Author: vemcoblogs

A Short Guide to Moisture Control in Air Compressor Systems

by vemcoblogs -

It’s not uncommon for moisture and condensation to accumulate in your compressed air systems. Hence, you need a solution that can help prevent excess condensation in your compressor, especially if you’re in an industry that demands 100% moisture-free condensed air.

Why does your air compressor contain moisture?

Moisture is a natural by-product of the compression process. It just extracts the moisture that already exists in the ambient air.

Some of the common causes of moisture build-up in compressors are:

  • Equipment damage – When the internal parts of compressors wear out, it leads to moisture build-up. This causes the machine to lose its power to extract air as well as heat up, leading to more moisture build-up.
  • Environmental factors – Humid conditions also cause the machine to take in more moisture leading to more condensation.
  • Pressure on the compressor – When your compressor is strained beyond capacity, it gets heated up further more. This is especially the case with piston compressors, which heat up more when used for longer periods of time.

Why is excess moisture harmful?

Excess moisture hampers the workings of your air compressor. Some of the consequences of excess moisture are:

  • Rust and corrosion – Build-up of water in your compressors can lead to rust in and corrosion of the machine and pipes.
  • Damage to pneumatic controls – The machines that rely on pneumatic controls suffer from severe damage when there is moisture build-up inside them. That can result in rust and scale build-up.
  • Rapid wear and tear of production equipment – Moisture can cause the lubrication inside compressors to wash away. This causes metal components to wear away faster.
  • Damaged circuits and in-line filters – In-line filters help clean particles and oil from your compressor. Moisture increases pressure in the machine and reduces the filter’s efficiency.
  • Contamination – Moisture can damage end products, valves, and motors. It can easily contaminate solvents, lubricants, and food products.

How to eliminate excess moisture from your compressor?

Some of the solutions you can try out to remove moisture build-up from your compressors are:

  • Install an air dryer – An air dryer works in tandem with an air compressor to remove moisture. There are four common types of air dryers: refrigerated dryers, desiccant dryers, membrane dryers, and deliquescent dryers.
  • Get a piping system – Piping systems are one of the most cost-efficient systems. In these setups, the metal pipes absorb heat to bring down the air temperature, and can be a good solution for office buildings.

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 customized support in this field. We also provide a number of ELGi air compressors. Contact us at +919819907445 and we would be happy to help you determine the right air compressor for your needs.

A GenNext Technology In The Pump Industry – KirloSmart

by vemcoblogs -

Kirloskar Brothers (KBL) is one of the leading pump manufacturing companies in India. Based out of Pune, they have years of experience in engineering and fluid management systems. They have recently launched an advanced version of its signature Internet of Things (IoT)-based pump monitoring system – KirloSmart.

Master Associate | Blog

KBL was the first company to launch this innovative solution in 2016 in India after testing it inhouse, at the Kirloskarvadi factory in 2010. With this launch, KBL lives up to its expectation of engineering excellence and inventing technology to improve customer satisfaction.

What is KirloSmart?

KirloSmart is an IoT product with a specialized capability of remotely monitoring pumps through Kirloskar Brother’s web portal, triggering alerts when the pumps are not showing problems.

KirloSmart merges hardware and software technology to enable the user to remotely monitor and troubleshoot pumps on a real-time basis with zero manual intervention. It helps predict and come up with corrective measures to prevent unnecessary breakdowns and ensure that the pump is healthy enough to offer optimum performance. This works by transmitting the analytical field parameters of the pump on the KBL web-based portal and interactive mobile app. These cloud services are completely SOC (System and Organization Controls) compliant.

