Author: vemcoblogs

Industrial Air Compressor Preventative Maintenance

by vemcoblogs -
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

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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?

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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

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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?

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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

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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

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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

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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

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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

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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

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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.

Debunking myths about compressed air systems

by vemcoblogs -

A lot misperceptions continue to prevail around the functioning of air compressor systems. Whether it is about their safety or the tasks that can or cannot be accomplished with them, myths around their use galore!

In this blog we debunk 7 of these major myths.

Myth #1: Compressed air can be used for cleaning dust and dirt from work spaces.

There is a fundamental difference between your domestic vacuum cleaner and an air compressor. The former sucks in air while the latter pushes compressed air with great pressure and speed. Quite clearly therefore, using compressed air for cleaning an office space will only result in dispersing the dust or waste particles wider across the floor, rather than being sucked in and vanishing into the compressor system.

A pneumatic tool operated using air compressors could in fact accelerate the debris particles and shoot them into people’s eyes causing severe injuries. Besides the particles could also land in vents, outlets and machinery causing blockage or damage.

Myth #2: To make the best of part–load performance, the most optimal solution is a variable–speed drive.

While it may make for a great sales pitch, air compressors cannot really be adjusted to suit different operations simply by changing their speed.Variable-speed air compressors are not really helpful across a wide range of applications.

Myth #3: Oil carryover is accelerated in variable speed drives.

In reality, speed drive has no impact on the rate of oil carryover. It is only aided by two factors, that is, heat and low pressure. In fact, lowering the air flow makes things more efficient by reducing the speed in the separator.

Myth #4: Flow controllers are unnecessary on air compressors with variable–speed drives.

Flow controllers enable most systems to offer their best possible performance simply by providing greater stability and pressure consistency. Flow controllers can even be beneficial in systems with VSD’s as they can help optimise their performance.

Myth #5: Synthetic air compressor fluids are all identical.

None of the synthetic air compressors are made of a hydrocarbon base. However, that’s where their commonality ends. These fluids otherwise vary drastically in terms of how they impact the performance of the compressors. Air compressor fluids are usually made of the PAO and PAG base stocks and each could have a unique effect on an air compressor system.

Myth #6: Aftermarket replacement parts are just as good as original parts sold by the manufacturer.

Original manufacturers design replacement parts keeping in mind the nuances of design and performance of your system. On the other hand, buying generic parts from an aftermarket manufacturer could impact efficiency, longevity and safety of the system. It is highly recommended to buy replacement parts from the original manufacturer only.

Myth #7: Compressed air is generally impure.

As opposed to common perception, compressed air is highly clean. In case there are any impurities, these exist due to poor maintenance, dirt in the ambient air or dirty system tubes and tanks.

VEMC is an ISO 9001:2015 certified company with more than 72 years of industry experience. We provide best-in-class solutions and customized support and are the authorised dealers of Elgi air compressors. Contact us at +919819907445 and allow us to help you determine the right air compressor for your needs.

Renewable Energy vs. Nonrenewable Energy – The Key Differences

by vemcoblogs -

One of the most widely discussed topics today on news media and social media is climate change, and how we ought to reduce our impact on the environment. We mostly hear experts advocate the use of renewable over non-renewable energy which release less or no emissions. In this blog, let’s try to understand the main differences between renewable and non-renewable energy sources.

What are renewable and non-renewable sources of energy?

A renewable source of energy is available to us infinitely. It replenishes itself naturally without any human intervention. This energy comes from natural sources such as sun, wind, water and organic matter.

On the other hand, non-renewable sources of energy are available in limited amounts. Once consumed, these cannot get replenished at all, or get replenished over a very long geological timeframe, in effect making them unavailable for repeated human use. Most of these are fossils such as coal, petroleum and natural gas.

Difference between renewable and non-renewable energy

  • Non-renewable energy sources such as fossil fuels are created over millions of years under the surface of the earth or the ocean bed. But our rate of consuming this energy source is so fast that we could run out of them within a generation or two. Renewable energy comes from those sources of energy which cannot be exhausted even after repeated human use.
  • Non-renewable energy has a negative impact on the environment. Burning fossils leads to emission of carbon-dioxide resulting in the rise of global temperatures and subsequent environmental issues. Renewable energy is easy on the environment as it does not release any harmful gases or substances. On the contrary, by shifting towards renewable energy like wind, solar and tidal, and reducing the reliance on non-renewable fossils, we can slow down climate change and make a decisive move towards sustainable development.
  • Renewable energy has a high upfront cost. This is because the technology used in generating renewable energy like solar and geothermal power is still in its incipient form. With increase in research and development, and manufacturing of equipment in greater volumes in the future, the costs are expected to come down. On the other hand, non-renewable energy sources are comparatively inexpensive in terms of the upfront costs.
  • Infrastructure for renewable energy like solar or wind is not easily accessible especially in developing countries like India. These technologies usually require vast open areas like fields or building terraces to generate useful amount of energy. Such vast spaces and enormous number of panels may not be very economical for developing nations. On the other hand, non-renewable energy is lower on infrastructure costs or area requirements, and can therefore be utilised throughout the world with equity.

