Important Considerations for Installation and Functioning of Industrial Boilers

Be it in any industry you would know that industrial boilers are one of the most critical components that drive industries. This has been so since the early days. It is true that it is a simple process, which involves transferring heat to water in order to create steam. Boilers are a key link in the production of energy. When heated to its boiling point, each unit of water expands many times and thereafter forms steam. This steam can be harnessed to provide power to generate electricity, heat buildings and perform other useful work.

Why right Boiler installation and maintenance is essential?

It is true that the boilers perform many important functions. However, at the same time, this expansive power of steam can be dangerous if not monitored or properly handled. It is why boiler safety devices are so important to have in place and be fully operational. It is important they are rightly installed and maintained.

The 2 most important boiler safety devices:

Safety Release Valve

When it comes to proper boiler functioning for proper boiler safety the safety valve is a key device. This is what ensures the opening to release excess pressure that forms inside a boiler. You must note that the safety release valves rely on mechanical actuation, such as a spring-loaded component. They usually do not require electrical power or other potentially-unreliable inputs to function. It is true that their design is not complex. However at the same time, they do demand careful attention, maintenance and testing to ensure a perfect response in case of an emergency.

To ensure that the proper functioning of the safety valves of boilers you need to use the services of approved repair professional in the field. He is the one who has the right expertise and can ensure that the safety valves function properly. Apart from this ensure that the incoming water supply is pure. Boilers are often susceptible, to scaling and rust as a result of impurities in water which comes into the boilers. This is why it’s important to have pure water.

Low Water Cut- off Valve

While having boilers installed at your manufacturing facilities you must also note that boilers also utilize another type of valve to maintain safe operating conditions. This is basically a device which is used to monitor water levels within a boiler. It responds with appropriate actions should the water level drop too low. A low water level is very risky and hazardous. The reason is that water serves as a coolant to keep the metal casing from being overheated. In case there is a leak or failure to maintain an appropriate water level, then the metal will heat beyond its safe point and fail.

In order to ensure proper functioning of boilers and their safety, the cut off valves must work in tandem. Apart from this the proper inspection and maintenance of the cut off safety valves become crucial for the better safety of the boilers.

In conclusion, we can say that if you are looking for the installation of the boiler in India then you must ensure that the installation is done correctly by experts in the field. You need experts in the field to be it for Boiler Installation, Boiler Operation, Boiler Overhauling or Boiler maintenance. Get it done only from experts in the field.

Effective Tips on the Way to Care and Maintain Industrial Chiller

Industrial chiller is very important for the proper functioning of a factory. Chillers get congested at times and create huge nuisance in industry operations.

These essential tips will help you eradicate problems with chillers –

Keep a daily log

Keeping a daily log is essential for any industrial heavy equipment. Always have a data ready for your chillers. Parameters like temperature, pressure, fluid levels and flow rates should be recorded and monitored. These will come in help during maintenance and repair. Remote monitoring technologies will allow you to inspect your machines periodically. It will also allow you to generate trend reports that can pinpoint functional problems.

Keep tubes clean

This is crucial for effective heat transfer. Condenser tubes should be cleaned at regular interval. Industrial Chiller performance will be greatly compromised if the heat transfer is interrupted by contaminants. Cleaning ensures that the tubes remain free of sludge, mud, scale, algae, dust and other contaminants.

Treat condenser water

Condenser water loops that uses open cooling sources requires water treatment to stay free from corrosion, scale and biological growth. The water quality should be well monitored to ensure proper chilling and heat transfer.

Decrease entering water temperature

Decreasing the temperature of the entering water increases chiller efficiency. Keeping the chilled water flow between 3 to 12 feet per second ensures better efficiency.

Maintain proper level of refrigerant

Keep the refrigerant level as per the chilling requirements. Too low or too high level of refrigerants is detrimental for the health of chillers.

Check compressor oil

Send compressor oil samples to laboratories to check its quality. This spectrometric analysis reveals a lot about the overall health of the chiller. Change the oil when the reports indicate anything wrong.

Install variable speed drivers

As the chillers have huge electrical intake, VSD should be installed for electric saving. This also prevents electric charge overflow.

