Month: March 2022

Understanding The Cost of Compressed Air

by vemcoblogs -

Compressed air is an indispensable part of most industries. Without it, entire sectors of production would be defunct! It is so essential that it is referred to as the ‘fourth utility,’ after electricity, water, and gas. However, there is a significant cost attached to it. In fact, about 10% of the electricity consumed industrially goes to generating and using compressed air.

Keeping industrial units supplied with compressed air costs a substantial amount of money. So, it would be prudent for businesses to focus on the consumption of energy, which makes up the majority of the cost of generating compressed air. Energy consumption costs are much higher than the initial cost of air compressors or their maintenance. A whopping 80% of the total cost of the compressed air system will be from the electricity it uses up. Because this is such a huge percentage, determining the cost of compressed air becomes important in order to minimize waste heat and electricity bills.

To identify the ways that you can save such costs, take a look at your business’s requirements of compressed air as well as the components of your compressed air system, along with all the associated costs. When you do this, make sure to account not just for your business’s current system, but also for the one you envision to be in place in the future. Plan for the longer-term demands rather than just the current ones.

Here’s an overview of the components in a compressed air system that you need to look at:

Air compressors

Aim to have an energy-efficient air compressor rather than one that just carries a lower price tag. As mentioned earlier, the initial cost is just a small fraction of the total cost.

Dryers and filters

Compressed air has contaminants that, depending on the application at hand, need to be filtered. There is an additional cost and equipment to this process, so be mindful of that.

Drains

Drains remove the collected condensate of the compressed air system as required.

Piping

A good piping system is crucial for smooth movement of the air and eliminates air restrictions, leakages, and pressure drops.

Ventilation

Ventilation is key to cutting down heat circulation to subsequently reduce energy consumption.

Air leakage

It is of paramount importance to detect and fix any air leaks because these can have a heavy cost otherwise. Monitor your air compressor constantly to prevent this from occurring.

Central controller

In systems that consist of more than one air compressor, a central controller may play a big part. It can decrease the average pressure band (a pressure reduction by one bar reduces energy usage by 7%), regulate the compressor speed, and control compressor capacity.

A streamlined air compressor system strategy can help you reduce your operational costs significantly, so plan ahead and reap the benefits!

VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services. We are a well-established industry leader and authorized Elgi air compressor dealers. Contact us on +919819907445 and we would be happy to help you determine the right air compressor for your needs.

Solar Success Story: Installing a Rooftop Solar PV System for Abhijeet Dies & Tools

by vemcoblogs -

VEMC recently completed the installation of a 182.49kWp solar rooftop system at Abhijeet Dies & Tools Pvt Ltd. in Naigaon East, Bapane, Maharashtra. We designed this solar rooftop photovoltaic (SRTPV) system using the space available on the terrace at the client’s site with a module by Jinko and inverters by Polycab.

Execution

The application of the installation was in machinery and light loads. The project commenced in November 2021 and was completed in January 2022, well within the targeted time, but for a slight delay in net meter installation due to a hold up by Maharashtra State Electricity Distribution Company Limited.

Superior safety protocols

We executed the installation smoothly and took extra precautions to maintain the highest levels of operational safety. We ensured that every team member working on the site used the required personal protective equipment (PPE) including safety helmet, safety harness, and safety belt. We were also careful not to use mobile phones and other electric devices that could distract us during the process. Additionally, we used the crane or forklift to unload the modules and checked that a qualified person operated it. We kept the speed limit below 10km per hour.

Training and instructions

We designated an adequately sized team to lift the modules manually up the stairs so that they were easy to handle. We also gave our team rigorous training and proper instruction during the installation which they followed diligently. This way, we were able to avoid damage to any of the modules. The entire process was supervised by a team of qualified engineers.

Routing the AC cable

When the AC cable was routed, the tray was secured from any wear and tear. Once the tray was clear of any damage, it was carefully positioned to keep it moisture free.

Earthing

During the process of earthing, the speed of the boring machine was always maintained at below 10 km per hour. Our team strictly adhered to materials like cotton, PVC, and leather gloves while fixing electrodes, handling the backfilling compound, and connecting the electrical panel. Welding goggles, face shields, and aprons was also used during the welding of the system.