As a leading solar EPC company in Mumbai, VEMC has unmatched expertise in the field of electromechanical engineering products, allied equipment, and services. Whether it is solar panel installation, procurement, commissioning, net metering, or electrical connections, we are the leaders in solar solutions. For installation and support, reach out to us at 022 43436655 or mail us at marketing@vemc.co.in. We’ll be glad to offer you our customized support and services.

Keep Your Fire Pumps Ready for Action with Regular Inspection and Testing

by vemcoblogs -

Fire pumps come into use in the most dire of situations, that is, when a building or apartment is on fire. They form a highly critical component of your sprinkler systems. As soon as pressure drops on activation of sprinklers, fire fighting pumps are required to maintain the pressure and keep the water flowing. Building owners expect fire pumps to spring into action as soon as fire is detected so that minimum possible damage is incurred. This can only be ensured with regular checks and inspections.

Weekly Inspection & Testing Requirements

A weekly inspection and testing regime is must for both diesel and electrical fire pumps. In case of electrical pumps, this must also include the visual inspection of the pump house and the electrical system powering your pump.

With regard to the pump house, the main thing you need to look for is the temperature. The minimum temperature for both electrical and diesel pumps (with engine heaters) has to be 40 degree F. For diesel pumps without an engine heater, it has to be at least 70 degree F. Use an engine jacket water heater if you are unable to maintain the temperature. Other things to check while inspecting the pump house is whether there is any water pooling on the floor, and whether all the ventilating louvres are functional.

Inspection and testing requirements for the pump and its electrical system

As per the NFPA 25 standard, one of the most important tests for fire pumps is the weekly no-flow or “churn” test. Electric pumps must be run in a no-flow condition for a minimum of 10 minutes and diesel pumps for 30 minutes. In this test, the flow should not exceed 140% of the rated pressure. In case the risk analysis of a pump requires, this test can also be conducted more or less frequently than a week.

Apart from the churn test, some additional weekly tests to be conducted are listed below:

For electrical fire pumps:

  • Ensure the pump suction, discharge and bypass valves are fully open.
  • Look for any signs of leaks in the piping.
  • Check pressure to make sure the suction line pressure is within the acceptable range.
  • Make sure the water inside the suction reservoir is at the proper level.
  • Check if the wet pit suction screens are in place and unobstructed.
  • Make sure the water-flow test valves and hose connection valves are closed.
  • Ensure that the coupling guard is in place.

For diesel fire pumps:

  • Refill the tank if it is lower than two-thirds full.
  • Make sure the controller selector switch is in auto position.
  • Make sure the valve in the fuel supply lines from tank to driver filter or pump system is locked in open position.
  • Ensure all the alarm pilot lights are off.
  • Check if the water-jacket heater is functional.

VEMC is an authorised Kirloskar fire fighting pump dealer and also offers AMC services for pumps. With our thorough experience and unmatched expertise, we resolve diverse issues related to motors, engines and pumps. Feel free to give us a call on 022 43436655 or email us at marketing@vemc.co.in.

Have you got the right remote monitoring system for your pumps?

by vemcoblogs -

Having a remote monitoring system for your pumps enables you to keep tabs on various parameters that impact their performance and longevity. These factors include temperature, pressure, power fluctuations, etc. These are also important when it comes to preventive maintenance of the pump. A sudden spurt or drop in a metric may indicate some issue with the pump that warrants your attention. 

An incredible remote monitoring system that can effectively perform all these functions for you is Kirlosmart. Let’s find out what it is and how it makes your life simpler!

What is Kirlosmart?

Kirlosmart is an IoT-based product that helps you monitor the various parameters of your pump remotely, thus turning your conventional pump into a smart pump. These parameters include flow, pressure, vibration, voltage, current, energy consumption etc. Any erratic reading of these metrics may suggest a technical snag or sub-optimal performance of the pump. 

Why go for Kirlosmart?

Apart from the core benefit stated above, Kirlosmart helps convert ordinary pumps into IoT pumps by providing certain additional and allied benefits.

  • Apart from monitoring and analysing faults, it also provides suggestions for tentative actions to be taken if or when these faults arise.
  • It also send SMS or e-mails to the owner with all the relevant data on daily basis. This is crucial to analyse the performance of the pump over a longer time horizon.
  • By monitoring data continuously, it also bolsters your efforts towards predictive and preventive maintenance.

