Centrifugal Pumps are Energy Guzzlers. How does Pump Energy Audit Help?

Centrifugal Pumps

A centrifugal pump can seriously raise your energy costs if you’re not keeping tabs on its efficiency levels. It is necessary that you take timely measures to eliminate inefficiencies or replace the pump altogether as the last resort. The most effective method in this regard is a thorough energy audit that can bring forth all the irregularities or issues with the pump’s performance. It can also give an estimate of energy savings if you switch to a different pump. In this blog, we talk about how an energy audit of your centrifugal pump can contribute to significant savings and cut down on costs.

Costs of Pumping

Pumping is a rather expensive affair across the world and more so in an energy-strapped developing country like India. According to some estimates, pumps consume 10% of power across the world, and switching to a more efficient water pump could save up to 4% of electricity globally. 

The main reasons behind the high costs of pumping could be an inappropriate selection of pumps, old inefficient design, improper layout, etc. By switching over to a more energy-efficient pump, you can reduce your bills, increase productivity, boost profits and enhance business competitiveness.

Centrifugal Pumps Consume a Lot of Power

Centrifugal pumps consume anywhere between 25% and 60% of a plant’s electrical motor energy. This can be made worse if the pump is improperly sized or poorly performing. Lack of maintenance and poor condition of the pumps is other reasons for the spike in running costs of a pump. This requires proper matching of a pump of the right capacity with the operation at hand. Likewise, a properly scheduled maintenance regime is a must to eliminate inefficiencies and overdrawing electricity over the lifespan of the pump.

Steps to Follow

An energy audit is the best way to keep the rising electricity costs in check. It is highly beneficial for business, society, and the environment at large. A pump energy audit is conducted by following these steps:

  1. Shortlist all the pumps for the audit
  2. Measure parameters like flow, pressure, and energy consumption
  3. Calculate the pumping efficiency
  4. Discuss the case with a specialist like an engineer or the maintenance staff
  5. Analyze data
  6. List recommendations and present them in the final report

How you can Save Energy

After an energy audit, you can get an in-depth understanding of the gaps, and the affirmative action that must be taken to fill them. With comprehensive data collection, analysis and modeling, it also gives you an idea about how much you can save by switching to a new alternative. In most industrial pumping systems, energy audits can help save up to half the energy costs!
VEMC can take care of the energy audit services of your pumps. We have all the expertise required to carry out Performance Measurement and energy optimisation of pumps and motors. Our team can provide a superior analysis of your current energy consumption and also the annual expenditure followed by a cost-returns-based proposal for different alternatives. For further information, feel free to call us at 022 43436655 or email us at marketing@vemc.co.in.

What To Know Before Installing Solar Project

Installing Solar Project

Solar energy is being received with enormous excitement across the country. Many homeowners are even able to save almost 100% of their electricity bills thanks to their solar panels. No wonder the installation of PV systems has grown exponentially from just 5 MW in 2010-11 to a whopping 5000 MW in 2019-20. However, the installation of a solar project on your roof has certain prerequisites which must be met to ensure it works at the optimum capacity. In this blog, we take you through all the critical ones.

Can your roof support solar panels?

First things first, make sure your roof can provide the physical strength and stability to install solar panels and mounting structures which are typically quite heavy. Do not install the system unless your roof is firm. The possibility of your roof collapsing under the weight of the structure could cause serious injuries or even loss of life.

Is your roof the right shape and type?

The type of roofing you have also determined the possibility of installing a solar project. A tin roof with a sharp slope can pose serious challenges while installing the mounting structures and even then these might not remain stable. A terrace on the other hand can offer a great deal of convenience. Likewise, how much space is available on the rooftop is also crucial to consider.

Which direction does the slope of your roof face?

To generate the maximum amount of electricity, solar panels must face the sun for as long as possible. This makes the direction of the slope of your roof quite significant. The best placement for your panels according to most professionals is either south or west.

How efficient is your installation location? How much energy do you use?

The amount of power generated also depends upon the installation location. You would obviously want the sun to strike your panels for the most part of the day. But this also depends upon your energy needs from the solar panel. In case you rely almost completely on your solar panels for electricity, choose your location carefully. The technician should be able to help you find the right spot for the panels, and in case of prior installation, can also help move the installation to a different location.

How do you connect to the grid?