Unique features of KirloSmart

Some of the advantages of the KirloSmart system are:

  1. Predictive maintenance alerts with probable causes through email and SMS
  2. 24×7 real-time monitoring, historical data and trend monitoring, and graphical indications
  3. Remote diagnosis of the issues at the earliest stages
  4. Pump spares management such as estimation of service life
  5. Backup storage in case of communication failure
  6. User configurable sensors
  7. Communication mode selection such as mobile data, GPRS, and ethernet
  8. Cost-effective, simple plug and play
  9. Facilitates easy integration with existing integrations

Benefits of KirloSmart

The benefits of using KirloSmart for your commercial space are:

  • Boosts profitability by reducing operational costs, repair costs, and labour costs
  • Reduces chances of unplanned breakdowns and improves plant safety and reliability
  • Boosts lifespan of equipment and reduces down time
  • Eliminates costs of assets such as servers, modems, and computers
  • Boosts equipment productivity and efficiency

IoT based pump monitoring solution

With the help of IoT technology, KirloSmart generates alerts for the possible causes of pump failures through built-in analytics and spare management modules. This helps pump owners monitor pump health and measure the critical health parameters of the pump. It also helps them in prompt diagnosis and resolution of issues. The system can also send alerts and notifications through SMS, email, and push notifications.

VEMC supplies KirloSmart to IIT Powai

IIT Powai wanted to monitor the performance of their pumpset installed for freshwater application. For this, VEMC was to employ a person daily.

However, by introducing KirloSmart, VEMC was able to monitor the performance of the pumpset without any human intervention.

The benefits achieved as a result were long-term and involved reduction in manpower requirement and replacement with IoT-based machine.

For further information on IoT and smart pumps, motors, and other equipment, feel free to contact us at +919819907445. KBL is a pioneer in remote pump monitoring technology and we would be happy to assist you in finding the best match based on your requirements. VEMC is an authorized KirloSmart dealer. It is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

6 Air Compressor Maintenance Tips to Avoid Breakdown

by vemcoblogs -

Air compressors of all makes and models require varying degrees of maintenance. Whatever the model or quantity of compressors you use for your operations, it’s essential to regularly inspect the parts and service them, whenever necessary. Failure to perform routine maintenance on your compressors can lead to early failure or expensive repairs.

Air Compressor Supplier Johor Bahru (JB), Rotary Screw Compressor Supply Malaysia, Air Receiver Tank Suppplies ~ JCompressor Services Sdn Bhd

Here’s a short guide on how to keep your air compressors running at full capacity:

1. Drain your air receiver tank

Use the drain and plug at the bottom of the compressor to drain the air from the compressor’s air receiver tank. Collection of air in the machine leads to the accumulation of water and moisture while the machine is running, especially during summer, when humidity is higher. The moisture gets collected in the receiver tank and if not drained regularly, it can lead to corrosion of the receiver tank and piping. An automatic and a manual bypass drain during daily inspections is ideal.

2. Inspect the hoses

Hoses are often the most vulnerable parts of compressors because they need to be strong enough to transfer air between the machine and the final point, which can put a lot of strain on them. Checking your hoses on a weekly basis is extremely important. Cold weather also affects hoses — it causes them to crack or corrode and hence leak. Routine checks are ideal for keeping the hoses clean and leak detection devices are ideal to find the leaks.

3. Alter the air filter

Air filters usually trap a lot of junk. The filters are designed to bear a heavy load, without which, a lot of impurities will accumulate and degrade the performance of the compressor. This contamination is critical for industries such as food and beverage, hospitals, and labs. Air filter inspections should be done regularly, especially in dusty conditions.

4. Clean the intake valves

The intake valves of an air compressor must be clean to function fully. When compressors are put to constant use, dust particles and other elements get sucked into the vents. Cleaning the vents at least once every three months is essential.

5. Change the oil

The compressors that run on oil need the oil to be changed regularly as well. Fresh oil helps run the various parts of the engine smoothly. Especially in humid conditions, the oil loses its viscosity and fails to lubricate the different parts.

6. Get it inspected by a professional service team

Allowing a professional service team to regularly check leaks and perform preventive maintenance and required repairs, can offer a lot of peace of mind. Scheduling this regular maintenance can help save time and money in unnecessary breakdown repairs.

