Month: April 2024

Compressed Air System Piping: Design Considerations for Pressure Drop Reduction

by vemcoblogs -

Compressed air is a major source of power in an industrial setting. But to get the most out of your air compressor system, you need to make sure all the ancillaries are well-designed and installed. Piping is an essential support system which plays a huge role in how well your compressed air system performs overall. We at VEMC are a top-notch ELGi dealer in Mumbai and in this blog, we tell you all you need to know about the design consideration of your piping to reduce the pressure drop in your air compressor system.

Factors contributing to pressure drop in piping

  1. Pipe diameter: This is one of the most obvious factors that impacts the pressure of the compressed air in the piping. Pipe diameter impacts the velocity of the air moving through the pipes. To put it simply, larger the pipe diameter, lesser will be the pressure for a given volume of air.
  2. Length of the pipe: Longer the pipe, greater will be the friction loss and hence lesser will be the pressure exerted by the compressed air. Pressure drop is thus directly proportional to the pipe length.
  3. Material: The friction that the moving air particles experience against the walls of the piping also contributes significantly to the drop in pressure. Thus, the material of the piping walls will also determine the extent of pressure drop.
  4. Fittings: How the piping is designed and fitted is an important factor that affects the drop in pressure. A highly complicated design with too many bends will reduce greater amount of air pressure as compared to a more straightforward one.

Strategies to minimise pressure drop

Now that we have understood what factors cause drop in pressure, let’s take a look at how to avoid or at least minimise it.

  1. Appropriate pipe sizing: Make sure the pipes are of the right size in terms of both length and diameter. Both long as well as broad pipes can cause unnecessary drop in pressure.
  2. Avoid unnecessary bends and restrictions: As much as possible, the piping design should be simple and straightforward. Too many bends and restrictions can also cause a drop in pressure due to greater friction.
  3. Use smooth-surfaced pipes: As mentioned above, friction of air particles with the internal surface of the pipes can also reduce the pressure of the compressed air. It is therefore advisable to use smooth-surfaced material for your piping.

It is quite clear that not only does the power and capacity of your air compressor matter but also the overall system and piping design. With the right piping design and installation, you can maintain optimum performance by reducing drop in pressure.

For more expert advice on your air compressor systems, feel free to call us on 022 43436655 or email us at marketing@vemc.co.in. We at VEMC are the leading ELGi compressor dealer in Mumbai with a wide array of air compressor options available to meet your needs. 

The Impact of Liquid Viscosity on Centrifugal Pump Performance

by vemcoblogs -

Pumps do not operate with the same efficiency and effectiveness with all liquids. One of the most important characteristics of the liquids that impact pump performance is their viscosity. VEMC is a leading Kirloskar pump authorised dealer based in Mumbai and in this blog, we tell you about the impact of liquid viscosity on centrifugal pump performance.

Definition and units of liquid viscosity

Let’s first try to understand what viscosity really means. In simple terms, viscosity can be thought of as the thickness of a liquid. However more technically, it refers to the resistance to flow at a given temperature. At the molecular level, it represents the interaction (more specifically friction) between molecules in a particular liquid. Higher viscosity means a liquid is thicker, that is, it offers more resistance to flow and hence requires more energy to be displaced from one point to another.

Unit of viscosity: Viscosity is measured in Newton-Second per Square Metre.

How viscosity affects pump efficiency and flow rate

As stated above, more viscous liquids are harder to move due to the greater resistance to flow they offer. As such, higher viscosity has a negative effect on the performance of a pump in terms of flow rate as well as head. This means if you are looking to displace highly viscous liquids such as oil or honey, you will need a really powerful pump.

Selecting the appropriate pump type and size for liquids with different viscosities

Let’s now take a look at which pumps are suited for which levels of viscosity.

  • For low viscosity fluids such as water, centrifugal pumps are the best. However, even with a slight increase in the viscosity of the liquid, centrifugal pumps’ performance may be affected.
  • For highly viscous liquids such as oil or honey, positive displacement pumps are most suitable. These can be run at lower speeds and varying flow rates to make up for the thickness of the liquids. 
  • Finally, peristaltic pumps can handle both high as well as low viscosity liquids with relative ease. These are suited for repeatable dosing applications and can run dry without any risk of pump failure.

