Month: December 2023

The Role of Pumps and Air Compressors in the Circular Economy

by vemcoblogs -

As opposed to a linear economy which proceeds through the stages of ‘take-make-waste’, a circular economy is restorative and regenerative. The economic activity in a circular economy builds and rebuilds the overall health of the system. It aims at decoupling growth from the consumption of finite resources. The three most significant features of a circular economy are resource efficiency, waste reduction and closed-loop systems. A circular economy offers enduring benefits like environmental sustainability, economic growth and job creation.

VEMC is the leading air compressor dealer in Mumbai, and in this blog we take you through the role of pumps and air compressors in a circular economy.

Industries that rely on pumps and air compressors

A range of industries such as manufacturing, wastewater treatment and energy production rely on water pumps and air compressors. Here are some of the major functions performed by them:

By pumps:

  1. Transporting fluids such as chemicals, oil, water etc. from one place to another
  2. Removing pollutants and contaminants from fluids
  3. Providing the necessary pressure required for industrial processes
  4. Mixing and blending liquids

By air compressors:

  1. Pushing and propelling gases through pipelines
  2. Blow cleaning and spray painting operations
  3. Powering pneumatic tools such as drills, abrasive blast equipment etc.
  4. Shifting AC refrigerants

All the above-mentioned functions consume energy. To create and sustain a circular economy, it is important that energy efficient pumps and compressors are used, so that operations are performed at peak levels without wastage of energy.

Recycling and remanufacturing pumps and air compressors

Air compressors and pumps that are in use for a very long time will inevitably undergo wear and tear. This will affect their performance and energy efficiency. However, if these equipment are procured from trusted manufacturers like VEMC, you can expect longevity and consistent performance. This is not just great for your business as it avoids sudden breakdowns, loss of business and unexpected capex investments, but also for the circular economy as it avoids wastage of resources and lowers the carbon footprint. Besides, techniques like retrofitting can offer a second life to your equipment while enhancing their performance and efficiency.

Role of compressors and pumps in a circular economy

One of the most important aims of a circular economy is to reduce wastage and lifespan costs of equipment. This is ensured in three main ways:

  • Products like compressors and pumps which are designed keeping the concept of circular economy in mind, aim to extract maximum value out of resources. As soon as the products reach the end of their service life, their parts are salvaged and re-processed to leave as little waste as possible. 
  • Product design also ensures that as little wastage of material during operations (through friction) takes place. The simplicity of design to avoid as much metal-to-metal contact can help reduce lifetime costs of the equipment significantly. 
  • The product designs also ensure minimal consumption of energy and enhanced operational efficiency. This contributes to lower carbon footprint and energy savings throughout the service life of the product.

For more on how VEMC promotes the idea of circular economy through its air compressors and pumps, call us on 022 43436655 or email us at marketing@vemc.co.in. We are the leading pump and air compressor dealers in Mumbai.

How Pumps are Helping Combat Water Pollution

by vemcoblogs -

Water pollution is one of the most critical issues in urban and industrial areas. It poses serious risks to everyone especially newborn children and the elderly. Water-borne germs can cause diseases like diarrhoea, dysentry, typhoid fever etc. In extreme cases, they can be a cause of serious neurological and reproductive disorders. Polluted water also affects the environment by altering the chemical composition of the soil, suffocating indigenous species of plants and animal, and causing algal blooms. VEMC is the leading Kirloskar water pump dealer based in Mumbai, and in this blog we talk about how pumps help combat water pollution.