Keeping your air compressors healthy and functioning smoothly is essential and possible through regular maintenance. VEMC is an authorized ELGi air compressor dealer and provides end-to-end solutions for all your industrial energy requirements. Guided by more than 72 years of industry expertise, we aim to offer you specialized support in this space. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. Please feel free to contact us at +91 98199 07445, and we will be happy to assist you.

Success Story: The Installation of Vertical NK Pump sets at MCGM Mahim Pumping Station

by vemcoblogs -

This project was carried out at the sewage pumping station on Swami Vivekananda Road in Mahim, Mumbai. VEMC, a leading dealer of industrial water pumps in Mumbai, was proud to have bagged and worked on the project.

Pumping station | Egger Pumps

Nature of the Project

VEMC supplied vertical NK pump sets and valves to the MCGM Mahim Pumping Station. It also took over the successful supply, installation, testing, and commissioning of pump sets and associated valves.

Execution

The execution of this project happened in 4 stages:

  1. Procurement of material from KBL and Jyoti
  2. Pre-dispatch inspection of the motor in Gujarat, pumpset at KOV, and valves at Nashik in the presence of MCGM officials
  3. Dispatch of materials to the site
  4. Installation, testing, and commissioning of the installed system

Challenges Faced During the Project

The VEMC team faced quite a few roadblocks during the project:

  • The unloading phase was challenging. The unloading of material at the site was a bit difficult due to inadequate space for hydra. Moreover, the location was a high-traffic road and hence, a lot of intervention from the traffic police was required.
  • The installation location was 70 ft below the surface level. Hence, transporting the materials i.e., the pump and motors, to the location was not very easy.
  • Installation of valves in the existing pipelines because they were completely corroded.
  • Fabrication of duck foot bend from pump suction to the valve in CIDF.
  • During the delivery stage, dismantling the joint connections seemed a bit difficult due to space constraint and fitting issues.

How VEMC Overcame the Roadblocks

VEMC took proactive steps to ensure that the execution went smoothly. Here are the ways in which we overcame the challenges:

  • Completed the unloading work at night to avoid traffic issues
  • Closed penstock gates every night during the installation of suction valves. This was carried out efficiently even though it was difficult since sewage water was blocking the valve path.

Safety Measures Taken During the Project

VEMC ensured that the entire execution happened in adherence to all safety measures. To this end, all team members were provided with safety hand gloves and shoes.

Takeaways

Some major takeaways from the project were:

  • Execution planning and how to align the execution with the bar chart/methodology
  • Time management to ensure the project was closed within the stipulated time

Outcome of the Project

With VEMC’s successful installation, the client experienced smoother operations as well as reduced maintenance needs and costs.

For more information on industrial pumps, motors, and other equipment, please contact us on +91 98199 07445. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services. For inquiries, contact us at marketing@vemc.co.in.

Why is it important to understand the difference between gauge and absolute pressure?

by vemcoblogs -
Difference Between Gauge and Absolute Pressure Measurement

Pumps and similar systems are built in a way so as to generate and retain pressure. In gas-based systems such as air compressors, the pressure is fairly low. This is because gasses when compressed incessantly makes air molecules huddle nearer to each other in the application of energy. This pressure doesn’t extend to the tubes or chambers of the compressed air systems.

In brief, pressure can be defined as a force acting over a certain area. It’s most commonly measured in pounds per square inch (psi).

There are multiple systems to measure pressure. Two of the most common ones are absolute and gauge pressure. There are quite a few differences between the two that have considerable impact on their use and measurement. Once the purpose behind measuring pressure is identified, the next step involves choosing which system to use: gauge or absolute pressure. This is a crucial decision since choosing the wrong system can severely impact the accuracy of measurements.

The pressure inside a compressed air system is comparatively lower. Hence, even minor deviations such as 10 psi or 20 psi can lead to major operational issues.

Here are the differences between the two systems in great detail:

Gauge Pressure

It’s one of the most commonly used systems of measurement and uses atmospheric pressure as its base value. So, any chamber will equalize based on the atmospheric pressure, when vented. This makes it easy for calculations and tests since the atmospheric pressure doesn’t have to be subtracted.

