Month: November 2022

Pump Energy Audit Leads to Substantial Savings

by vemcoblogs -

Pumps are an essential resource for several verticals such as the industrial sector, the hospitality sector, the agriculture sector, and the medical sector. As a result, they are extensively used in operations across industries. This also means that they consume a lot of energy to run efficiently. For example, in agriculture, groundwater pumping consumes about 16×109 kWh of electricity and about 2,000 million litres of diesel oil in a year. 

Pump energy audits reveal that around 30-50% of the total energy consumed from pumps can be saved. This means that if you replace your old pumps with new, efficient pumps, you can not only save energy but also significant energy costs. With rising energy prices, getting an energy audit done by professionals is a prerequisite. 

What is a pump energy audit? 

A pump audit is an energy optimisation audit of your pump system. It helps analyse the efficiency of your pump system and identifies energy-saving options through switching to a new pump or pump line. Additionally, it also illustrates the monetary benefits of the switch for your company. 

There are several reasons why your pumps can have lower efficiency:

  • Undersized pipes (less initial cost but high frictional head loss and operational cost)
  • High delivery point (excessive height increases energy consumption)
  • Poor fittings (leads to leakage and losses)
  • Inefficient pumps (due to improper selection and mismatched prime movers)

Benefits of a pump energy audit

Investing in an energy audit can be beneficial for your company as well as the environment. Here are the advantages of energy optimisation for your organisation: 

  • Reduced energy bills (up to 40%)
  • Lower operating costs
  • Low pump failure rates
  • Shorter payback periods
  • Reduced need for fuel imports
  • Conservation of insufficient resources
  • Building a sustainable environment

VEMC’s check parameters

With VEMC’s energy audit, you can unlock hidden savings from your pump installation and bring down pump operational costs. The three parameters of energy optimisation that VEMC aims to help your organisation achieve are energy consumption, service maintenance, and purchase price.

Steps to achieve energy efficiency by VEMC

To unlock the hidden savings, VEMC does an energy check that comprises the following aspects:

  • On-site inspection – A 3-4 hour survey of pump installations with a focus on key parameters such as age, head, and power consumption. 
  • Energy check report – The findings from the inspection are documented in an energy check report. The report offers details on pump installation, recommendations, savings, investment, and pay-back period.
  • Savings – In this step, the report is presented and recommendations are discussed, along with a plan of action. This happens in a 1-2 hour meeting. 

How to save pump energy?

The various ways you can achieve energy savings for your pumps are:

  • Choose a pump with the right dimensions and avoid oversizing
  • Trim the impellers to reduce pressure and flow
  • Investing in variable frequency drives to control motor movements as per situations
  • Use multiple pump systems
  • Optimise the system pipework to limit frictional pressure drop
  • Carry out routine maintenance for your pump systems

Why choose VEMC?

VEMC’s energy audit helps you understand whether your pump system is working efficiently or not and offers solutions to help reduce your carbon emissions and operating costs. This helps build a “No Cost and Low Cost” culture. 

For more information on conducting an energy audit for your industrial pumps, motors, and other equipment, feel free to contact us at +91 98199 07445. We would be glad to assist you in finding the best match for you based on your requirements. VEMC is an authorized dealer of Kirloskar dewatering pumps and provides end-to-end project management services to its clients. We are ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

What is a VFD Control Panel?

by vemcoblogs -

Variable Frequency Drive or VFD are control panels that help control the speed of electric motors and feed pumps used in various industrial facilities. Each motor has a different frequency and voltage and hence, a separate VFD control panel is required to monitor and control them. 

With VFD panels, you can bring multiple motors with variable frequencies and voltages under one roof. This will also protect your motors from moisture, corrosion, dust, and other damaging elements. 

VFDs are a crucial part of any manufacturing plant. Without them, the plants will not be able to maintain their output consistently. It can also cause failures that can severely hamper the production capacity of the plant. 

