse boxes.
  6. Control panel: All the low tension alternating current distribution board (LT ACDB) panels provided were Central Power Research Institute (CPRI) approved, and had copper busbars, appropriate switch gears, quality enclosures, and detailed designs. This meant ample protection for the solar plant and other equipment on the site. Moreover, the LT panels used had in-built multi-function meters to record data like energy generated, current, and voltage.

Impact

The benefits include:

  • An estimated generation capacity of 4.87 lakh units or 500400 kWh annually.
  • An estimated reduction in CO2 emissions by 412 metric tonnes annually and 8250 tonnes over the entire lifespan of its operation. 
  • A 500.4 ton reduction in the building’s carbon footprint.

VEMC, a 72-years young organisation, is a pioneer in the field of electromechanical engineering products, allied equipment’s, and services. Leveraging the decades of experience, VEMCO Solar (Check out our solar story), was able to successfully execute the MCGM project and deliver results. VEMCO Solar is a market leader in solar solutions — be it solar plant erection, procurement, commissioning, net metering, or electrical connections. If you have any requirement, please feel free to contact us on +91 98199 07445. We would be glad to assist you.

7 Things to keep in mind for the smooth operation of your solar power system

by vemcoblogs -

Effective operation and maintenance (O&M) of your solar power system is important to ensure peak efficiency and improve the longevity of the system. Here are 7 things to keep in mind for the smooth operation of your system:

  1. General checks: These have to do with the overall physical protection of the system and include the following checks:
  • There is adequate drainage and no roof clogging or water pooling
  • There is no ground erosion at the base of the ground mount system
  • No corrosion in the racking system
  • Electrical enclosures are accessible to authorized personnel only
  • No loose hanging wires in the array
  • There are no signs of animal infestation (especially mice) near the system
  • There is no debris in the inverter pad area or elsewhere

           Specific checks comprise the component-wise measures that are essential for preventive maintenance.

  1. Modules: Cleaning of modules must be done fortnightly. The water used for cleaning must have TDS (Total Dissolved Solids) below the level of 250 parts per million (ppm). Hard brushes may damage the glass surface of the modules and must be avoided. After washing, the modules must be wiped dry to ensure no stains remain, as these could affect the energy efficiency of the solar power system.
  2. Inverter: Keeping in mind the dusty Indian conditions, monthly rather than quarterly servicing is recommended. Use of high-quality filters for ventilation can be very beneficial. It is also important to track and prevent sharp voltage fluctuations.
  3. Cabling connector: There must be no gap between the male and female connector pipes as this could result in an accidental fire, causing damage to the modules.
  4. Transformer: Parameters like Operating Temperature, Oil Temperature and Winding Temperature must be monitored regularly. The transformer must also be cleaned once every six months.
  5. Protection from external elements: It is important to prevent the entry of rats and other rodents which can get electrocuted, causing a short circuit. Besides, high-pressure water can damage the modules. The system must therefore be completely sealed to prevent incidents like these.
  6. Remote monitoring: This is a new development in preventive maintenance in which data from components like inverter, probes and meters can be remotely received and monitored on a continuous basis.

At VEMC, we work to maintain solar plant infrastructure and equipment, to improve the longevity of equipment by preventing excess depreciation and impairment. This enables the solar power plant to produce the maximum amount of energy throughout its operational life, and perfectly align the interests of developers, clients, and investors.

 For further information on any aspect of solar energy, feel free to contact us on +91 98199 07445. Check out our solar story here. We would be happy to assist you in finding the best match based on your requirements. With 72 years of market experience, VEMC provides end-to-end EPC services to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. 

Variable Frequency Drives Control Panel – Uses and Benefits

by vemcoblogs -

A Variable Frequency Control Panel is used to control the speed of the electric motor and feed pump. These are widely used in drilling, pumping, and applications like conveyors and compressors. VFD panels use the frequency of the voltage applied, to alter the speed of the motors which provides very effective control due to constant flux density.

Most of the industrial applications require variable speeds at peak load conditions and constant speeds at normal operating conditions. In this blog, let’s look at the uses and benefits of VFDs.