A number of things need to be taken into consideration with regard to your connection with the grid. These include the following:

  1. How long will it take to get the connection?
  2. Are you liable to pay any fee?
  3. Will your supplier enter into a net metering agreement for surplus energy that you feed back to the grid?

Solar installation at home or business could create a lot of confusion and dilemmas. The best way to get all your queries addressed is to contact the experts. VEMC is one of the top solar company in Mumbai that can make your life much simpler when it comes to your solar installation. Before you install or move your PV system, get in touch with our experts at 022 43436655 or email us at marketing@vemc.co.in.

How to Calculate Total Dynamic Head for an Industrial Pump

TDH for an Industrial Pump

The total Dynamic Head in an industrial pump refers to the total pressure when water is flowing in a particular system. It has two parts: the vertical rise and friction loss. In this blog, we explain to you the complete calculation of the TDH. So let’s get started.

Broadly, the TDH of a pump can be calculated by following these steps:

  1. Calculate the value of the vertical rise 
  2. Find out the friction losses in the system as the water passes through the pipe and other components
  3. Add both these values to arrive at the TDH.
  • How to calculate the vertical rise:

As the name suggests, this parameter seeks to calculate the distance up to which the liquid has to rise from its starting point in the system below to the endpoint. If the liquid level at the bottom goes down, the vertical rise will naturally increase. Likewise, in case the level of liquid rises at the bottom, it has to rise over a shorter distance to reach the endpoint, and hence the vertical rise will decrease. With the increase of the value of vertical rise, the TDH also increases.

  • How to calculate friction loss:

To find out the friction loss, it is necessary to calculate the desired flow. The greater the flow going through your pipes more will be the loss due to friction. Friction loss also depends on the type of pipe in use, its vertical and horizontal length, and its schedule. You must also factor in the elbows, valves, connectors, or other components that come in contact with the liquid, and hence contribute to the friction loss. 

  • The result: Total Dynamic Head calculation:

As stated earlier, TDH is simply the summation of vertical rise and friction loss. To arrive at the TDH value, first ensure both are in the same units of length, say feet. For instance, if the vertical rise in the worst-case scenario is 25 feet, and the friction loss of the system is 6 feet, the TDH value would be 31 feet.

  • Alternative scenario:

Always considers the worst-case scenario in case of vertical rise to ensure you have sufficient amount of TDH. For instance, in the above case, if the water level never goes below 5 feet, the vertical rise will always be 20 feet and hence the TDH value will only be 26 feet.

Other Considerations When Calculating Total Dynamic Head

A few other factors also have an impact on the Total Dynamic Head. These include viscosity, specific gravity, and temperature. The specific gravity of a liquid can slightly alter the friction losses. Likewise, viscosity can significantly increase friction losses. 
For any information on centrifugal pumps, multistage centrifugal pumps, horizontal multistage pumps, or vertical pumps, feel free to call us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the authorised Kirloskar dealer that deals in the entire range of pumps suited for various operations. VMC is an ISO 9001:2015 certified company with a rich industry experience of 72 years.

Solar Power Returns Are Better Than The Bank

Whenever you invest in a new source of energy, one of the most critical things you look out for is the returns you get. Energy inevitably involves finances and any savings you make on it are as good as earnings. A cursory look at our history tells us that the costs of energy never go down and on the contrary are always on the ascendant. The fact that your finances are intricately tied to your energy needs makes it all the more important to make the right decisions when it comes to choosing the source of your energy.

When it comes to solar power, you can actually calculate these returns to great levels of precision. In fact, these returns are actually so healthy that they can even exceed the interest yielded by your bank deposits. In this blog, we take you through a full-fledged calculation to prove how solar power returns are even better than your bank investment. 

Let’s do some simple math!

In India, the average rate of return on a fixed deposit across banks these days is 6%. The figure is obviously subject to changes in government policies from time to time, depending upon a number of macroeconomic factors. However, if you were to deposit an amount of Rs. 100,000 in a fixed deposit today, you would receive somewhere around Rs. 511 per month summing up to Rs. 6136 per year.

Now if you invest the same Rs. 100,000 in a solar plant, it will produce electricity of around 8 units per day at a place with adequate sunlight. The prevalent rate of electricity in India is Rs. 6 per unit (this is a very modest estimation as the rates are always growing by the day). This means you produce electricity worth Rs. 48 (8×6) per day and Rs. 1440 (48×30) per month. The total worth of electricity you will produce in a full year would be Rs. 17,520 (48×365). Solar power returns, therefore, are almost thrice the amount you will be receiving as interest on a fixed deposit of the exact same amount!