Chillers in most cases represent the single largest electric load in a plant. Hence, proper chiller maintenance is very important too keep it light on pocket. At Energy Plus, we offer best of its kind chiller operation and maintenance in India to give you a smooth factory experience.

An Essential Guide on Storage Tank Fabrication in India

Storage tank fabrication is crucial for every industrial production. Knowing about the types of tanks and building materials is also very important.

At Energy Plus, we have pioneered the field of storage fabrication in India, we want share our experiences with you regarding the same.

First let us be aware of the kinds of storage tanks.

Types of storage tanks

Spherical Storage Tanks: These kinds of tanks are used predominantly for the purpose of storing high pressure fluids. They provide even distribution of stresses on the sphere surfaces.

Advantage: They have smaller surface area per unit volume.

Disadvantage: Costliest among the storage tanks.

Cylindrical Storage Tanks: These are more widely used than spherical cylinders for their cost efficiency. Though, they may have weaker points that can be averted by constructing them from the material used in the construction of spherical tanks.

Advantage: Costs less than spherical tanks

Disadvantage: Has many weak points.

Fixed roof storage tanks: A fixed roof storage tank consists of a cylindrical steel shell with a cone or dome shaped roof that is permanently fixed to the shell.

Advantage: It has a breather valve that allows the tank to operate at the slightest internal pressure. This is the least expensive option.

Disadvantage: They are the most minimally acceptable form of storage.

Floating roof storage tanks: These tanks stores near atmosphere pressure. Floating roofs are designed to move vertically within the frame of the tank to provide a constant minimum gap between the product surface and the ceiling and provide a continuous seal between the periphery of the tank and the floating roof.

Advantage: Can be used in the areas of extreme rainfall and snowfall

Disadvantage: Very expensive and involves complex machinery.

Materials of construction

Storage tanks are welded from both stainless steel and carbon steel. Let us tell you the benefits of both.

Stainless Steel Carbon Steel
Resistant to corrosion Better heat distribution
Extremely durable Wear resistant
Eco-friendly Has higher carbon content
Leak free Good for indoor storage
Long life span Malleable
Various linings can be added More affordable
Affordable Requires less materials
Recyclable Can be heated up easily
Wide range of products can be stored Harder and stronger

Storage tank fabrication is a tedious process and should be done in accordance with the budget, place of storage, weather, type of products etc. Use the above guidelines for a stress free storage.

What are the different types of Industrial Air Compressor available?

Air compressor enables air pressure control for effective production. Air compressors are diverse in nature with different functionality and applications. Listed below are the different kinds of Industrial Air Compressor.

Types of Industrial Air Compressor

Classification of air compressor can be carried out in different ways but the most popular one is based on the principle of its operation. This way the air compressor is divided into two large categories named – Positive Displacement Air Compressor and Roto-Dynamic Compressor.

Positive displacement compressor classifications

These compressors are further divided into reciprocating and rotary compressor. Reciprocating and rotary compressor can be of various types as stated in the chart.

Reciprocating Compressor Rotary compressor
In-line compressor Screw compressor
V-shaped compressor Vane type compressor
Tandem-piston compressor Lobe and scroll compressors
Single-acting compressor
Double acting compressor
Diaphragm compressor

Rotodynamic compressor

Under this category, we have a centrifugal compressor and axial flow compressor.

Now let us understand the most popular types of air compressors…

Reciprocating In Line Compressor –

This is the most widely used air compressor

Simplest in design

Has a varying pressure tag

Directly driven by electric motors or diesel engines

V-shaped compressor –

Air cooled compressor –

Has two cylindrical head unit with concentric valves mounted on each

Single acting compressors –

It has piston at one end

Double acting compressor –

These have two sets of suctions and delivery valves on both sides

Compressed air delivery is continuous in comparison to single acting compressor

Rotary compressor –

These are not reciprocating in nature. They do not have any piston and crankshaft. They are efficient in low air pressure requirements.

The various classification of air compressor enables you to select the best for your farm as per requirements.

At Energy Plus, we understand the value of maintaining air compressor and are always prepared with any kind of air compressor operation in India. With our increasing list of satisfied customers and years of experience, we cannot lay enough stress on how much air compressor maintenance can avert future complexities.

