Month: July 2021

5 Steps to Achieve Maximum Air Compressor Efficiency

by vemcoblogs -

The key to optimal air compressor efficiency is to maintain the integrity of your entire pneumatic system. This includes the air compressor, fittings, air hose, and tools. An efficient pneumatic system will ensure that you’re getting the air you need when you need it. An inefficient one will cost you time and money. So, here are 5 steps that will make sure your pneumatic system keeps operating the way it was intended to.

  1. Use 3/8-inch Air Hose: Whenever possible, use a 3/8-inch air hose to ensure you get the maximum amount of pressure to the tool. While a 1/4-inch air hose is lighter to work with, its smaller diameter restricts airflow and causes a greater degree of frictional loss. As a thumb rule, opting for a larger diameter hose ensures the maximum amount of pressure to the tool.
  2. Use Shorter Lengths of Air Hose: The longer the distance air has to travel, the greater is the loss of pressure. For the maximum amount of pressure, use shorter lengths of air hose wherever possible. This, however, may not be possible in certain unavoidable situations, and in that case, using an auxiliary tank can come to your rescue.
  3. Use an Auxiliary Tank: An auxiliary tank acts as a reservoir of extra air and allows a user to maximize the distance between the compressor and the tool. It also helps minimize frictional loss.
  4. Lubricate your Pneumatic Tools Regularly: Using lubricants on movable parts can reduce friction and achieve greater levels of efficiency. It is important to consider the frequency of lubrication as well as the type of lubricant being used in the tools. For tools that are used daily, 4-5 drops at the start of each shift, is the norm. Using the wrong type of lubricant can damage the O-rings and other critical components.
  5. Check the System for Leaks: This can be done simply by allowing the compressor to build top pressure with the air hose and other components connected. Once the compressor has stopped pumping, watch the tank pressure gauge and listen carefully for any hissing noise. If the needle of the pressure gauge drops continuously, it indicates a leak. If on the other hand, it stays put and there is no hissing noise, the system is completely leak-free. Leaks in the system can cause excessive running of the compressor, leading to early wear and tear. A leak can be detected by spraying soap water on the hose and other components and looking for the formation of bubbles.
5 Steps to Achieve Maximum Air Compressor Efficiency

For assistance to decide on the air compressor that suits your needs the best, feel free to contact us on +919819907445. We would be happy to assist you in finding the best match based on your requirements. As one of the leading ELGi air compressor dealers, VEMC provides seamless services to its clients. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.

Different Types of Air Compressors

by vemcoblogs -

Compressed air is a great source of energy in wide-ranging industrial operations and is used for powering tools like impactors, drills, and other equipment. Air compressors, therefore, act as engines to create and supply this powerful driving force. Compressors are prone to falling into disrepair, especially due to impure, humid, or hot air, and therefore require regular maintenance, care, and protection to ensure optimum level performance.

Different types of air compressors are used in the industry, each with unique designs and operation specifics. So, you must understand the difference between all of these air compressors. Buying the right type of compressor from a reputable company ensures a longer lifespan and higher returns on your investment. In this blog, we shall take a look at the most common types of air compressors in use today.

Reciprocating Air Compressor

A Reciprocating Air Compressor, also known as a Piston Compressor uses one or more pistons to compress the air which enters it through a system of valves. The compressed air then flows into the holding tank. This is one of the most widely used types of industrial air compressors and finds application in areas like chemical processing, gas transmission, and hydrocarbon refining.

Screw Air Compressor

Screw Air Compressors make use of two closely meshing helical screws to compress air. Once the air enters into the chamber, the helical screws are turned to push it down into an extremely constricted space, which increases its pressure manifold. These compressors are mostly used in refrigerators and automated manufacturing systems. In the construction sector, these are used to provide compressed air to jackhammers, riveting tools, pneumatic pumps, sandblasting operations, and industrial paint systems.

Centrifugal Air Compressor

A centrifugal compressor makes use of a fast-rotating impeller and radial blades which create centrifugal force to suck the air in. These days, centrifugal compressors have high-speed electric motors to drive the impellers and create powerful centrifugal force. These compressors are used in gas turbines, automobile turbochargers and superchargers, oil refineries, natural gas processing, air-conditioning, and HVAC systems.