Solar means independence

Energy dependence is a major issue in our society and even politics today. Energy is basically the very lifeblood of our modern economy. With growing research & development in the field of solar power, we could have a unique opportunity to rid ourselves of our dependence on fossils and other conventional sources of energy. Solar being a perpetual source of energy, especially in a tropical country like India, energy independence won’t be such a far-fetched dream after all, if we are able to make the most of this abundant source. This also entails a lot of benefits for not just human societies but also the environment at large. Quite clearly, solar power is on many levels the fuel for the future!
For further information on solar payback or solar O&M, feel free to call us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is one of the top solar companies in Mumbai. It is an ISO 9001:2015 certified company with a rich industry experience of 72 years.

Industrial Air Compressor Preventative Maintenance

Air Compressor Maintenance

Maintenance of equipment is necessary to ensure longevity and energy efficiency. This applies to air compressors that are used daily in an industrial setting. In this blog, we take you through some of the pressing issues with regard to the preventative maintenance of your industrial compressors.

Difference between preventative and standard air compressor maintenance

In an industrial setting, it is necessary to have an inspection regime in place to make sure your compressor and its allied equipment are functioning at the optimum level. This set of checklists or procedures is known as standard maintenance. 

Preventative maintenance on the other hand is all about finding and arresting mechanical issues before they spread and cause costly downtime. The schedule of preventative maintenance varies from component to component. While some may require daily inspections, others can be checked once or twice a year.

Benefits of preventative maintenance for industrial air compressors

  1. Avoids downtime: Downtime for any production facility can be costly for business and with preventative maintenance, this can be avoided to a great extent.
  2. Saves costs: Sudden breakdown of systems can cost more as compared to regular preventive checks.
  3. Ensures energy efficiency: Preventative maintenance brings to the surface any gaps or issues behind the sub-optimal level performance of the air compressor.
  4. Increases longevity: With regular check-ups, fine-tuning, and cleanups, an air compressor system can be kept in good health. This helps avoid fatal faults or wear and tear in the system and increases its life span.

Recommended preventative maintenance checks

  1. Oil filter: Oil must not be allowed to leave with the compressed air as it can corrupt the surface if the compressor is being used for spray painting. Oil filters must be checked weekly and replaced after every 4000-8000 hours of use. 
  1. Lubrication: Change the lubricant every 3 to 6 months to ensure the health of the compressor. Non-lubricated surfaces of the system could cause serious corrosion of moving parts.
  2. Air filter: Check, clean, and replace the air filter regularly. You do not want unclean air or air laden with particulates to come out of the compressor and hit a surface being spray-painted or cleaned with the compressor.
  3. Motor bearings: Make sure the bearings are sufficiently lubricated. Carry out regular inspections and check the bearings after every 4000 hours. Lack of lubrication can cause the bearings to get stuck in place.
  4. Intake vents: The air entering the vents can become dirty if the intake vents are lined with dirt, dust, and grime. The same air will then be released in compressed form.
  5. Belts: Belts must remain firm to ensure the proper functioning of the pulleys and connected parts. Replace the belts before they lose their tension or break down in the middle of a task.

Which maintenance checks should a technician perform

While some maintenance tasks can be performed in-house by your own team, for others, it is best you consult the compressor technicians. Some of these situations are

  • Replacement of motor
  • Relocation of heavy compressors
  • Safety shutdown instructions
  • In case of a mechanical breakdown

For operation and maintenance tasks of your air compressors by our skilled and qualified technicians, get in touch with us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the authorised Elgi air compressor dealer with an experience of over 72 years.

How to Use an Air Compressor: Things to Consider

How to Use an Air Compressor

A number of things need to be considered while using an air compressor for your operations. These include maintaining the right parameters like pressure, checking oil levels, having safety measures in place, etc. In this blog, we take you through all these aspects in detail.

Picking the right compressor for your needs

For domestic purposes, the most commonly used air compressor is the reciprocating piston type. This works by reducing the space to increase the pressure of the air inside the compressor. This is quite similar to the working of an internal combustion engine. 