Also known as effective pressure, gauge pressure is signified by BARG or BARE and PSIG or PSIE.

Absolute Pressure

Comparatively, absolute pressure is used less frequently, since it signifies zero pressure or a perfect vacuum. A good example of the measurement of absolute pressure can be that of barometric pressure.

Absolute pressure is commonly signified by BARA and PSIA.

Choosing the right system: gauge or absolute pressure

The most fundamental difference between gauge and absolute pressure is that gauge pressure uses atmospheric pressure as its base or zero point whereas absolute pressure uses absolute zero as its base or zero point.

So, if the idea is to measure a type of pressure influenced by atmospheric pressure, it’s best to use a gauge pressure. It will help measure the pressure minus the atmospheric pressure. This is the system used to measure the output of pressure of air compressors.

Again, if the idea is to measure a type of pressure not influenced by atmospheric pressure, absolute pressure is used as a reference. An example of this can be leak testing a sealed container.

VEMC, an authorised Kirloskar pump dealer in Mumbai, supplies centrifugal and industrial water pumps that are ideal for both commercial and industrial operations. We provide the best end-to-end project management services to our clients. For more information on industrial pumps, motors, and other equipment, feel free to contact us at +91 98199 07445. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

What type of piping is needed for my compressed air system?

by vemcoblogs -

Compressed air systems find use in various industries such as construction, automotive, metal-work, and wood-work. Tools used in these industries require compressed air to run and since they don’t need motors, they are lightweight and handy to use.

Compressed air systems work best when air is released from the system at the right pressure, volume, and consistency. These systems can run the risk of miscalibration which robs them of their power and leads to rust and debris build-up in the pipes.

This makes choosing the right air compression system as well as its parts integral to their efficient functioning. Pipes are one of the most critical components in a compressed air system and defective and inefficient pipes can often lead to loss of power. Moreover, obstructions and blockages, moisture build-up, and sharp angles can also affect the pressure of compressed air systems negatively.

Paying proper attention to the size, layout, installation, and maintenance of pipes used in compressed air systems is a prerequisite to ensuring their powerful performance. Two materials usually go into making pipes: plastic and metal. Of these two, metal pipes are the preferred choice for compressed air systems.

Here are some of the common types of metal pipes used for compressed air systems along with things to consider when choosing them:

  • Black steel pipes are the most commonly used ones because they are strong and durable. However, it can be time-consuming to install them and they are also susceptible to corrosion. There’s also the risk of the threaded connections slipping and leaking.
  • Another widely used type is galvanised steel pipe. They help solve the corrosion problem. However, in some cases, the galvanised coating can come off and cause blockages in the air flow.
  • Copper pipes come with a lot of advantages. They are free from corrosion from condensation and are easy to cut and weld. They are lightweight and come with a wide range of fittings to choose from. Their smooth interior means that they can sustain solid laminar flow. However, they can be a bit expensive since they require time and skill to install, especially the threading and soldering bit.
  • Aluminium pipes can also be a good choice since they are lightweight, durable, and anti-corrosive. They’re also easy to install and maintain than other types. The only downside is that it can be as expensive as copper.
  • Stainless steel pipes are corrosion-free, both from the inside and outside. Moreover, they are easy to weld and press. However, they can be heavy and the material cost can be on the higher side.

VEMC, an authorised ELGi compressor dealer in Mumbai, supplies ELGi air and reciprocating compressors that are ideal for both commercial and industrial operations. Our range of screw and piston (reciprocating) compressors are cost-effective and long-lasting solutions for light-to-heavy-duty industrial applications. To know more about our range of compressed air systems and for help in choosing the right one, contact us on +91 98199 07445. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.

How often should I change the oil in my pump/piston?

by vemcoblogs -
How often should I change the oil in my pump/piston?

Air compressors need to be in optimum condition to give the best performance. Maintaining them properly ensures that they last long and help save money in the long run. There are several maintenance routines to consider for a smooth-functioning air compressor. One of the most important routines is changing the oil in the pump or piston of the air compressor. While focusing on other maintenance routines, many people overlook this one, which often leads to poor performance of the air compressors and, in some cases, also causes damage to the systems.