Pumps in wastewater treatment

When it comes to wastewater treatment plants, there are three processes involved: primary, secondary and tertiary. While the processes differ according to municipalities and businesses, all of them require pumps to remove waste, treat the water and transport it from one point to another. By effectively treating wastewater, pumps play an important role in water conservation. Some of the pumps used in wastewater treatment are:

  1. Submersible pumps: These pumps are self-priming, quiet, vertical and available in a range of sizes. Most importantly, these are water-tight and work very well in wastewater treatment industry.
  2. Centrifugal pumps: These are the most commonly used pumps for wastewater treatment. They produce ample velocity to move the fluid through the treatment system. They’re simple to install and require very little space. Unless there is an issue with the impeller, these pumps do not clog easily. Their parts are also very durable due to which these pumps enjoy quite a long lifespan.
  3. Positive displacement pumps: These use impellers, gears and rollers to transfer the fluid. These pumps can handle a range of fluids in terms of viscosity and are hence well suited for wastewater treatment. These pumps also offer a consistent flow and speed.

Pumps in groundwater remediation

Groundwater could get polluted by industrial chemicals, fuel oil, solvents and metals that trickle down through the soil. This problem is especially severe in industrial, mining and refining towns. The water can however be treated using pumps. Groundwater is drawn up using extraction wells and pushed through an above-ground treatment plant to remove the dissolved chemicals. Cleanup methods such as activated carbon or air stripping is usually used to treat groundwater. As soon as the treated water meets the regulatory standards, it is then discharged for further use.

Pumps in stormwater management

Stormwater can carry mud, sludge, silt and a range of hazardous contaminants. These can affect crops as well as animals. Stormwater can also affect human habitations by causing infectious diseases which in extreme cases can assume epidemic proportions. With stormwater pump stations in place, all these calamities can be prevented as they enable transporting the excess stormwater safely away from fields and human settlements.

Pumps are of immense service to mankind as they play a great role in protecting our water resources from pollution. To know more, get in touch with VEMC by calling on 022 43436655 or emailing us at marketing@vemc.co.in. We are the top-notch water pump dealers based in Mumbai.

Pain points of traditional pump monitoring vs. the advantages of Kirlosmart

by vemcoblogs -

Monitoring pumps regularly and continuously is important. This is because any deviation in parameters can cause serious wastage of energy, wear and tear and drop in performance. Traditionally, pumps have been monitored by physically checking the parameters at the pump site and taking readings. However, with the advent of IoT, pump monitoring has been transformed like never before. VEMC is one of the top-notch industrial water pump suppliers in Mumbai, and in this blog we take you through the pain points of traditional pump monitoring and how Kirlosmart has  successfully overcome these.

Challenges of traditional pump monitoring methods

  1. Physical monitoring: Traditional methods require physical monitoring of pumps using equipment like flow meters. This meant the technician had to personally go to the site and take readings.
  2. Costly: Traditional monitoring techniques were costly as these involved visit by a trained technician or training of an in-house resource for monitoring pump performance.
  3. Passive: Traditional monitoring is non-continuous in nature, in the sense that it takes place far and in between during the pump’s working life. Otherwise, it is done when the pump exhibits unusual behaviour such as noise or too much vibration.

Kirlosmart: Next-gen monitoring

When it comes to monitoring pumps, Kirlosmart is the next-gen solution. It operates using the cutting edge IoT technology which keeps your pumps connected to your laptop or smartphone device through WiFi at all times. This means a continuous stream of real-time data is being transmitted from the pump to your device and monitoring is going on 24×7. 

Any deviation in pump parameters such as flow, vibration, voltage etc. will quickly be indicated by the Kirloskar app to alert the user. Thus, a proactive intervention can be done to avoid any sudden breakdown of the pump.

With Kirlosmart app in place, you no longer need to physically visit the pump site, call a technician with his equipment and take readings of parameters. Everything is being recorded and transmitted online. This avoids the monitoring costs significantly.

Kirlosmart offers users an interactive app interface which includes pump statistics in an easy-to-understand graphic style. The app also keeps a record of past data which helps predict when a breakdown might take place, thus also facilitating the scheduled maintenance of the pump.

How Kirlosmart helped pump-owners brace the pandemic

Kirlosmart came as a godsend to Kirloskar pump owners during the pandemic years. This is because it enabled them to monitor their pumps without physically venturing out to reach pump sites. All the parameters were available on their screens in real-time and only in case of any deviations physical intervention was required. This kept the owners safe while keeping the operational and maintenance costs of the businesses in check.