Other considerations for highly viscous liquids

Apart from choosing the right pump types for the right levels of viscosity, you must also be mindful of the ancillary setup such as suction and piping. For highly viscous liquids, make sure there is no restriction on the suction end. Also, for such liquids, the pipework size must be larger to compensate for the friction loss or extra drag.

If you’re still not sure which pump is best suited for your liquid type, we are here to help you out. Feel free to speak to our experts by calling on 022 43436655 or emailing us at marketing@vemc.co.in. VEMC is the leading Kirloskar pump dealer based in Mumbai with over 72 years of rich industry experience in supplying and installing pumps, valves, fire panels and other high-standard electromechanical equipment.

Selecting the Right Dryer to Remove Moisture from Compressed Air

by vemcoblogs -

Moisture in compressed air could be problematic especially if you’re using it for food processing, spray painting or electronics. Moist air can cause growth of microbes, rusting of pneumatic tools or damage to circuits. To remove this moisture, it is necessary to use an air dryer in your compressor. But you must know which air dryer suits your needs best. We at VEMC are the top ELGi air compressor dealers in Mumbai and in this blog, we tell you how to select the right air dryer for your compressor.

Types of compressed air dryers

Let us first look at the top 3 compressed air dryers and their working mechanism.

  1. Refrigerated dryers: These are the most commonly used air dryers and these operate by using an air-to-air heat exchanger and air-to-refrigerant heat exchanger. These remove moisture from the air through condensation.
  1. Desiccant dryers: Desiccant dryers use adsorbent material such as silica, activated charcoal, calcium chloride, calcium sulphate or zeolites to remove moisture from the compressed air.
  2. Membrane dryers: These dryers use a membrane to remove moisture from the air. The membrane is usually made of polyamides or polyurethane. The compressed air is passed through the membrane which has tiny pores that allow air to pass through but retain the moisture.

Factors to consider when choosing a dryer

A number of factors go into consideration when deciding upon which air dryer to choose for your operations. These are:

  1. Moisture removal capacity: First of all, find out how capable the air dryer is to remove the moisture from the compressed air. This is after all your main concern and should get the highest level of importance.
  1. Pressure dew point: This represents the temperature to which compressed air can be cooled without condensation. A good air dryer brings down the pressure dew point so that the moisture is turned into liquid and can then be removed with ease.
  2. Energy consumption: What amount of energy is your air dryer consuming is another factor you need to watch out for. This is especially true as electricity prices are rising every passing year, and most businesses aim to optimise their energy resources to be reduce their carbon footprint.

Impact of compressed air quality on downstream equipment and processes

When operating in an industrial setting, it is not just necessary to have compressed air, but the quality of the air also matters significantly. Compressed air loaded with moisture can cause rusting and early wear and tear of equipment including the compressor itself. Likewise, if you’re operating in sensitive industries like pharmaceuticals or food processing, moist air can hasten the growth of microbes in the product leading to spoilage.

For more on which air dryer will meet your needs the best, feel free to get in touch with our experts by calling on 022 43436655 or emailing us at marketing@vemc.co.in. We at VEMC are the leading dealers of ELGi reciprocating compressors and oil lubricated screw compressors.

How to Read a Water Pump Curve

by vemcoblogs -

In its most basic form, a pump curve displays two things: Flow and Pressure. However, depending upon its sophistication, it can also show information like efficiency, power etc. Reading a pump curve correctly helps you discern whether the pump is suitable for your application. VEMC is one of the leading water pump dealers in Mumbai, and in this blog, we teach you to read a water pump curve.

How to read the pump curve

As mentioned above, a water pump curve shows the relationship between flow rate and pressure. Usually, the flow rate is shown on the horizontal axis and pressure on the vertical axis. So the curve displays the flow rate at a certain pressure or conversely the pressure of water at a certain flow rate. It is presumed that the water pump curve has been plotted for water.