Like other control panels, VFDs comprise a range of equipment such as:

  • Harmonic filters
  • Protective equipment such as relays, circuit breakers, and stabilizers
  • A bypass control to keep the VFD operational in all conditions
  • Programmable Logic Controllers (PLC) for advanced control
  • Communication equipment such as switches and modems
  • Temperature control equipment such as air conditioner or anti-condensation heater
  • Motor starters

Benefits of a Variable Frequency Drive (VFD)

Does your industrial facility need VFD? Absolutely! Here are the top 4 reasons why you should get a VFD for your manufacturing unit: 

  • Power switching and protection – VFD control panels act as an intermediary between the power source and your equipment. In case there is a short circuit or a power overload, it will cause the circuit breaker of the VFD to trip. This way, your drive or any equipment connected to the line will not get affected. 
  • Speed backup – The VFD panel doors usually have a frequency control potentiometer. This helps send command signals to the motor as per the operator’s settings. In case the VFD fails, a bypass switch helps keep the motors functioning.
  • Equipment protection – Any manufacturing plant workplace is filled with moisture, dust, and other damaging particles. It can be cumbersome to protect your equipment from these. Long-term exposure to these materials can damage the tools permanently. One of the major risks is chemical accumulation on the open connections that can negatively impact performance. Moreover, dirt accumulation can reduce the lifespan of the equipment too. 
  • Visual control – VFD panels can provide crucial real-time data on the drive’s energy consumption, frequency, and other diagnostic data that operators require. Operators can also use the embedded controls to shift frequencies or take precautionary measures as per the monitored values. 

NEMA Ratings

VFD control panels have different ratings from the National Electrical Manufacturers Association (NEMA). There are 13 ratings, some of which are: 

  • Type 1: General purpose, for indoor use, protection against solid foreign objects
  • Type 2: Similar to Type 1 but with extra drip shields
  • Type 3: Protecting the equipment from external weather conditions such as rain
  • Type 3R: For outdoor use
  • Type 4: Water-tight, shielding equipment from at least 65 GMP of water

You can choose a specific protection by VFD panels based on the NEMA guidelines for the best usability and equipment protection. 

How can VFDs reduce energy consumption?

VFDs can reduce energy consumption significantly and help save production costs. Traditionally, motors would need valves and dampers to control pumps and fans. This would consume huge amounts of energy. VFDs can do the same without consuming so much energy. Moreover, the flexibility to adjust fan and pump speeds offers more control to operators to save energy. 

Why VEMC VFD panels? VEMC has all the resources you need to get the right VFD control panel for your system. Our excellent team of experts will offer end-to-end services right from the design selection to delivery, installation, and maintenance support. We are a 72-year young organization with ISO 9001:2015 certification and are CRISIL MSE-1 rated. We are pioneers in the field of electromechanical engineering products, allied equipment, and services. We will be happy to help you choose the right VEMC control panels for your manufacturing plant. Reach out to us at +919819907445.

Overview of Multistage Centrifugal Pumps: Here’s All You Need to Know

by vemcoblogs -

Multistage centrifugal pumps have been growing in popularity in recent years. Many engineers choose them because of their flexible flow range and excellent energy efficiency.

But are they a right fit for you? Let’s find out.

What are multistage centrifugal pumps?

A multistage pump is a category of pump that contains 2 or more impellers that can be of the same or different types. The impellers can be mounted on the same or different shafts. In case the outlets require high pressure, the impellers can be connected in a series. For high flow output, they can be connected parallelly.

What is the difference between a single stage centrifugal pump and a multistage centrifugal pump? 

The primary difference between single and multistage centrifugal pumps are the number of impellers or stages present. As the name implies, single stage impellers have only one impeller whereas multistage pumps have two.

The impeller of a centrifugal pump helps pressurise and transfer the liquid. Since multistage pumps have multiple impellers, they have better pressure ranges and flow rates than single stage pumps.

Where are multistage centrifugal pumps used? 