Kirlosmart is clearly a revolutionary technology in the field of pump monitoring. To know more about this path-breaking technology, feel free to call us on 022 43436655 or email us at marketing@vemc.co.in. We at VEMC are the leading industrial water pump dealers in Mumbai.

Refurbishing Mechanical Pumps: A Cost-Effective Alternative to Replacement

by vemcoblogs -

Mechanical pumps, like any other equipment, are prone to damage and depreciation. This often leads to performance-related issues, drop in efficiency and even failure. These problems can compel an owner to take a decision as to whether to replace or refurbish the pump. 

VEMC is the leading Kirloskar pump distributor based in Mumbai and in this blog, we tell you why refurbishing your mechanical pump is a great alternative to replacement.

What is pump refurbishment

Refurbishment of a pump involves diagnosing a problem, designing a fix and delivering the right solution to eliminate the issue. This enables you to use the same pump for an extended period of time after proper repairs.

Why refurbish rather than replace

Refurbishment of pumps offers many benefits that replacement doesn’t:

  1. Cost savings: Often, minor issues with any of the components can cause a breakdown. Components like these can be easily repaired to restore the pump. This makes refurbishing the pump much more cost-effective as compared to replacement.
  1. Extended lifespan: Pumps are expensive pieces of equipment and owners always want to get maximum service from them. By refurbishing the pump, you can prolong its lifespan significantly ensuring more returns on investment.
  2. Improved efficiency: Refurbishing pumps addresses leaks, reduced flow and unexpected noise and helps restore their performance to peak levels. This helps improve efficiency and productivity, reduces energy costs and avoids downtime.

Process of refurbishing pumps

  • Refurbishment is done with complete overhaul of the pump, and after analyzing all the parts (bearings, gears, seals etc.), and the ones worn out are replaced with fresh ones. 
  • In case they’re not available commercially, these components are redesigned and re-manufactured. 
  • The pump is then re-assembled and final test done to check performance and efficiency. Clearly, refurbishing the pump requires a thorough know-how on the part of technicians and VEMC –– a top-notch Kirloskar pump distributor offers you just that!

Factors to consider for refurbishing/replacement

  1. Cost: For starters, the cost consideration should guide you as to whether the pump could be repaired or must be replaced. Investing in a new pump is always going to be costly, but at times, refurbishing a pump that is beyond restoration can also be heavy on your pockets, besides not giving satisfactory performance in the long run.
  1. Age of your pump: older pumps may be more susceptible to breakdown or have outdated technology. As such, finding spare parts for these pumps can be quite challenging. In such situations, it would be more practical to replace the pump with a new one.
  2. Expertise: Refurbishing a pump requires experience, expertise and know-how. Only when your maintenance team or a consultant technician have these, should you consider refurbishing the pump.

Besides having a business impact, refurbishing your pumps instead of replacing them also has  significant environmental implications, by avoiding unnecessary wastage of material, overproduction and emissions. If you need more advice on refurbishing your pumps, feel free to get in touch with VEMC by calling us on 022 43436655 or emailing us at marketing@vemc.co.in. We are the leading Kirloskar water pump dealer in Mumbai.

10 Ways PMI (Positive Material Identification) Inspection Prevents Pump Failures

by vemcoblogs -
10 Ways PM Inspection Prevents Pump Failures
Kirloskar pump distributor

As a pump owner, if there’s one thing you’re always concerned about, it’s sudden breakdowns. Depending on the functions your pump is performing, sudden breakdowns can lead to serious business consequences due to unexpected downtime. One of the most effective ways to prevent this is positive material identification or PMI for short. 

VEMC is the leading Kirloskar pump distributor, and in this blog, we talk about how PMI prevents pump failures.

What is PMI?

PMI is an analytical test of a material (generally an alloy) to determine the composition in percentage terms of its constituent elements. The most common methods for carrying out PMI are optical emission spectrometry (OES) and X-ray fluorescence (XRF). One of its greatest benefits is that it is a completely non-destructive method.