Let’s take the adjacent graph for illustration. As you can see, the pump produces no flow at 41 meters of head and a maximum flow of 2100 litres per minute at 23 meters. This is because a pump operates under a number of influences such as speed and frequency of the motor which affect its flow and pressure. The speed of the motor for instance, directly impacts the flow rate and pressure.

Selecting the right pump based on requirements and operating point

A system curve is another graph to watch out for. It plots points between resistance of a system (head to be overcome by the pump) and flow rates. The system curve depends on factors such as height, diameter or length of piping, fitting type and number etc. The suitability of a pump is determined by how well the pump and the system curves match. The pump operating point is where the system curve crosses the pump curve on superimposition. 

Limitations of pump curves

While pump curves are extremely useful tools to understand the relationship between your pumps’ flow rate and pressure, and also to determine the right pump for the right task, they do have certain shortcomings as well.

A pump curve does not explain the relationship between operating point and equipment reliability which experts consider highly important. This relationship makes a huge difference in terms of pump longevity, and cost of repairs and replacement. 

Likewise, the Best Efficiency Point (BEP) indicates the point or area with highest efficiency for a given impeller diameter. In an ideal world, pumps would never operate outside of a BEP. However, in reality, factors like system upsets and fluctuating demand can make the BEP to shift. This can cause cavitation, rise of temperature, or wear and tear of seals and bearings.

For more on how to use tools like the water pump curve to make the right pumping decisions, feel free to speak to our experts by calling us at 022 43436655 or emailing us at marketing@vemc.co.in. We are the top Kirloskar pump distributor based in Mumbai with decades of rich experience and unparalleled expertise in pumping. 

The Role of Solar Charge Controllers in Protecting Batteries and Optimizing System Performance

by vemcoblogs -

If you are a solar PV system owner, you must be aware of the critical accessories that are necessary for the health of your system. One such equipment is a solar charge controller which regulates the charging and discharging of your batteries and also controls the power output. VEMC is the leading solar energy company based in Mumbai and in this blog, we tell you about the role that a solar charge controller plays in protecting and enhancing the performance of your solar power system.

Functions of solar charge controllers

  • Overcharge protection: 

For starters, a solar charge controller protects your batteries from overcharging. As soon as the voltage exceeds the protection voltage, the battery is automatically disconnected. 

  • Deep discharge prevention: 

Converse to overcharge protection, solar charge controllers also prevent deep discharge of your batteries. When the voltage of the battery falls below the over-protection voltage, the solar charge controller turns off the battery output to prevent deep discharge, only to restore the power supply when the battery is recharged.

  • Battery health monitoring: 

A solar charge controller is connected to the same battery terminals and can therefore keep track of the voltage to determine the state of the charge. By constantly monitoring the voltage of the battery, a solar charge controller keeps up-to-date about its health

Types of charge controllers and their suitability

Lets now talk about the two main types of solar charge controllers and the scenarios they best fit into.

  • Pulse Width Modulation (PWM) controllers: 

These are traditional solar charge controllers which operate by connecting directly from the solar array to the battery bank. These controllers are smaller and are suitable only to operate at battery voltage. These must be used with arrays matched with battery voltage.

  • Maximum Power Point Tracking (MPPT) controllers: 

These, on the other hand, are more advanced as compared to the PWM controllers and operate at maximum power voltage. As a result, the output produced is maximized which is great in cold conditions when the voltage of the solar array is much higher than the battery voltage.

Using proper settings for maximum energy harvest and battery lifespan

The right charge controller settings can bring rich dividends when it comes to power output as well as the lifespan of your battery. Different types of batteries work well with different settings. Some of the most important settings that need proper configuration for best results are:

  1. Battery floating charging voltage
  2. Battery over-discharging protection voltage
  3. Battery over-charging protection voltage
  4. Charge controller capacity
  5. Maximum charging current
  6. System voltage

If you’re a solar panel owner, you must make sure you have a quality solar charge controller in place to have maximum harvest and also prolong the working life of your batteries. For more information

on solar charge controllers, feel free to call us on 022 43436655 or email us at marketing@vemc.co.in. We are the leading solar power company based in Mumbai.