Multistage centrifugal pumps have a wide range of applications. They can be used for delivering water to high-rise buildings, reverse osmosis (RO), boiler feeder water, high pressure cleaning, water works, fuel delivery, oil and gas production, mining and other industries where high pressure and temperature are necessary factors.

What are the different types of multistage centrifugal pumps?

There are several kinds of multistage pumps: 

  • Horizontal Multistage Centrifugal Pump
  • Vertical Multistage Centrifugal Pump
  • Submersible Pump
  • Horizontal Split Case Pump
  • Vertical Turbine Pump

What are horizontal multistage centrifugal pumps?

Horizontal multistage centrifugal pumps are those that have two or more impellers and where the liquid travels horizontally. In this case, each stage acts like a separate pump. These are ideal for services that require moderate to high Total Dynamic Head (TDH). A single horizontal shaft can house up to eight stages. 

What are vertical multistage centrifugal pumps?

Vertical pumps are not that extensively used as horizontal pumps and have limited applications. As the name implies, their orientation is vertical where the impellers are placed on top of each other. The clearances in vertical pumps are also smaller than horizontal ones which makes them suitable for clean water applications. Moreover, if there’s a floor space crunch, these pumps can fit in well too.

For more information on industrial pumps, motors, and other equipment, feel free to contact us at +91 98199 07445. We would be glad to assist you in finding the best match based on your requirements. VEMC is an authorized dealer of Kirloskar multistage centrifugal pumps and provides end-to-end project management services to its clients. We are ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

7 Effective Ways to Improve your Air Piping Design

by vemcoblogs -
Air Piping
Air Piping

Have you discovered recently that you are not getting the most from your compressed air systems? Air compression systems need a lot of investment. So, if they are not performing at their optimum, there’s a need to investigate further.

One of the usual suspects in the case of inefficient compressor systems is the air piping design within the system. Often, improving it can go a long way in boosting the efficiency of your air compressors. This also ensures that the tools within your compressor are getting adequate air to function optimally.

Having problems with air supply? These are some effective ways you can improve the air piping design and make your air compressor systems more efficient:

1. Eliminate quick couplings – Quick couplings, despite their benefits, can increase the chances of leakage. You should avoid using them, except when you require a fast and easy disconnect of the hand tool or paint gun. In all other scenarios, connecting your machine to a hard pipe or a flexible connection with a hose pipe should be more than enough. 

2. Consider the pipe length – The length of airflow directly impacts the pressure in your machines. The longer the airflows, the more significant the pressure drop. Hence, pipe length should be an important factor for consideration when optimizing your piping design. Understanding your compressed air needs and aligning pipe length accordingly can be beneficial in making your system more efficient. 

3. Evaluate the pipe diameter – Pipe diameter too plays an important role in determining whether your systems are receiving adequate air or not. Consider this — will you draw enough air into your lungs from a straw as compared to without it? In the same way, the pipe diameter should be big enough to ensure adequate air flow into the systems. Trying to pass high-volume compressed air through a small diameter pipe can be detrimental. The high velocity can cause more friction and lead to a significant loss in air pressure. This would be reason enough to choose a pipe with an appropriate diameter after careful consideration. 

4. Reduce piping elbows – Nothing affects air pressure as much as piping elbows. Those sharp changes in direction severely impact air pressure. So, fewer the elbows, the better. If you must use piping elbows, the long radius elbows are a better choice. This is because they cause lesser friction than the short radius ones and hence, lead to lesser pressure drops. 

5. Check the size of components – Ensure that you don’t overlook the size of your components when optimizing your piping design. When the filters, valves, regulators, and quick connections, are appropriately sized, they improve the airflow in your systems significantly. When they are undersized, airflow gets restricted and consecutively, pressure is reduced. It’s also important to avoid quick connect couplings as much as possible since they lead to considerable pressure drops. 