Why is it important to change the oil?

The oil in a compressor has several functions apart from lubrication. It helps the compressor parts to cool down so that the motor doesn’t overheat. The oil also acts as a sealing agent during the compression process.

If the compressor doesn’t have enough oil, it may not perform as efficiently as it’s supposed to. Low oil levels cause the compressor to overheat since air compression produces heat and oil absorbs the heat. Moreover, low oil levels also increase friction, which can lead the compressor to overheat. It’s also important to replace the contaminated oil from the air compressor regularly. Failing to replace the old oil with new oil causes debris and particles to build up and hampers its smooth functioning. Lack of sufficient oil can also increase the chances of rust, wear and tear, and corrosion. Finally, oil has a tendency to oxidise in the presence of water and heat. This reduces its effectiveness which can lead to costly breakdowns.

In some systems, overheating leads to an automatic shutdown. In such situations, the compressor can be used again only after it has cooled down and the oil has been replaced.

How often should the oil in an air compressor be changed?

Air compressors need consistent lubrication to prevent friction on the pumps or pistons and hence, the oil level must be checked regularly. The frequency of changing oil in compressors depends on the type of compressors used. Some compressors need more frequent changes than others and it’s best to consult the user manual that comes with the system. It’s possible to even find the life expectancy of some oils in terms of service hours in some of the manuals.

For rotary screw compressors, the oil should ideally be changed every 2000 hours or 12 months, whichever is earlier. For reciprocating air compressors, the oil needs to be changed every 3 months.

Performing an oil analysis that checks for important factors such as viscosity, particle count, water contamination, and total acid number (TAN) can help determine when to change the oil. It’s ideal to conduct an oil analysis every 500 to 2000 hours, depending on the user manual and the warranty.

VEMC, an authorised ELGi compressor dealer in Mumbai, supplies ELGi air and reciprocating compressors that are ideal for both commercial and industrial operations. Our range of screw and piston (reciprocating) compressors are cost-effective and offer long-lasting solutions for light-to-heavy-duty industrial applications. To know more about our range of compressed air systems and for help in choosing the right one, contact us on +91 98199 07445. VEMC is a 72-years-old young organization with ISO 9001:2015 certification and is CRISIL MSE-1 rated.

Solar Success Story: Successful installation of solar rooftop system for a commercial building

by vemcoblogs -
Solar Success Story

VEMC, a 72-year-old solar power company in India, has played an integral role in helping companies transition from electrical to solar energy. It has helped companies adopt smart solutions in solar power and taken over the end-to-end execution as well. In this blog, we take a look at how VEMC helped install solar rooftop systems and inverters on the industrial rooftop of Caravan Logipark Pvt. Ltd. and executed the project successfully. The site is located in Koproli, Uran, in the state of Maharashtra. The building authorities were looking to reduce their energy consumption and substitute it with a renewable source of energy.

Challenge

The main challenges arose during the excavation work for AC cabling. The first step was to trench the road where there was already a lot of vehicle movement. Next, the cable had to be placed and sand and bricks had to be filled on the top or bottom of the cable. During the final termination phase, the grid had to be shut and the connection terminated. However, there was cold storage which couldn’t be shut for more than 15 minutes; otherwise the food stored will get spoilt. There was also a dearth of continuous light and so, it was arranged source like DG for cold storage.

Our Solution

VEMC steered the success of this project with effective time, cost, quality, team, procurement, and communication management. One example of this was during the excavation work for AC cabling. The team took the smart decision of trenching half the road first and installing the cables, and then taking up the other half. This ensured that vehicle movement wasn’t hampered. Moreover, the team worked at a stretch during shut down and ensured the DG was loaded at the same time as the grid shut down.