PMI has an important role to play in pumping, where it is used for safety compliance and quality control. It also enables you to meet the legal and regulatory requirements set by local governments. But most importantly, it can prevent pump failure and its subsequent business costs.

How PMI prevents pump failures

Let’s now try to understand how PMI prevents pump failures across industries.

  1. With PMI testing, businesses can ensure every single component of the pump meets quality specifications, and critical parts are especially made up of the right grade of alloy. 
  1. PMI helps avoid the pump or its parts’ potential failure during the manufacturing process.
  1. PMI helps find potentially mixed-up alloys. This can be the single most important criterion for buyers to decide which pumps to choose and which sellers to trust.
  1. It enables buyers to determine whether the welded components have used the right filler material.
  1. With failure analysis PMI, you can unearth the root cause of a pump failure to avoid it the next time around.
  1. PMI ensures that the metal used in a pump meets the correct standards and specifications as per regulations and that it is safe to use for the customer.
  1. PMI testing reduces the risk of company liability, thanks to documented safety standards. It comes in handy when the documentation for the equipment is lost.
  1. Besides testing the composition of the alloys, it helps find out if the wrong material has been used in the construction of a pump or any of its parts.
  1. Due to its non-destructive procedure, it is beneficial in case of metals or materials that are too expensive to break down.
  1. PMI is also the best way out in situations where a part cannot be taken for a sample test.

Quite clearly, PMI is a remarkable novelty in pump testing. This is especially because of its cost effectiveness as no pump part or material is destroyed. Besides, the testing requires simple hand-held equipment, which requires no special training for employees.

For more information on how PMI can be useful, get in touch with VEMC at 022 43436655 or email us at marketing@vemc.co.in. We are the leading Kirloskar pump dealer, based in Mumbai.

Retrofitting as a cost-effective alternative to replacement

by vemcoblogs -

Pumps are usually designed to meet specific needs and expectations such as de-watering, supplying oil and petrochemicals or irrigation. However, over a period of time, the requirements may change and pumps may be needed for new operations altogether. Besides, the old pumps may undergo wear and tear especially in the chemical industry where there is a high likelihood of corrosion. All this can leave the pumps ill-equipped for taking on new tasks. This is where retrofitting comes in as an easy and cost-effective alternative to meet performance and reliability expectations. 

VEMC is a leading Kirloskar pump distributor in Mumbai and in this blog we talk about retrofitting of pumps.

What is pump retrofitting?

When pumps reach their wear and tear limit, retrofitting can give it a second life. It involves restoring an old pump by salvaging its component parts and if required fitting new ones to make it functional again. Retrofitting is highly economical and also has positive implications for the environment as it avoids unnecessary wastage of material. Retrofitting in other words offers a quick, efficient, cost effective and nature-positive overhaul for old pumps.

Cost effectiveness of pump retrofitting

Pump retrofitting can be immensely beneficial for companies looking to save not just on their Capex but also on Opex in the long run. Retrofitting also has implications for the environment and reduces your carbon footprint significantly. Here are some of the top benefits owners can expect from retrofitting their pumps.

  1. Avoiding Capex: The most outstanding benefit of retrofitting your pumps is that you get to avoid shelling out a huge sum at once. Buying a new pump can actually be quite expensive and make a dent in your finances. With retrofitting however, you get an opportunity to salvage your old pumps and prolonging their working life. 
  2. Improved reliability and performance: Equipment and component parts in critical business areas need to be up and running at all times. Once you retrofit your old pumps, its reliability and performance improves significantly. This avoids unplanned downtime and the business costs associated with it.
  3. Lower operating costs: To reduce your operating costs, it is important that your equipment is operating at peak efficiency levels. Operating cost throughout a pump’s service life is many times more than the initial Capex. With improvements in hydraulic design, your retrofitted pump can offer better performance, higher efficiency and lower power consumption.