Oil-Free Scroll Compressor

Air compressors have a number of moving parts which create friction and wear and tear, leading to early degradation of the compressor. As such, oil lubrication is a must for air compressors. However, frequent oil lubrication can be burdensome and may not be suitable in operations where cleanliness is of utmost importance. Oil-free scroll compressors can come in handy in such situations. These use the rotary movement of scrolls to compress air into a very small space and pass it through the air outlet located at the centre of the scroll.

For assistance to decide on the air compressor that suits your needs the best, feel free to contact us on +919819907445. We would be happy to assist you in finding the best match based on your requirements. As one of the leading ELGi air compressor dealers, VEMC provides seamless services to its clients. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.

4 Tips on Increasing Solar Panel Efficiency

by vemcoblogs -

As the demand for sustainable energy grows, solar power stands out as the most favoured choice for the future. However, as solar systems require significant investment due to the high cost of semiconductors and allied components, it is important that maximum possible energy is generated from each square foot of a photovoltaic panel. Solar Operations and Maintenance (O&M) companies play a huge role in ensuring the highest efficiency of the solar power systems but some simple tips based on a common understanding of solar energy can go a long way in enhancing your output.

Well, the science behind solar energy is very simple — the higher the exposure of solar cells to sunlight, the greater will the output be. It is around this fundamental principle that most of these efficiency-enhancing tips revolve:

  1. Avoid shade: Due to the installation of intricate groupings of solar cells in a panel, even if a small part of the panel is covered by shade, the whole module will have less energy conversion. Shade is therefore a major inhibitor of solar energy and must be minimised as much as possible. This requires careful placement of the solar panels, away from a permanent high-rising object like a chimney or a vent. Tall trees around the facility must be well-trimmed to ensure their shadow doesn’t fall on the panels at any time of the day.
  2. Careful orientation: Solar panels must be oriented in the direction where they receive maximum sunlight throughout the day. This completely depends on the geographical location of the installation. India being a country in the northern hemisphere, the solar panels are always made to face the south to receive maximum sunlight. In the US, both south and west are the favoured directions and have been known to produce the maximum output.
  3. Proper upkeep: Solar panels can get covered in dust, dirt and bird droppings in a very short span of time. As they are mostly installed on rooftops, it might get a little difficult to clean the panels regularly. This could reduce the efficiency of the panels as some or whole of their surface area is screened from the sunlight. Providing convenient access to the panels and cleaning them regularly is therefore important.
  4. Weather: Hotter days ironically generate lesser energy due to increase in current and drop in voltage. While controlling the weather is beyond our ability, we can surely be mindful about buying panels with the lowest temperature coefficient, which refers to the amount by which the output of a panel reduces after temperature rises beyond 25⁰C.

For assistance to decide on the solar panel that suits your needs the best, feel free to contact us on +91 9819907445. 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 73 years of market experience, VEMC provides end-to-end solar services to its clients. VEMC is ISO 9001:2015 certified and is one of the leading solar EPC companies in India.

Challenges in Operations and Maintenance of a Solar Plant

by vemcoblogs -

From keeping plants running in optimum condition, manpower optimization, budget, and spare management for the smooth operation of a plant, to maintaining safety protocols, there are several challenges in solar operations and maintenance (O&M). In this blog, we will take a look at the multi-dimensional nature of these challenges.

The unexpected challenges of solar power | World Economic Forum

Preventive Maintenance

Preventive maintenance is a continuous process that aims at preventing sudden breakdowns and various costs accruing from it. It is carried out systematically, by following Standard Operating Procedures (SOP’s) and Standard Checklists, which help ensure consistency and quality of work. 

Condition Monitoring 

A significant change in the condition of the equipment is often clearly visible and can indicate the increased likelihood of breakdown at some point. It is important to repair or replace the equipment in time, especially if it is crucial to the working of the plant.