Dewatering in Construction

by vemcoblogs -
Kirloskar water pump dealer (1)

Excavation is a huge part of construction and water logging on the sites is a very common problem. To ensure smooth progress of the project, it is necessary that you manage the groundwater well. However, a number of different dewatering techniques are used, each suitable for a certain set of conditions and project specifications. VEMC is the leading Kirloskar water pump dealer in Mumbai, and in this blog, we tell you all you need to know about dewatering in construction.

Types of dewatering methods

  1. Subsurface drainage: 

This is a drainage method which helps remove water that has percolated into the subgrade. It is used in areas that have a very high water table or receive incredibly heavy rainfall. Subsurface drainage typically has a permeable base to remove water rapidly, a pipe collector system to convey the liquid away, and a filter layer to prevent the clogging of drainage.

  1. Sump pumps: 

This is one of the simplest and most cost-effective methods of dewatering. It involves digging pits in the drainage area to collect water which is then removed by using pumps.

  1. Wellpoint systems: 

A number of small wellpoints are installed around a site. These are connected with a central header pipe which has a vacuum function. Wellpoint systems are great for lowering the groundwater levels and facilitating construction work by creating a dry area.

Selection criteria for dewatering methods based on project specifics

The working conditions and project demands can vary from one construction site to another. The choice for dewatering methods must be made accordingly. For instance:

  • In conditions where there’s heavy rainfall, high water table or deep permeable soils, subsurface drainage can be the best option. It is also useful to drain heavy and poorly drained soils, or those that might have an impending layer at some depth, say clay.
  • In case of construction sites with shallow excavations and low-permeability, sump pumping can be the most feasible and cost effective method to remove water. However, it carries with it the risks of sudden collapse or erosion. 
  • In case of shallow excavations or fine-grained soils with low permeability, wellpoint systems can be the method of choice. It is quite cost effective and also easy to install. 

Environmental and safety concerns

Dewatering involves significant environmental and safety risks. For example, uncontrolled dewatering can deplete the groundwater of an area. Likewise, it can also cause increased sediment levels in waterways. In cases when seasonal conditions add more surface water to work sites, unmonitored dewatering can have an accidental impact on the environment.

Dewatering could be a dicey activity. To make sure environmental and safety risks are averted, builders must follow proper guidelines. For more on which dewatering method to choose for your construction site, and how to ensure environmental and personal safety, feel free to call us on 022 43436655 or email us at marketing@vemc.co.in. VEMC is one of the top-notch Kirloskar pump dealers in Mumbai with a rich industry experience of over 70 years. 

Understanding Air Compressor Discharge Pressure

by vemcoblogs -

If you’re an air compressor owner, you must be acquainted with some of the basics of your equipment. Discharge pressure is one of the most relevant notions that significantly impacts how your air compressor performs. VEMC is one of the leading air compressor dealers in Mumbai, and in this blog, we take you through all you need to know about discharge pressure.

Definition and importance of discharge pressure

Discharge pressure simply refers to the air pressure at the output end, that is, the discharge flange of your compressor. Maintaining optimum discharge pressure is necessary to ensure maximum levels of efficiency and productivity. However, higher than required discharge pressure could cause wastage of energy as well as damage to the system. This is because of the rise in temperature leading to metal fatigue of valves and thermal stress on lubricants.

Factors affecting discharge pressure

Discharge pressure of an air compressor is quite dynamic and a number of factors affect it. Some of these are:

  1. Size and speed of the condenser fan
  2. Size of the discharge line
  3. Condition of the condenser coil
  4. Leakage of air
  5. Cooling effect by oil, water , etc.
  6. Rotational speed in case of a screw compressor
  7. Voltage and frequency of the power grid
  8. Suction temperature and pressure

Impact of discharge pressure on system performance and efficiency

For starters, discharge pressure directly impacts the air flow of a compressor, and the simple Boyle’s Law equation can substantiate this. 