6. Eliminate leakage – Testing regularly for leakage in your compressed air systems is a must to ensure their optimal functioning. The most common material used for piping is PVC and PVC pipes become brittle with usage. In comparison, aluminium and copper pipes leak less. Aluminium also has the added advantage of not rusting or scaling. This helps keep your air compressor system clean. The common phrase “a stitch in time saves nine” applies here — repairing the smallest of leaks can save you a fortune in annual repair costs. 

7. Consult air compressor experts – It may not be possible for you to know all the nitty-gritties of your piping designs. Thankfully, there are air compressor experts, like VEMC, who can help prevent unnecessary breakdowns or repair expenditures. 

With these tips, you can successfully get the most out of your air compressor systems. An efficient compressor system can help save money and time, while offering smoother airflow. 

For your reference, here’s a chart to guide you in choosing the right pipe length and diameter for your compressed air systems: 

Source

VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. With more than 72 years of industry experience, we provide best-in-class solutions and customised support in this field. We are the authorised dealers of ELGi air compressors. Contact us at +919819907445 and we would be happy to help you determine the right air compressor for your needs.

5 Reasons Why It Is Worth Investing In Solar For Companies

by vemcoblogs -

Solar power is becoming increasingly popular among companies in India. With the country becoming a proponent of solar energy globally, India’s total installed solar energy capacity has increased 19.3 times in the last 8 years. Many organisations are considering investing in solar energy and with good reason. For them, it’s a win-win situation. Energy costs make up for a large proportion of expenses for businesses, both big and small, and hence, cost-efficiency is always a critical goal. There is also the need to be socially responsible and include sustainability in brand ethos. Solar energy helps them meet most of these goals.

So, if you are considering making the switch to solar energy, it could be absolutely worth it.

5 reasons why solar energy is worth investing in

1. Reduced overhead expenses – Going the solar route can help companies save huge on energy costs. Since most of the things in a workspace, such as computers and electrical equipment, run on power, solar energy can help reduce dependency on erratic energy sources. The fluctuating prices of non-renewable fuels too will not affect you. You can let solar energy take over the majority of your existing energy sources. This way, you have more control over the quantity and cost of energy. 

2. Dependable power supply – Power outages are not uncommon in India and unreliable power supply can create interruptions in business. With solar power, you can expect a reliable and stable power supply. India’s total land area gets about 5,000 trillion kWh with most parts receiving around 4-7 kWh per sq. m. per day. Hence, with solar panels in place, you can generate sufficient solar energy to run your operations. 

3. Ease of maintenance – Installing solar panels in your workspaces can be an efficient and one-time investment. They are made from durable materials and can be long lasting. You can rely on expert solar panel EPC companies, such as VEMC, to help assess your energy requirements, check the available installation area, confirm the budget, and install the solar panels accordingly. 

4. Long-term savings – Solar energy helps save costs in the long run. You will need to make a one-time investment for the installation. Post that, you can start enjoying the returns on your investment. The maintenance costs are not exorbitant either. 

5. Sustainable and ideal for CSR – Investing in solar energy can help save the environment. You will be able to invest in a clean energy source, cause less pollution, and reduce your dependency on fossil fuels. Solar power also makes for a good investment to meet your corporate social responsibility (CSR) goals. This can help you stand out to your customers and investors as a green company with low carbon footprint. 

VEMC is a well-established solar EPC company in Mumbai and a pioneer in the field of electromechanical engineering products, allied equipment, and services. VEMCO Solar is a market leader in solar solutions — be it solar panel installation, procurement, commissioning, net metering, or electrical connections. If you are looking for solar panel installation in Mumbai or solar O&M, please reach out to us at +91 98199 07445, and we will be happy to provide you with customized support and services.

4 Interesting Ways Compressed Air Is Used

by vemcoblogs -

Beyond the traditional applications, air compressors are used for, there are several unique ways in which compressor systems can be used. The amazing feats your air compressors are capable of are sure to leave you surprised! These are unconventional arenas, further away from the traditional applications such as in the manufacturing, pharmaceutical, and food and beverage industries. 