Retrofitting maximizes revenue generation

A retrofit is a cost-effective way to deal with high demand and throughput without the cost and time needed to install a new pump. A retrofit also has the additional benefit of maintaining existing piping and foundations, further minimizing costs and downtime, and boosting revenue significantly.

Retrofitting is a great way to breathe new life into your old pumps. For more information on retrofitting, feel free to get in touch with VEMC by calling us on 022 43436655 or emailing us at marketing@vemc.co.in. We are the leading Kirloskar water pump dealer based in Mumbai.

4 Common Misalignment Issues in Pump Sets and Their Impact

by vemcoblogs -

As your pumps get older, they will likely develop misalignment issues. This is due to the persistent movement and vibrations that make the shaft deviate from the desired position. Conversely, misalignment can cause further deviation by changing angles and orientations of the pump. 

VEMC is one of the leading industrial water pump suppliers in Mumbai, and in this blog, we talk about the 4 common misalignment issues in pumps, their impact, and ways to correct them.

Coupling misalignment

This is one of the most common types of misalignment and takes place due to a build-up of heat in bearings as a result of persistent friction. This causes wear and tear on the bearings, resulting in a reduced lifespan. In case of carbon journal bearings that are lubricated by the pumped liquid, the wear and tear could take place elliptically, thus sharply reducing the pump’s functionality. In extreme situations, coupling misalignment can lead to fractures in the casing, increased noise, and shaft failure.

Shaft misalignment

In case of misalignment in coupled shafts, the shafts are forced to rotate eccentrically. This leads to an excessive consumption of electricity, creates vibrations, increases the stress on the shafts and couplings. This reduces the mechanical seal life, causes fatigue and failure, and in extreme cases, could even lead to a complete breakdown of the pump.

Misalignment in piping

This can be caused due to incorrect installation and engineering. This often takes place when fixed pipe-work is connected to a smaller pump. In this case, misalignment could take place as a result of excessive nozzle loading. Besides, if the piping is not supported sufficiently, the weight of the fluids and the self-weight of the pipe could cause it to sag. Likewise, flow of hot liquid through the pipes could cause it to expand, forcing the joints apart and leading to misalignment.

Misalignment due to foot issues

Often one or more of the pump feet aren’t making enough contact with the base. This is known as a “soft foot” situation and is common for most rotating equipment. This is often detected when the pump is rocking, but very often it may not be detected at all until it has caused complete failure or breakdown.

How to correct pump misalignment

Pump misalignment is clearly a serious problem and can be dealt with in a number of ways. Here are some of the common ones:

  1. Simply realign the pump along the centrelines of its shafts. 
  2. Loosen the motor’s bolts to shift it to one side (horizontal adjustment) or add/remove shims under its feet (vertical adjustment).
  3. Support the piping carefully throughout the pump system.
  4. Use a Laser Shaft Alignment (LSA) to easily and quickly realign couplings and shafts.

For more on how to correct misalignment, feel free to give us a call on 022 43436655 or email us at marketing@vemc.co.in. We at VEMC are one of the top-notch industrial water pump dealers in Mumbai.

When to Repair vs. Replace a Pump

by vemcoblogs -

Whenever any of your equipment breaks down, you are required to make a choice between repairing or replacing it. This applies to industrial pumps as well. However, several variables come into play when making the repair vs. replace decision. Some of these are skills of the technician, current technology and of course the costs involved. 

VEMC is the leading Kirloskar dealer in Mumbai and in this blog, we talk about the repair vs replace dillemma that every pump owner has to face at some stage.

The repair vs. replace decision

The repair vs. replace discussion is often held whenever breakdown maintenance of a pump is being carried out. The decision is routed through a number of variables such as:

  1. What is the problem that caused the breakdown?
  2. Can it be fixed either internally or outsourced to an experienced technician?
  3. How much will it cost to fix the issue?