Corrective Maintenance

Despite all the efforts, some faults might arise in the system, which may need immediate corrective measures. This could include replacement of the faulty equipment or intervention by technical staff to restore its functioning.

O&M Budget

Cost control is an essential part of any solar O&M strategy and must be viewed in a comprehensive way. It is essential to reconcile the interests of the stakeholders with the objectives of controlling costs associated with system maintenance, quality checks, and testing procedures.

Documentation

A complete record of all activities taking place at a solar plant site must be well-documented and available for reference to all stakeholders, to ensure identification and removal of loopholes and procedural inconsistencies.

Spare Management

A formal inventory management system must be in place to keep a record of the type and quantity of spare parts available. These must be stored in an organised way to ensure ease of access during a breakdown.

Skills Training and Development

Working on-site can be full of challenges for which the personnel must be trained in order to increase their capacity across a range of tasks and reduce on-site accidents. This includes the development of technical skills and knowledge of standardized procedures and checklists.   

Plant Performance

To keep the plant at peak performance levels, it is essential to take a holistic view across human, technical and environmental dimensions of the plant. This includes functions like periodic module cleaning, vegetation control, spares management, manpower management, quality control, and Supervisory Control and Data Acquisition (SCADA) monitoring.

Safety

Safety measures while being on-site are essential for both personnel as well as the equipment. Proper safety procedures must be followed and protective gear must be used to prevent any kind of hazard. For assistance to decide on the solar panel that suits your needs the best, feel free to contact us on +919819907445. We would be happy to assist you in finding the best match based on your requirements. As one of India’s best solar companies, having 73 years of market experience, VEMC provides end-to-end solar services to its clients. VEMC is ISO 9001:2015 certified and is one of the leading solar EPC companies in India.

Maintenance for Air Compressor Systems

by vemcoblogs -

Maintaining air compressor systems is simple but very important! It requires combating heat, moisture, and loss of air pressure, to ensure peak levels of performance and also prevent early degradation of the compressor system. Heat causes motors, bearings, and oil to break down while moisture can affect the internal parts of the compressor by corrosion and microbial growth. Loss of air pressure makes the compressor do more work for the same volume of compressed air. So, in order to ensure the smooth running of operations, avoid interruptions and unexpected downtime, it is crucial to maintain the compressor at regular intervals. In this blog, we take a look at the measures that need to be taken.

Maintain the Coolers and Filters

  • Heat being the number one enemy of compressors, it is extremely important to keep the intercoolers and aftercoolers clean. These cool the air between the stages and after compressing the air respectively. 
  • It must also be ensured that the oil cooler is working properly. This is mainly responsible to prevent the degradation of oil and reduction in its life with rising in temperatures. Regular testing of the compressor oil is an important maintenance practice to predict the breakdown of oil before it becomes problematic.
  • The air inlet must be kept safe from dust, dirt, and contaminants. Regular replacement of air filters is very effective in keeping the air compressor clean on the inside.

Remove Compressed Air Condensate

  • As air is compressed, it ejects excess water that it cannot hold. In the humid spring season, this water could gush into your distribution system while in winters it can freeze inside the system and damage the piping. Clogged traps and stuck open valves must be regularly checked to ensure the removal of condensate from the system.
  • It’s important to check the drain valve regularly to ensure only clean and dry air is coming out. Any presence of moisture indicates retention of the condensate in the compressor and must be treated immediately to prevent corrosion and fungal and bacterial growth inside the system.

Avoid Compressed Air Pressure Loss

  • It is essential that the air pressure is maintained at the level suitable for your operations. Any drop in the pressure means the system is not operating at peak efficiency vis-à-vis the consumption of energy.
  • Change the inline filters and point of use filters as soon as they reach saturation. It is recommended that these elements are changed when the indicator reaches 6-8 PSI. Besides the filters must be inspected twice a year to ensure that they haven’t been compromised.

For assistance to decide on the air compressor that suits your needs the best, feel free to contact us on +919819907445. We would be happy to assist you in finding the best match based on your requirements. As one of the leading ELGi air compressor dealers, VEMC provides seamless services to its clients. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.