It can, in fact, help power some of the most ambitious projects of human beings. Looking beyond conventional uses can help you realise the true power of your air compressors. 

Let’s look at 4 such unconventional applications: 

1. Artificial Snow – If you think all sky-high hills are natural, think again. Organic, white, and fluffy snow is not as easy to procure. However, they can surely be created artificially. Compressors are an indispensable tool to achieve this. The huge machines that create lofty hills of artificial snow depend on water from compressed air at the right temperature and humidity. And voilà, you have snow on demand!

2. Projects by NASA – Air compressors also help power space shuttles at the International Space Station (ISS). Two of the most important applications of compressors are to launch space shuttles and help sustain human life in space. 

For example, the speed required by space shuttles to escape the Earth’s atmosphere is around 25,000 mph. This feat is achieved by compressors along with turbine engines. Without compressed air to increase pressure and deliver liquid hydrogen and liquid oxygen to the engines, they won’t be able to combust fuel effectively and provide adequate energy.

Also, human life in space is heavily dependent on compressors. Compressed gas, when introduced into space, and decompressed and mixed, can act as a precious source of oxygen. From a real-life example, when ISS was launched into space, compressors were used as the primary backup for oxygen. 

3. Roller Coasters – Not just scientific inventions; compressors find applicability in recreational activities as well. The air brakes, safety gates, special effects, and launch systems are all powered by compressors. This helps create an other-worldly experience for people and makes it safer for them. Compressed air in roller coasters also help them run on water and reduce the need for electricity. 

4. Trains – Can you imagine the speed at which freight and passenger trains run? It’s around 220 mph. However, the essential thing is not only to move at that speed, but also to stop when required. This is where air compressors come in. The brakes in these trains run on compressed air. Compressors provide the force which closes pads onto the discs and blocks the wheels, thus forcing the trains to stop. 

Air Compressors for your Industry

Compressor systems can be a powerful resource for any industry. It can help bring to life some of the biggest ideas of mankind. Whichever industry you are in, compressors can help power your operations. Vijay Engineering and Machinery Company (VEMC), an ISO 9001:2015 certified company, is a pioneer in the field of electromechanical engineering products, allied equipment, and services. With over 72 years as an ELGi air compressor dealer, we can guide you to best use compressors for your industry. Feel free to call us on +91 98199 07445 and we would be happy to assist you.

3 Must-Have Compressed Air System Accessories That Improve Performance

by vemcoblogs -

Have you ever observed your air compressor functioning closely? Their entire efficiency depends on receiving the right proportion of clean and dry air, at the right locations and at the right pressure. When your compressor system is not working properly, it means that at least one or two of its components are malfunctioning — perhaps a blocked filter, lack of an air dryer, or an unsuitable pressure regulator. 

It’s commonly said that your air compressor system is as powerful as its weakest component. Hence, it’s extremely important to ensure that your compressor has all the right accessories it needs to function properly. They not only help boost your energy efficiency, but also reduce frequent needs for maintenance. The ultimate benefit is the long life of your compressors. 

In this blog, we list out 3 of the most important accessories you need to keep your air compressors healthy and running: 

1. Compressed Air Regulator – Air compressors run on extensive amounts of energy, with requirements varying for different applications. So, when the energy input goes wrong, it can damage the components in the system. It also means wasted energy and ultimately, wasteful expenditure. 

Choosing the right pressure helps you zero in on the right energy requirement for your compressor. If your compressor runs at a higher pressure than is required, you may be wasting energy, while adding unnecessary pressure on the other parts such as hoses and fittings. This will lead to wear and tear and reduce the lifespan of your compressor. If a component is best suited to work at 100 psi and you operate it at 150 psi, it will not perform optimally.

Regulators help solve this problem by regulating pressure from the machine and aligning it with specific components based on different pressure requirements. 

2. High-performing Filter – Your compressor systems don’t necessarily have clean air inside them. They may contain several particles, aerosols, and vapours often found in the natural environment. 