What makes kirlosmart an intelligent RMS?

Kirlosmart represents state-of-the-art technological innovation. It combines the benefits of robust pumping performance and the excellence of Information Technology. All in all, Kirlosmart is the most intelligent remote monitoring system you can come across.

  • It enables you to monitor your pump performance from anywhere.
  • It is the only product that has in-built ethernet and GPRS facility.
  • It allows you to monitor the performance of your pump live on your smartphone.
  • It gives timely information about wear and tear of spare parts, and notifies which ones are due for replacement.
  • The product also includes an in-built field sensor and a web portal.

How does it provide benefits to the customer?

The above given features are a clear evidence of the cutting-edge technology that Kirlosmart represents. The product was a big hit among customers during the pandemic when they could only monitor their pumps locked up from their apartments. 

But even in the post-pandemic world, Kirlosmart is proving immense convenience to customers who cannot afford to physically check in on their pump health every now and then, whether due to hectic work schedules or travelling away for work. 

By acting as an early warning system for imminent defects, it enables the customer to keep an authorised technician in loop for changes in spare parts or other maintenance work, thus reducing any prolonged downtime.

Kirlosmart is an absolute necessity for modern pumps. VEMC, an ISO 9001:2015 company is an authorised Kirloskar dealer that can help you find the best match based on your pumping needs. Feel free to call us on 022 43436655 or email us at marketing@vemc.co.in.

What is pump cavitation? How to get rid of it

by vemcoblogs -
What is pump cavitation?

Cavitation is one of the most common issues in centrifugal pumps. Often this surfaces as strange noise, vibration and reduced performance of the pump. Prevention of cavitation is necessary as this may otherwise impact the lifespan of the pump. But before talking about the ways to prevent it, let’s understand what cavitation really is.

What is cavitation?

Cavitation is simply the accumulation of bubbles around the pump impeller. Bubbles are formed in liquids of any viscosity and when these burst inside the pump, high energy shock waves are created inside the pump. This is analogous to the ripples created in a pond when you throw a stone into it. However, with the enormous number of bubbles exploding inside the liquid, cavitation can cause serious erosion of pump components over time.

How does pump cavitation occur?

When the pressure quickly drops below the vapour pressure, bubbles or voids are formed inside the liquid. When the same bubbles experience high pressure, they collapse and create small shockwaves in the process. These shockwaves create tiny holes in the pump components over a period of time. This is called “pitting”.

How to prevent pump cavitation

1. You can prevent pump cavitation most effectively by increasing the pressure upstream from the pump’s impeller. This pressure is called Net Positive Suction Head (NPSH). NPSH can be increased in the following ways:

  • By increasing the water level of the upstream reservoir
  • By adding an inducer to the pump inlet
  • By reducing the flow losses upstream
  • By operating the pump at lower flow rates

2. Even the smallest amount of air going into the pump can cause cavitation. Check and make sure all the joints and connections are sealed perfectly well. Check all the O-rings and any other mechanical seals regularly. Cavitation can also be caused by the bubbles created by a foaming liquid. In such a case, run the pump slower and remove all the contents periodically, including air.

3. Use a booster pump to reduce the pressure on your primary pump. Increase the liquid level around the suction area and if possible, reduce the temperature of the pump, liquid or other components.

Types of cavitation

Let’s try to understand two of the most common types of cavitation, that is, suction cavitation and discharge cavitation.

1. Suction cavitation

Also known as classical cavitation, this happens when the pump is under low pressure or high vacuum conditions. Pressure is dropped instantly when the liquid being pumped enters the eye of a centrifugal pump. Bubbles or cavities are formed near the eye of the impeller which gradually move to areas of higher pressure.

2. Discharge cavitation

This happens when a pump discharge pressure is extremely high or the flow is restricted and cannot leave the pump. This results in majority of the pump fluid getting circulated within the pump. The bursting of bubbles creates intense shockwaves, resulting in premature wear and tear of the impeller.

VEMC is a Kirloskar authorised dealer and deals in swimming pool pumps, submersible sewage pumps, vertical turbine pumps etc. We also offer AMC services for pumps and resolve technical issues. Avail our services by giving us a call on 022 43436655 or email us at marketing@vemc.co.in.

Why powering your industry with solar energy will be the best investment decision you can make?

by vemcoblogs -

As we reduce our reliance on fossil fuels and other conventional sources of energy, solar energy is emerging as a leading renewable source. India being a tropical country has enormous potential to tap solar energy. According to the Ministry of New and Renewable Energy, India receives a total of 5000 trillion kwH per year and most parts receive 4-7 kwH per square meter per day.

This can contribute significantly to most sectors of our economy, and a diverse range of industries can benefit from it.

Here are 9 reasons why solar energy can be your best ever investment decision.