The first step is identifying the problem which in itself can be quite challenging. Often pumps break down due to more than one issue. To zero in on the problems requires plenty of expertise, skill, experience and even some amount of luck. In case an internal team-member is unable to resolve the problem, it may be better to outsource it to a third-party technician. 

At any rate, what really matters is how much cost will be involved in solving the problem. This is where the owner must figure out whether it would be more affordable to repair the pump, or simply to replace it with a new one. As a thumb rule, if the repair costs exceed half the costs for replacement, the pump should be replaced.

Age and performance history of the pump

If your pump is old, it is very likely to have undergone a significant amount of wear and tear. Plus, its technology has possibly become outdated which means it will be difficult to find spares for it. In terms of energy efficiency as well, the pump may not be performing up to the mark.

Another factor to look out for is how the pump has performed over the years. If it has had multiple breakdowns which has resulted in costly downtime, that makes another reason for you to consider replacement.

The environmental angle

Environmentally, it is always desirable that you prolong the lifespan of your equipment as much as possible and avoid frequent replacement. The latter causes unnecessary emissions and wastage of precious resources. However, if the outdated equipment has poor energy efficiency, it can be a heavy burden on not just the business but the environment as well. The eco-conscious pump owner is thus required to walk the tightrope between these two alternatives.

The repair vs. replace dillemma is one of the most confounding business decisions that any pump owner has to make. If you’re confused about what course of action to take on pump breakdown, let us help you navigate this uncertain territory. Call VEMC, the top-notch Kirloskar authorised dealer, on 022 43436655 or email us at marketing@vemc.co.in. 

Importance of Conducting Pump Performance Testing

by vemcoblogs -

Pumps are expensive pieces of equipment, and to keep them going, continuous monitoring is important. With time, there will inevitably be wear and tear, which will cause deviations in performance. In other words, your pumps will gradually lose capacity and efficiency over time.

VEMC is one of the leading Kirloskar pump dealers based out of Mumbai, and in this blog, we tell you why regular and frequent performance testing is important.

Establishes mechanical integrity

Performance testing enables you to verify the design and establish its mechanical integrity. It helps prove compliance with industry standards and regulations. A mechanical run demonstrates that a pump runs without causing any mechanical issues such as leakage, high temperature, or vibrations.

Detection of issues

Performance testing is carried out under a range of different conditions. This essentially demonstrates the uniform performance of the pump in both hot and freezing temperatures without developing any faults or defects. A bearing temperature test is important to find out the levels of temperature at which pumps perform well. Temperature is measured before the start of the performance test and the minimal allowable rise of temperature above ambient levels is 70 degrees F. Likewise, as vibration levels increase, pumps may become more susceptible to leakages in gaskets, seals, etc. Performance testing ensures none of this takes place.

Finding operational problems

Performance testing can also be an opportunity to find out if a pump has any operational issues. These include misalignment or excessive vibration. These issues, if left unresolved, could cause serious and long-term damage to the pump, thus having an impact on its lifespan. Get in touch with any Kirloskar pump dealer to find out how to get these issues resolved.

Testing energy efficiency

A very important aspect of operating a pump is the level of energy it consumes. This is important as energy prices are soaring and any waste or increased consumption can raise costs significantly. Statistical reports that are received after performance testing demonstrate the level of energy efficiency of a pump.

Compliance testing

Your pump must comply with industry standards as well as government regulations. They need to comply with several standards, such as Hydraulic Institute (HI) vertical pump tests and ANSI/HI 2.6-1994. Non-compliance with any of these standards could attract severe penalties.

Testing the pump’s performance

Finally, and most importantly, the role of performance testing is to find out whether the pump is providing the performance that it promises. For this, the NPSH test is performed using two methods –– vacuum suppression and suction valve throttling. 

Pumps are expensive assets that you wish to make the most of for an extended period. This makes it very important that you keep a regular eye on how it is performing. For more information on performance testing, feel free to get in touch with VEMC by calling 022 43436655 or emailing us at marketing@vemc.co.in. We are the leading and most reputed Kirloskar pump dealers in Mumbai.