Safety Measure During Execution

VEMC ensured the execution of the installation was done with all safety measures in mind. Some of the measures taken were:

  • Avoiding the use of mobiles or electronic devices during the installation
  • Using crane and forklift managed by trained experts for unloading of modules and limiting the speed to 10 km/hr
  • Constant training of installation staff to avoid any damage to modules
  • Thorough checking of cable for damage before the cable routing process
  • Limiting the speed of the boring machine within 10 km/hr during the earthing process
  • Use of cotton, PVC, and leather gloves while fixing electrodes, handling backfilling compound, and connecting the electrical panel
  • Use of welding goggles, face shields, and aprons during the welding system

Our post-installation feedback revealed that the client had savings of 4-5 lakh units of electricity monthly from this system.

VEMC is a well-established solar power plant company in India and a pioneer in the field of electromechanical engineering products, allied equipment and services. With decades of industry experience, VEMCO Solar was able to successfully execute the Prince Care Zinnia project and deliver superior-quality results. VEMCO Solar is a market leader in solar solutions — be it solar plant erection, procurement, commissioning, net metering, or electrical connections. If you have any requirements in this space, please feel free to contact us at +91 98199 07445. We would be happy to help you.

Understanding the Basics of Fire Pumps

by vemcoblogs -
Understanding the Basics of Fire Pumps

Fire pumps form an effective part of a building’s fire protection system. This is especially the case for high-rise buildings, for example, buildings that are 400-500 ft and higher. The role of a fire pump in these cases is to distribute water through sprinklers to areas that fire-fighting equipment can’t access. Fire pumps help make fire-fighting safer and more structured.

A fire pump is a critical part of a fire sprinkler system since it supplies high-pressure water to the sprinklers. These centrifugal pumps can be used both for transportable use such as on fire fighting vehicles or as portable fire pumps or for stationary use such as hydrants and sprinkler systems.

Types of Fire Pumps

Here are the various types of fire pumps typically used for fire-fighting:

1. Vertical MSMO Pump set

These pumps are mostly used for offices, hotels, and residential buildings as sprinkler and hydrant systems.

Some of the benefits of using these pump sets are:

  • Reduces the need for multiple pumps for different head requirements
  • Helps in saving on constructing separate pumphouses
  • Prevents water shortage on individual floors
  • Vertical structure offers better mechanical stability
  • Allows more building space to utilize for selling/renting etc.
  • Requires less pipe work and valves
  • Ring section type diffuser construction completely eliminates radial loads
  • The suction/delivery pipe can be placed as per the user’s requirement throughout 360° with an interval of 90°

2. FM/UL Pump sets

These pump sets are ideal for use in commercial complexes, high-rise buildings, oil and gas on-shore and off-shore platforms, petroleum and petrochemical complexes, and power and transformation stations.

Some of the benefits of using these pump sets are:

  • Helps meet every site’s individual requirement
  • LCD display and control panel helps in easy operation and visual indication of conditions
  • Print-friendly and downloadable logs help in easy monitoring of the system
  • High-quality materials mean that there can be a reduction in corrosion and higher product longevity

3. Fire Sprinkler Set

These pump sets are ideal for showrooms, bungalows, or 2-storey buildings.

Some of the benefits of choosing this pump set are:

  • Plug and play packaged system delivered to site
  • Cost-effective solution for premises with limited space
  • Quality assurance from the manufacturer
  • Clean environment at site due to minimal activity
  • Digital display for monitoring pressure and faults
  • Precision control through pressure transmitter and controller
  • LED indications of pump status

Case Study

VEMC has a proven record of installing best-in-class fire safety systems for its clients. A classic example of this is the project undertaken for One Avighna Park, which received 40 national and international awards for its excellence and exclusivity. VEMC helped supply the Fire-Fighting Control Panel that helped the fire pump start automatically when it detected a drop in pressure from the pressure switch.

VEMC is a leading fire-fighting pump dealer in Mumbai that provides best-in-class products and installation services to its clients. We would be happy to assist you in finding the best match based on your requirements. For more information on our fire-fighting solutions and control panels, feel free to contact us at +91 98199 07445. VEMC is ISO 9001:2015 certified and a pioneer in the field of electromechanical engineering products, allied equipment, and services.