1. Reduced electricity bills

You can reduce or completely remove your dependence on the power grid by switching to solar. This can be all the more beneficial in the wake of fluctuating power tariffs and will entail healthy savings for your business. 

2. Renewable energy

Solar being a renewable source of energy, your business will be doing its bit to remove the pressure from non-renewable conventional sources of energy like coal and petroleum. 

3. Increased value of energy-efficiency

The efficiency of solar panels at present is about 15-20% but it can go significantly higher upto 42% in some cases. Overall, with the improvement in the material of the PV panels, and greater research and development, solar energy is bound to become more efficient every passing year.

4. Reduced Carbon emissions

By reducing your reliance on fossils, solar allows you to become an eco-friendly business. This is becoming increasingly crucial not just for the planet but for your own company as well. It will enable you to save on some critical carbon tax going forward and also meet your CSR goals effectively.

5. Easier monitoring of your ROI

After investing in a solar power system, you would want to ensure it is working optimally and getting you healthy returns. Monitoring the output of your solar panels is very easy. A number of companies are already providing services to analyse data related to your solar energy supply and also point out any discrepancies or slack in performance. 

6. Low maintenance costs

Solar panels are by and large a one-time investment. These are hassle-free installations made from durable materials with a life-span of around 25 years and very low maintenance costs.

7. Self-consumption of electricity

The electricity generated by solar panels is utilised on site which keeps the transmission losses at a bare minimum, and reduces or excludes the dependence on the utility grid.

8. Company image

As consumers are becoming increasingly conscious about climate change, they are preferring brands known for having the least impact on the environment. Switching to solar will be an evidence of your commitment towards reducing emissions, making you a favourite among eco-conscious consumers.

9. Stay ahead of the game

Lastly, survival of businesses depends upon how quickly they are able to adapt to changing times and reinvent themselves. By phasing the conventional energy out, and adopting the energy of the future, you can stay ahead in your industry and beyond!

VEMC is a leading solar EPC company in Mumbai and has unmatched technical expertise in the field of solar O&M. For installation and support, call at 022 43436655 or mail us at marketing@vemc.co.in. 

Success Story : The Supply & Commissioning of Horizontal Split Case Pumps & Valves at BARC

by vemcoblogs -

A case study on how we powered the New Mandala water pump house at Bhabha Atomic Research Center (BARC) Anushakti Nagar, Mumbai with our domestic pumpsets including foot valves and accessories.

In 2020, VEMC won the tender to supply equipment and construct a pump house at BARC located in a suburban Mumbai locality called New Mandala, Anushakti Nagar. The purpose of this pump house was to transfer fresh water to the campus at a faster rate. It was a project worth over Rs. 11 lakh and was carried out between July and November 2020. The scope for VEMC was supplying Horizontal Split Case (HSC) pumpsets, valves, foundations, suction and delivery pipeline.

Carrying out the project successfully required tackling each of the administrative, technical and logistical challenges effectively. We started off by taking the requisite permissions from BARC officials and submitting all the relevant documents like medical certificates for fitness and ID proofs of the personnel. Soon after this we got all the construction material supplied to the site to begin the construction on time. Finally, the pump foundation was constructed as per the established BARC guidelines. At each and every step, the progress and quality of the work was inspected by the BARC officials. At our own end, we made sure that each installation was tested minutely for all the functions to leave no room for any technical issues later.

However, the project offered its fair share of formidable hurdles and roadblocks. For instance, the space available for the construction of the pump house was inadequate. We initially decided to overcome this problem by skipping the foundation work altogether which would have enabled us to lay the suction and delivery pipeline. But then we thought against this alternative and instead decided to puncture the wall for laying suction and delivery pipeline. Although the BARC officials were unwilling to proceed with this alternative, we eventually persuaded them and were able to execute it successfully. Apart from this, the foot valve had to be installed at a depth of around 18 feet below the surface which turned out to be rather challenging for the technicians. We also had to carry out core cutting of the water tank for successful installation of the suction line.

Nearly all of these issues required specialised knowledge and skill to handle. Hence we did not shy away from hiring the services of skilled experts to meet these formidable challenges, even at the cost of some extra funds. To ensure the safety of our staff and technicians throughout the project, they were provided with hand gloves and safety shoes for every task.

The project was not just a commercial undertaking for the team but also a great learning experience. The key takeaway was right planning followed by careful execution. Planning tools like bar charts came in handy and helped execute the project smoothly. Thanks to this pump house project, the BARC has realised some substantial benefits, most important of which is saving time and effort that was earlier dedicated to storing water in the tanks.

For more information on any of our other products, feel free to contact us on +91 98199 07445. We will do our best to introduce the right solution based on your requirements. As one of the leading valve dealers of the country, VEMC provides unmatched piping and supply service to its clients. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.