How we overcame challenges

Effective time management, cost management, quality control, team management, procurement management and communication skills were the key ingredients in the successful execution and completion of the project.

Learnings

This project gave us deep insights into the smooth operation of a DG-PV system as well as a DG sync configuration.

Key benefits post installation

We were able to reduce the client’s monthly electricity bill by INR 1.5lakh to INR 2 lakh after the installation of the solar rooftop photovoltaic (SRTPV) system.

VEMC is a well-established solar power plant company in India. With over 72 years of industry experience, VEMCO Solar was able to complete the project for Abhijeet Dies & Tools Pvt. Ltd. successfully. 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 requirements in this space, please feel free to contact us at +91 98199 07445. We would be happy to help you out.

A Guide To Select The Best Water Pump For Industrial Use In India

by vemcoblogs -

We need water for a variety of essential purposes — whether it is to cook, wash, clean, or perform industrial functions. This water comes to us from the source through a pump. When you are buying a water pump, there are a number of factors to consider before identifying the right kind for your application. Before we look at what these different factors are, watch this video to get an idea about how to select a water pump:

https://www.youtube.com/watch?v=9i_c-LBEXkw&ab_channel=VijayEngineeringandMachineryCompany

Flow rate

Given in cubic metres per hour (m3/h) or litres per minute (l/min), the flow rate of the pump measures its efficiency, that is, how much water it can pump out within a certain period of time. For industrial applications, this flow rate should ideally be on the higher side, of at least 2000 litres per minute. Another reason that the flow rate is so important is that it determines the daily energy consumption as well as the durability of the pump. The lower the flow rate, the higher the energy consumed due to more prolonged usage.

Discharge head

The total height of the discharge pipe which is known as the discharge head, as well as the height from where the water is pumped, are further aspects to consider when choosing the water pump. If you need to pump the water from a significant height, make sure that you choose a higher discharge head. Additionally, the suction head capacity will determine the depth of the water being pumped.

Inlet

The size of the inlet facilitates the correct flow of the water. Too small an inlet will create friction and a subsequent loss on the pump system. So, be careful that you choose a good-sized inlet for optimal water flow and pump performance.

Water quality

It is necessary to keep in mind that different water pumps and motors, such as trash pumps and dewatering pumps, are built to work with different kinds of water. Trash pumps transfer dirty water quickly while the latter kind moves clean water between locations. When you choose a water pump for your needs, it must fit the specific purpose you require it for and should not be used inappropriately.

Pump quality

Just as the quality of the water that goes into the pump must be suitable, you must also consider the quality of the pump itself. For the maximum efficiency and compatibility, select a pump from a reputed brand and do not compromise on its quality and design. A good quality pump will last much longer, cost much less to maintain, and will consume less energy in the long run. Kirloskar is a trusted name in the industry and would be a safe bet.

For more information on industrial pumps, motors, and other equipment, contact VEMC at +91-9819907445. As one of the authorized Kirloskar pump dealers in western India, we would be glad to assist you in finding the best match for you based on your requirements. We are ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

Here’s How You Can Understand Centrifugal Pump And Motor Torque-Speed Curves

by vemcoblogs -

A centrifugal pump is powered by a motor that has to produce adequate torque to start off the pump and take it up to the best speed. Without enough torque, the motor might not be able to start the pump at all or only have it function at a lower speed.

To determine the motor that is most appropriate for a pump, we use what is called the pump’s torque-speed curve. We can make this by vertically mapping the percentage of full load torque (FLT) against the percentage of horizontally mapped full load speed (FLS).

The torque-speed curve is common in all centrifugal pumps because though the pump torque changes with its squared speed, when the full load speed (FLS) is at zero percent or at rest, the full load torque (FLT) will never simultaneously be at zero percent. The motor must overcome static friction and inertia in order to start a rotating pump. This brings us to the question of how much full load torque is needed to do this. The answer — about 20% of full load torque. As the speed of the pump increases, the torque that is needed slowly decreases. (At 15% full load speed, about 5 to 10% full load torque is needed.)