A powerful filter can help remove contaminants from the compressed air and hence, it’s important to choose the right filter. For some applications, specialized oil-removing filters will make more sense; for others, dust and pre-filters may be apt. Before zeroing in on a filter, be sure of the requirements. 

Most choices usually boil down to coalescing filters, vapour removal filters, and dry particulate filters. 

3. Air Dryer – It’s natural for compressors to create lots of vapour while it is operating. This stagnant moisture can damage compressors and their parts. Especially in the case of metal or machinery, the presence of moisture leads to mould growth. This is not an ideal condition for any application, particularly in hospitality or healthcare. Blocked air pipes, stuck air cylinders, and rusted transmitters can also lead to increased maintenance and repair costs. 

Air dryers can help eliminate moisture before they reach the tip of the tool. Air dryers such as desiccant dryers use silica gel, activated alumina, or molecular sieves to de-vapourise air. You can choose from the desiccant and refrigerated dryers for your compressor systems. 

Getting the Right Parts

Your compressor system is heavily dependent on tools and accessories. Hence, the right tools are critical for compressors to function efficiently. Even if you are using a good air compressor, you may not get the desired performance if the quality of the parts is sub-par.

VEMC is a pioneer in the field of electromechanical engineering products, allied equipment, and services. You can order ELGi air compressors, air filters for compressors, and other accessories by calling us on +91 98199 07445. At VEMC, our technicians can guide you about the right parts, routine maintenance, and repairs, to help you get the most out of your compressor systems.

Solar Power: An End Date to Your Energy Bill

by vemcoblogs -

Most of us are used to paying our energy bills as per our electricity usages. The bills come in monthly, we pay them, and wait for the next one the following month. That’s how the cycle continues. If you analyse your energy bills over the years, you’ll observe a trend that indicates increased expenditure. But most of us don’t give much thought to it since we don’t have an alternative.

Solar Panel ROI: Calculate How Much Your Solar Savings Will Be

What if you could find an alternative that could help you beat the rising energy costs? Imagine having a lifelong subscription to clean energy and renewable energy independently. Solar power installation can help in achieving this successfully. 

Understanding your current energy model

Presently, we are dependent for our energy needs and whenever we need to consume power, we have to pay for it. This infinite cycle exists for the ones who haven’t made the shiftto solar power yet. 

The issue with this model is that your source of energy is dependent on you paying your bills indefinitely. However, the price of electricity hasn’t remained the same. For example, duringthe period 2009-2020, the cost of state electricity has doubled—from INR 3.4 per kwh to INR 6.15 per kwh.

Add to this the present state of climate change where the summers are getting hotter. This will inevitably lead to significant increase inenergy needs. On a global scale, the demand for energy will rise, leading tofurthersurge in the price of fossil fuels. 

Hence, as long as you’re tied to the present model, your energy costs are likely to go up exponentially. 

So, what’s the alternative?

Thankfully, there’s an alternative to this — switching to solar power. The shift can give youmore control overyour monthly energy payouts. A solar power consultant, like VEMC, can help design a system that perfectly fits your budget and needs. With the right guidance and the right model, solar power can be easily accessible foryou. This will be an investment that would offervalue in the long-term and will be sustainable too. 

Once you move to the new system, your current usage will be mapped and any additional usage will be accounted for. Once these are done, you won’t have to pay a monthly bill anymore. You would simply pay for the usage once the sun sets down and you can waive that off to by investing in a solar battery. 

VEMC is a well-established solar EPC company in Mumbai and a pioneer in the field of electromechanical engineering products, allied equipment, and services. VEMCO Solar is a market leader in solar solutions — be it solar panel installation, procurement, commissioning, net metering, or electrical connections. If you are looking for solar panel installation in Mumbai or solar O&M, please reach out to us at 8976951701 / marketing@vemc.co.in, and we will be happy to provide you with customized support and services.