O&M Issues in PV Solar Energy

by vemcoblogs -
Solar PV Operations and Maintenance

Solar power systems have a life-span of 20-25 years which makes their Operations and Maintenance (O&M) very important. This is to maximise energy production and minimise maintenance costs over the lifetime of the system. Maintenance is a continuous process which not only reduces the risks and costs associated with sudden breakdowns, but also keeps the system at prime efficiency levels. Fortunately, solar systems have lower maintenance and servicing requirements as compared to other energy generating technologies. In this blog, we’ll take you through some of the common O&M issues of photovoltaic (PV) solar systems and the approach to deal with them.

Natural Degradation

All solar cells degrade naturally, regardless of the environment they are installed in. However, the rate of degradation depends on the material of the PV panels. For instance, monocrystalline silicon panels have the lowest rate of degradation while copper indium gallium diselenide (CIGS) panels have one of the highest. Since the material directly affects the cost of the panels, choosing the type of panels is essentially a planning, budgeting and investment decision.

Lightning Protection

Lightning strikes can damage the solar power system by causing a power surge within the array. It is important to have a grounding system in place to redirect the energy from the lightning, away from the panels and into the ground. While the mounting system of the panels itself plays the role of grounding it, the material of the mounting system must be chosen carefully. This also depends on the type of foundation of the system. Besides having a robust grounding system in place, it is advisable to install surge protection equipment for backup safety.

Failure of Components

Cracking of panels and their visual discolouration can affect the efficiency of the panels. Both of these are irreversible damages. High temperatures can damage the solar panels by producing hotspots on them. Inverter downtime is another common issue with PV solar systems and their scheduled maintenance is a critical part of a solar O&M strategy. For static solar panels, ideal panel orientation is necessary to get the highest output. In case of tracking systems, it is important to regularly check the moving parts like gearboxes, motors, and actuators.

Weather Conditions

The environment impacts the durability of PV systems and adequate measures must be taken to offset its effect. For instance, regular cleaning and wiping may be required in windy or arid areas while sloping solar panels can avoid an accumulation of snow in cold regions. In the case of hailstorms, protective covers could be useful to prevent damage to the panels.

That said, it’s absolutely necessary to have an O&M plan in place for your solar plant to alleviate long-term costs. At VEMCO Solar, our valued clients are provided with customized plans to fit all their needs. VEMCO Solar (Check out our story) offers end-to-end solutions and has empanelled channel partners with the Ministry of New and Renewable Energy, Government of India, for solar PV rooftop, small power plant system integrators, and installation. Guided by the knowledge gained by VEMC over 72 years, our aim is to be by your side at every step of the way. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Please feel free to contact us on +91 98199 07445.

How KirloSmart Has Proved to be a Vital Technology During the Covid-19 Lockdown

by vemcoblogs -

Imagine having access to all the parameters of your pumps on your smartphone or iPad, without having to leave the comfort of your living room. Kirloskar has made this possible by designing “KirloSmart”, the first-of-its-kind software solution for remotely monitoring the parameters of a pump. This is a unique application of the cutting-edge Internet-of-Things (IoT) technology to augment your conventional pumping system and has given birth to a new generation of IoT pumps. Besides ensuring comfort and ease of monitoring, KirloSmart has a number of operational benefits that makes it an outstanding software solution for your pumping system.

With continuous real-time data streaming from the pumps, it is easy to prevent breakdown, especially in those systems where the pumps installed are very crucial and any breakdown could hamper the operations of the facility or increase the electricity bills.

Once KirloSmart is installed on your device, your new ‘smart pumps’ won’t need the traditional SCADA (Supervisory Control and Data Acquisition) system to monitor them. Also, there will be no need to employ any additional manpower to check and maintain the pumps on a regular basis. This can significantly reduce the running expenses of your facility and account for enhanced operational efficiency.