Horsepower (HP) is a combination of speed denoted by RPM, and torque. The horsepower of a motor is a basic measure of its abilities. The torque of a motor is calculated with the following formula:

T = (5,250 x HP) / N

(T = Torque, and N = RPM)

When you need to select a new motor for your pump, there are three important values you need to look at. These are:

  • Torque at zero flow
  • Torque at rated flow
  • Torque at maximum flow

Additionally, you will need to consider the inertia value of the pump at the motor shaft. The higher this is, the more time the motor will take to start off the pump and get it to the full load speed. This is important because the longer this is, the more heat is generated. The size of the motor must be suited to handle the inertia of the pump. Otherwise, the motor’s windings may get damaged.

In the case of the motor driving the pump directly, the inertia values of the pump-motor combination and the pump itself will remain constant no matter the speed of the pump. However, if both a gearbox and motor drive the pump, the inertia values will be affected greatly.

To choose the right kind of motor for your centrifugal pump, the above factors are important to keep in mind.

VEMC is an authorized Kirloskar dealer that supplies a range of industrial water pumps in Mumbai for various applications. We offer a diverse range of pumping solutions, including water pumps and process pumps. For more information on our products and help with selecting the most suitable ones for you, please contact us on +91 98199 07445. We would be happy to provide customized support. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

How Can You Mitigate a Mechanical Shaft Seal Leakage?

by vemcoblogs -
  • How Can You Mitigate a Mechanical Shaft Seal Leakage?

Why does leakage occur in a centrifugal pump? To understand this, we must first understand how a centrifugal pump basically works. As fluid goes through its impeller eye and up the impeller vanes, it starts with low pressure and velocity. As it flows into the volute and gets ready to exit, both the pressure and velocity increase. As the fluid flows out through the discharge, the pressure is high but the velocity gets reduced. The flow then goes out of the pump, which makes the pump exert pressure and raise the energy of the fluid.

When a component of the pump such as static joints and hydraulic malfunction, the whole system might break down. However, a majority of pump failures happen due to the mechanical seal of the pump malfunctioning.

A mechanical seal controls the leakage between a liquid and a rotating shaft. To do this, essentially all seals have to leak in order to maintain a film of fluid over the whole face of the mechanical seal. The leakage from the atmospheric side is quite less. But the leakage between the mechanical seal shafts and sleeves can cause significant issues. Often, the reason these happen is because of the fretting of the O-ring seal on the shaft. You will notice substances dripping from behind the seal close to the drive collar. Polishing the fretted part can provide a temporary fix, but it will not give you a solution. Here are some options you can choose in the short and long term:

Short term solutions

Replacing the shaft could be a practical option given that the maintenance cost is low and you would not have to overhaul the entire pump system.

When repairing or replacing the shaft is proving to be difficult, you can opt for a modified seal but you may have to plan in advance.

You can try relocating the O-ring of the seal sleeve with the help of a local technician. When you get to the bottom of the issue, you can check where the damage on the shaft is and shift the O-ring accordingly. If you still require a new sleeve, the cost will be only a little bit higher.

Long-term solutions

Upgrade the shaft to a higher quality material.

Consult a pump technician and coat the shaft below the seal sleeve with a substance like tungsten carbide. How much of the shaft you may need to coat will depend on the damage. Avoid the area around the drive collar set screws. Make sure to enlist professional support for this.

VEMC, one of the authorized Kirloskar pump dealers in India, supplies industrial water pumps in Mumbai for different industrial applications. We offer a diverse range of pumping solutions including water pumps. For more information on our products and help selecting the right ones for you, please reach out to us on +91 98199 07445. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

Solar Panels And EV Stations: How Solar-Powered EV Charging Stations Are Becoming the Prevalent Alternative

by vemcoblogs -
Solar Panels And EV Stations

What is an EV charging station?

Electric vehicles (EVs) powered by renewable energy are steadily emerging as the sustainable alternative to fuel-powered vehicles. With more and more electric vehicles on the road, there also comes the need to be able to charge them.

From where do EV stations source their energy?

EVs are charged in a charging station, which is also referred to as an electric vehicle supply equipment (EVSE) or an EV charger. An EVSE is a device that provides the electrical power to charge all kinds of electric vehicles. Now, although the source of power for EVs may be clean, the same might not be true for that of charging stations! In fact, natural gas is the most common source of power for charging stations. It is very affordable and widely available. However, all electricity is not necessarily generated by only fossil fuels. Charging stations are connected to the ‘grid’ or power supply, so although the EV produces zero emissions, the energy it draws from charging stations usually is not. But, even charging stations have can take the route of using clean, renewable energy.