  1. Power Switching and Protection: In case of any fault such as short-circuit or overload, a VFD panel holds a circuit breaker or a trip, which not only protects the drive but also the equipment connected to it.
  1. Saves Energy: In times of skyrocketing energy costs, a great amount of energy can be conserved when the motors are operated at variable speeds as per the requirement of the operation. Constant motor speed irrespective of the operation will naturally lead to wastage of energy and pile up the bills.
  1. Limits Starting Current: A VFD delivers low frequency when starting the motor due to which the motor draws less current which never exceeds its nominal rating.  In the absence of a VFD, a motor can draw up to 6 to 8 times more than the nominal current required while starting.
  1. Closed Loop Controlling: This is one of the greatest benefits of a VFD. Closed-loop working of VFDs maintains the speed of the motor at a constant level, even in case of input and load disturbances.
  1. Visual Control: VFDs have a number of field indicators installed to gain real-time information about their power consumption, frequency, and other diagnostic information. This is essential for the operator who may shift the frequency or take precautionary measures based on the monitored values.
  1. Smooth Operation: A VFD helps provide smooth operation especially when starting or stopping a motor. It also reduces the thermal and mechanical stress on motors and belt drives.
  1. High Power Factor: In-built power factor correction circuit in a VFD excludes the need for additional power correction devices. Low power factor results in poor utilization of power due to high reactive losses.
  1. Easy installation and maintenance: Pre-programmed VFDs are easy to install, connect and maintain. VFDs do however require protection from the environment as dirt or chemical accumulation may affect their lifespan.

As a renowned VFD control panel manufacturer, we would be happy to assist you in finding the best match based on your requirements. Feel free to get in touch with our experts on +91 98199 07445. One of India’s best control panel manufacturers, with 72 years of market experience, VEMC provides end-to-end services to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Our sub-brand VEMCO Solar is a market leader in solar system solutions — be it solar plant erection, procurement, commissioning, solar metering system, or electrical connections. Being one of the leading custom control panel manufacturers, our valued clients are provided with tailor-made solutions to fit all their needs.

6 Tips to Finding the Right Solar Installer Basis Your Requirement

by vemcoblogs -

Finding the right solar installer could be a challenging task as the market is flooded with installers claiming to have the required know-how. There are a number of aspects that must be considered while choosing the right professionals in the field. Here are 6 tips that will guide you in your quest for the right installer:

  1. Expertise: As the solar industry is rapidly expanding, there is growing demand for competent professionals with the right skills and expertise. In India, many solar installers go through formal training courses offered by reputed institutes like Indian Institute of Solar Energy and Gujarat Energy Research and Management Institute (GERMI). Certificates from these institutes are the best authentication for skills, knowledge, and expertise.
  2. Track record, experience, and references: Projects with previous clients could provide a good understanding of the level of experience an installer has. An installer must be thorough with the systems installed for other clients and be able to confidently discuss and demonstrate the projects. Speaking to their past clients could be a great way to find out how their installation was handled.
  3. Reputation in the market: Many online forums and sometimes, even the installers’ websites or social media pages can provide valuable insights into their clients’ experiences. A pattern of negative comments and customer complaints would indicate that you need to select another installer.
  4. Use of subcontractors: While installation by subcontractors is a common practice in the industry, there must be complete disclosure and transparency about their expertise, reputation, and track record. It will be important to fix responsibilities and confirm who stands behind the quality of the system.
  5. Warranty: What is the warranty being offered on the equipment? To give you a rough estimate, the average warranty offered on solar panels in around 20 years, and that on batteries and inverters is 5-10 years. Warranties shorter than this can indicate that the quality of the equipment is not up to the mark. 
  6. Competitive quotes: Finally, it is always recommended that you contact as many installers as possible and gather quotes, especially in a business-to-business scenario, where competing bids can help save expenses significantly. The contractors can prepare their bids only after visiting your facility to ascertain the various equipment, labour and logistics costs that will go into installing the system.

With the help of these tips, you can confidently stride towards the solar transformation of your facility.

If you need assistance on any solar engineering services, feel free to contact us on +91 98199 07445. We would be happy to assist you in finding the best match based on your requirements. As one of India’s best solar companies, with 72 years of market experience, VEMC provides end-to-end Solar EPC services to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Our sub-brand VEMCO Solar (Check out our solar story) is a market leader in solar system solutions — be it solar plant erection, procurement, commissioning, solar metering system, or electrical connections. At VEMCO Solar, our valued clients are provided with customized solar services solutions to fit all their needs.