However, the most path-breaking benefit of KirloSmart is predictive analysis for quick diagnostics and resolution. Sudden breakdown of the pumps can be disrupted as well as costly, but anticipating its incidence can enable the user to keep spares ready to avoid prolonged downtime. Unplanned breakdowns may bring critical production processes to a halt, but this can be prevented if accurate real-time data is available. KirloSmart also provides daily updates related to the energy and water consumption of the pumps, ensuring peak efficiency at all times.

The software is capable of monitoring the following pump parameters remotely:

  • Flow
  • Pressure
  • Power
  • Voltage
  • Current
  • Frequency
  • Power Factor
  • Pump and Motor Bearing Vibrations
  • Pump and Motor Bearing Temperature
  • Motor winding temperature
  • Pump run hours 

KirloSmart proved to be a path-breaking technology especially during the Covid-19 lockdown. Its users didn’t need to go out to monitor the condition of their pump and were able to remotely and wirelessly monitor the pump from their smart devices. They would receive preventive and predictive maintenance alerts, spare notifications and analysis based on the historical trend. This technology has revolutionized monitoring and diagnostics, and has become the single most transformative force behind the modern pumps of today!

For further information on industrial pumps, motors and other equipment, 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 project management services to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. For inquiries, contact us at marketing@vemc.co.in

Get Monsoon Ready with Dewatering Pumps

by vemcoblogs -

How to drive through flooded roads

Rain during monsoon can be a cause of concern for your facility as it brings along problems related to waterlogging, often disrupting production and causing unnecessary delays. Bouts of heavy rainfall can flood the whole facility in a matter of hours, requiring an urgent and powerful flush-out mechanism. Dewatering pumps are a one-time investment that can tackle this problem with absolute ease and efficiency.

The emergency-oriented nature of this product requires that you give priority to quality over cost. Relatively cheap dewatering pumps may be lighter on your pocket in the short term but can have a number of hefty and hidden costs. Cheap and low-quality pumps may break down or malfunction frequently, adding to repair and maintenance bills. Also, these may not be effective enough to flush out huge volumes of water in case of sudden rains or storms, bringing your facility to a standstill and causing excessive loss of business. 

VEMC installs and recommends only the most reliable and high-performing Dewatering Pumps that fall under these categories:

Submersible Pump

Kirloskar make Submersible pumps

Submersible Pumps are not just powerful but are designed with robust anti-corrosive material for increased durability. These can even flush out raw sewage with the maximum permissible solid size of up to 300 mm. Features that enhance their performance and control maintenance costs are:

  • Dry type submersible motor cooled by the liquid being handled 
  • Maintenance free grease-lubricated bearings sealed for life
  • Air-tested motor for leak-free operation
  • Liquid level controllers to avoid dry running

Self-Priming Water Pump

Kirloskar Make Self Priming Pumps

A self-priming water pump is designed to automatically trap water inside, before it starts pumping. Water inside the pump prevents the formation of air pockets which may impair proper operation. The following features make our Self-Priming Pumps of great utility:

  • No need of foot valve and priming the pump set every single time 
  • Non-clog impeller that handles solids up to 60 mm in size
  • Minimum vibrations prevent damage 
  • Consistent performance by maintaining concentricity
  • Easy maintenance and good interchangeability of components to enable servicing even at remote locations by semi-skilled technicians

Check out the Gen-next version of Self Priming here

Cutter Pump

Kirloskar Make Cutter Pumps

These are specially designed to grind soft solids into small pieces to be separately drawn away through pipes. These find use in discharging municipal waste, industrial effluents and domestic sewage. Here are some features that make our Cutter Pumps stand out in the market:

  • Easily serviceable and suitable for both temporary and permanent installation
  • Can either be installed on auto coupling system or can stand freely at the bottom of a pit
  • Water-tight cable plug connection to ensure no entry of liquid into the motor
  • Stainless steel clamp for easy and quick dismantling of pump casing without the use of any special tool 

For further information on industrial pumps, motors, and other equipment, feel free to contact us on +919819907445. We would be happy to assist you in finding the best match based on your requirements. Established in 1948, VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. VEMC has also been an authorised dealer of Kirloskar Pumps since 1948. Send your inquiries on marketing@vemc.co.in