P1 x V1 = P2 x V2

However, compressed air isn’t free and with every unit rise in discharge pressure, there is a proportionate rise in energy consumption as well. In fact, it is widely believed that for every 2-psi increase in pressure, the energy consumption increases by 1 percent. So while increase in discharge pressure does boost your performance significantly, it also reduces the efficiency due to overconsumption of energy. Besides, higher levels of discharge pressure can also cause leaks in the system and reduce the distribution of the compressed air, while reducing the lifespan of the air compressor in the long run.

Optimal discharge pressure settings for different applications

It is quite clear that operating an air compressor and deciding the right discharge pressure requires  some amount of nuance. There is no on-size-fits-all for every application that you use your compressor for. Industrial applications usually require a pressure of 100-200 psi while if you’re using the compressor for domestic use, anything between 90-150 psi should be enough. Pneumatic tools like nail guns require a pressure of 90-100 psi while sandblasters and spray painters would typically need 120-150 psi.

Discharge pressure seems to be a straightforward notion. However, to ensure you get the maximum out of your air compressor without wasting energy, you must operate it at the right levels of discharge pressure. For more on air compressors, feel free to call us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the leading compressor dealer in Mumbai.

The Future of AI and Blockchain in Solar O&M

by vemcoblogs -

Solar energy is fast becoming one of the most favored sources of renewable energy across the world. But one of the most exciting aspects of solar PV systems is their ability to blend seamlessly with the latest technological developments across the board. AI and Blockchain are two new technologies that have a promising potential to drastically improve operations and maintenance in the solar energy space. VEMC is a leading solar energy company in Mumbai, and in this blog, we tell you all you need to know about the role of these technologies in solar energy.

Applications of AI in solar O&M

  • Predictive maintenance: 

An immense amount of thought, effort and finances go into maintaining solar power systems. But with the ability of processing past data through AI, you can zero in on equipment that need your immediate attention to prevent sudden breakdowns. This can  help reduce costs and avoid downtime.

  • Anomaly detection: 

With AI, anomalies can be detected with precision and in a timely manner. These include hotspots, potential induced defects (PID) or problems with diodes, strings or junction boxes.

  • Performance optimisation: 

AI can perform an enormous role in boosting the performance of your solar panels. Specialised algorithms can accurately perform data analysis to determine the optimal use of solar power. AI can also be used to monitor modules and micro-inverters for quick redressal of any anomalies. 

  • Automation: 

By analysing data from solar power systems, AI can help in automating the decision-making process and ensuring highest levels of efficiency and performance. 

Blockchain for secure data management and traceability

  • Asset tracking: 

As the solar energy industry is growing rapidly every passing year, its supply chain is becoming ever more complex creating challenges for traceability. With blockchain technology however, granular data can be collected at asset level and can be recorded on-chain.

  • Performance logging: 

With blockchain-based platforms, users can gain real-time insights for optimum performance of their on-grid solar system. The distributed ledger system helps monitor and log data exchange between panels, storage systems and the grid.

  • Warranty verification: 

With its decentralised and distributed ledger, blockchain technology can be used in keeping immutable records of warranty claims and records of equipment. These records cannot be tampered with and can thus offer an authentic and transparent warranty management mechanism.

Benefits of AI and Blockchain integration

  • Improved efficiency: 

One of the most outstanding benefits of both AI and blockchain technologies is more efficient operation of solar power systems.

  • Reduced costs: 

By streamlining the operations, AI and blockchain help in reducing human effort, cost of energy and material.

  • Enhanced transparency: 

These technologies offer highest levels of transparency in terms of authentic data records and documentation. Blockchain especially is a highly innovative way to capture and communicate important information across the solar power system.

For more on how technologies like AI and Blockchain can transform your conventional solar power system, feel free to call us on 022 43436655 or email us at marketing@vemc.co.in. We are the industry leaders when it comes to solar power installation.