For industrial purposes such as large refrigeration or pneumatic tools, rotary screw air compressors are mostly used. These work by compressing the air inside in a continuous sweeping motion, thus avoiding any pulsations that may occur in a reciprocating piston-type compressor. 

Getting started

  • Place your compressor in the right position. Ensure that the compressor is on an even and stable surface and the power source is always grounded. 
  • Turn the power on and allow your compressor to run for a minute. 
  • Set the psi as per your requirements. Adjust the pressure till you reach the recommended pressure for a particular tool. 
  • Connect the air hose and the tool you’re going to be working with. 

Oil and air intake

  • Check the level of oil in your compressor. Add oil by removing the cap and filling up to the mark if required.
  • Check the drain valve located at the bottom of the air tank. Make sure it is tightly closed.

Moisture and drainage

It is necessary to remove excess moisture from your air compressor at frequent intervals. This is usually done through the drain valve present at the bottom of the air tank. Wrench open the valve, allow the condensed moisture to flow out, and replace the valve. Always store the air compressor in a cabinet away from moisture.

Power

Make sure you turn off the compressor’s switch before you plug it into a three-pronged socket. As much as possible, avoid using extension cords if you’re unable to reach the spot of operations comfortably. Instead use an additional air hose and plug it into the first one. Extension cords can cause overheating of the air compressor. 

Meeting all safety regulations

  • Always use polycarbonate goggles and closed-toe shoes while operating the air compressor. 
  • Pull on the safety valve to test if it works.
  • Ensure you are only applying the right amount of pressure for a particular operation and as per the requirements of a particular tool. Try to maintain the pressure on a slightly lower side for safety.
  • Only operate the tool while there is air in the tank.

For more tips or information on how to best use your air compressor systems, feel free to get in touch with us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the authorised Elgi compressor dealer with an experience of over 72 years.

What is The Difference Between PSI and CFM in an Air Compressor?

If you’re looking for the right air compressor for your business, and are researching on the specifications of the product, you must have come across acronyms like PSI and CFM. These are necessary to tell you which size of air compressors are fit for your needs. Both these parameters are performance indicators of air compressors and other air-powered equipment. The main difference between PSI and CFM is that the former measures pressure and the volume of the latter measure. In this blog, we take you through a detailed understanding of both these metrics.

What is PSI?

PSI stands for pounds per square inch. Quite clearly it measures how many pounds of air occupies a square inch area. The greater the PSI value of a compressor, the greater pressure it is exerting and hence the more powerful it is considered to be. Quite simply, an air compressor with a PSI reading of 120 would indicate that it delivers 120 pounds of pressure per square inch. On an industrial compressor, the PSI value is typically displayed within the compressor system. As a convention ‘PSI’ is written in small letters. 

What is CFM?

CFM stands for cubic feet per minute. This indicates the volume or output rate of the air compressor in terms of cubic feet of air per minute. Simply put, it indicates how much air is being moved per minute. CFM is always measured at a particular PSI and increases proportionately along with the horsepower applied. Domestic compressors typically offer a volume of around 2 CFM while large industrial compressors that usually run at 200 HP, can deliver up to 1000 CFM of airflow. 

How are pressure and flow related in an air compressor?

To run an air compressor optimally, both volume and pressure must be sufficient. The principle isn’t very different from that of a garden pipe. When you squeeze the end of the pipe with your thumb, you are in effect reducing the space and creating less room for it to flow out. This will make the water shoot out farther. In air compressors, PSI and CFM relate to each other in a similar way. 

For the purpose of mathematical calculations, the relationship of pressure with volume in a compressed system can be demonstrated by Boyle’s law which states that:

P1 x V1 = P2 x V2

(P1 and V1 represent initial pressure and volume, and P2 and V2 represent final pressure and volume.)

The risks of over-pressurisation

Many times, users may over-pressurise the air compressors to ensure enough pressure is applied for a given task. This could pile up irrecoverable costs of energy losses since an increase in PSI value invariably increases the energy consumed. It can also reduce the lifespan of your equipment as the ‘artificial demand’ (another term for over-pressurisation) can cause unnecessary wear and tear.
For any questions regarding flow rates or accurate pressure levels for your air compressor systems, feel free to get in touch with us at 022 43436655 or email us at marketing@vemc.co.in. VEMC is the authorised dealer of Elgi air compressors with a rich industry experience of over 72 years.

Pump Energy Audit Leads to Substantial Savings

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?

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.