How are EV stations and solar panels connected?

One of the most sustainable solutions to powering EV charging stations is through solar energy. Solar-powered stations for electric vehicles are one of the best ways to cut down on depending on fossil fuels.

To switch to solar for your charging station, you first need to determine the number of solar panels you would require to set up. For this, first consider how much you drive on average. For example, if you drive 300 km in one month, that would be about 10 km per day. Now, take a look at the energy requirement in kilowatt per hour (kWh) of your electric vehicle. Then, estimate how much direct sunlight you receive in your area. This will give you an idea of how much solar energy you would need, and how many solar panels you would need to set up to generate enough of it.

What is the future of solar-powered EV charging stations?

With the effects of global warming becoming an alarming concern, solar-powered EVs and charging stations are fast being hailed as the better alternative. A recent report found solar rooftop photovoltaic energy from solar panels to be an economic and feasible solution for EV charging, while also offering a cleaner source of energy.

Solar rooftop photovoltaic systems provide a plethora of benefits in EV charging. Thanks to their modular design, they can be installed easily. They are also a cost-efficient solution compared to charging from the grid. They minimize carbon emissions and also soften the blow from surging demands of EV charging power on the grid. A net metering solution can solve the issue of a disparity between solar energy generation and consumption.

VEMCO Solar, a solar energy company in Mumbai, provides end-to-end solutions. With over 72 years of industry expertise, we offer specialized support in this space. 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, and we will be happy to assist you with your solar power requirements.

Here’s What You Need to Know About ISO Classes for Compressed Air Quality

by vemcoblogs -
What You Need to Know About ISO Classes for Compressed Air Quality

We’ve heard the term “ISO standards” quite frequently. But what exactly are they, and why are they so important? Let’s take a look at the concept. The International Standards Organisation (ISO) is a non-governmental body made up of a network of institutes from 159 different countries. ISO is the world’s largest developer and publisher of international standards and is accepted universally.

Compressed air is an indispensable utility that is used widely across different industries. But, compressed air is not all of uniform quality. Some uses, such as pharmaceutical production and food handling, call for impeccable quality and cleanliness of the air. In other cases, the primary objective may be to ensure the lifetime and reliability of industrial tools that are powered by air. The ISO standards play a key role in determining the level of air purity required for your particular application. Meeting ISO standards is also important in maintaining and protecting the quality of your production. In some cases, not complying with them can lead to heavy penalties or even your production facility being shut down!

The ISO 8573 air quality standards and ISO 12500 compressed air filter standards help lay a sound foundation for selecting the right air treatment products. ISO8573 is the compressed air quality standard and comprises nine separate parts — part 1 for quality requirements of the compressed air, and parts 2 to 9 for the methods of testing for a range of contaminants.

Compressed air contains contaminants like moisture and pollutants, and must be filtered according to the application’s requirements. Usually, the purer the air must be, the more costly it is to produce. This is why it is crucial to choose the right levels of air purity in order to reduce costs and benefit the environment.

The ISO 8573-1:2010 is a useful tool that makes the task of choosing the right air purity for your application that much easier. It ranks the acceptable levels of different types of contaminants as classes.

The ISO 8573-1:2010 standard is divided into three groups of contaminants—solid particles, water (including liquid and vapor), and oil. Each of these categories is further classified into ten different purity classes — eight for particulates, ten for water, and five for oil. The lower the assigned number to a category, the higher the air purity requirement for it. For example, class 5 would require far less air purity than class 1.

Now that you know how to match the ISO class to the compressed air quality required, how will you select a filter? The answer is simple — just find the particular ISO class on the filter. Once you identify the ISO class for your particular task, planning the equipment you would need becomes much easier.

VEMC provides a variety of Elgi air compressors. For more help with understanding ISO classes for compressed air quality, contact us on +919819907445 and we would be happy to assist you. VEMC is ISO 9001:2015 certified and is a pioneer in the field of electromechanical engineering products, allied equipment, and services.