As one of the leading industrial utility service provider, we have plethora of maintenance services to offer to keep your business and industry run with the right pressure but not under it.


Tips and Tricks for Appropriate Boiler Maintenance

Proper maintenance of a boiler is something every business owner swears by. If neglected, a faulty boiler can lead to various problems. Those, in turn, lead to decrease in production rate. Hence proper boiler maintenance is essential.

It is wise to consult a mechanical utility service provider, if any operational delay is encountered as many options are available in India.

Few tips for the well being of boilers:

  • Regular servicing for boiler and other machines is of utmost importance.
  • For pressurized systems, check and adjust the pressure regularly.
  • Check the central heating timer to ensure proper functioning. In the summer months run the central heating system for 15 minutes, this will prevent the pump from seizing up.
  • The boiler condensate pipe should be correctly lagged otherwise, it may freeze.
  • If there is any black mark, then take expert help immediately as it indicates combustion hazards.
  • Ensure adequate ventilation around your boiler.
  • The pilot light in the boiler should be blue if it turns hazel or yellow ask for expert help.
  • Keep a carbon monoxide detector installed in the room where you have the boiler.
  • Flush the boilers twice a year.
  • If you have an oil boiler, keep an eye on the level of the oil. If it runs out of oil, the system will suck debris and sludge.
  • Keep accurate data log of your boiler operation. Fuel consumptions and fuel gas temperature should be recorded on a daily basis.

At Energy Plus, we understand the value of maintaining the boiler and is always prepared with any kind of boiler operation and maintenance in different cities in India. With our increasing list of satisfied customers and years of experience, we cannot lay enough stress on how much boiler maintenance can avert future complexities.

As one of the leading industrial utility service provider, we have the plethora of maintenance services to offer to keep your business and production running smoothly.

Setting up a routine for boiler maintenance and training staffs to perform it in regular intervals can manage issues with the boiler. Effective maintenance will ensure longevity. Boiler repair is an expensive business and requires a huge amount of labour. The entire production of the farm will be affected if the boiler is not working properly. Hence, we always advise to take care of the boilers from the day of installation.

How Does A Chiller System Work?

It is important for chillers to use vapor-compression or absorption refrigerant cycle for cooling the fluid for transfer of heat. Three principles are followed: Firstly, when a liquid is heated, it transforms into gas and when the gas is cooled, it condenses into liquid. Secondly, if the pressure is lowered above the liquid, it actually reduces its boiling point and vice versa. Thirdly, heat always flows from hot to cold.

The Three Basic Principles The Chillers Follow to Function Properly

The Working Mechanism of Chillers 

  • Before start up of chiller, check water in cooling tower sump and ensure all valves are open.
  • In most cases the process of cooling applications, a pumping system works actively for circulating cool water or glycol solution. We at Energy Plus provide service for Chiller Operation and Maintenance in India and follow this process rigorously, thus ensuring our services to be envious and smooth.
  • The basic cooling cycle is the same for both vapor-compression and absorption chillers. Both systems utilize a liquid refrigerant that changes phase to a gas within an evaporator which absorbs heat from the water to be cooled.
  • While a vapor-compression chiller consists of four primary components of the vapor-compression refrigeration cycle, an absorption chiller uses a heat source to drive the refrigeration cycle in place of a mechanical compressor.

The chiller will usually be located either in the basement or on the roof and this depends on what type of chiller is used.

For the system to work smoothly with practically no hitch, a reliable service provider is required to operate and maintain the equipment 24×7 as per the manufacturer’s SOP and SMP. This is where Energy Plus’ assistance can come handy in playing a crucial role.

What Is Facility Management Service And How It Helps In Boosting The Core Production?

Facility Management is best described as the integration of processes within an organisation to maintain and develop the agreed services which support and improve the effectiveness of its primary activities.

They are not key organizational functions but are essential to ensure a smooth operation of the business. For this purpose Facility Management Services (FMS) are generally outsourced to keep in focus the key issues.

Benefits of outsourcing Facility Management Services:

  1. Improves Operational Efficiency
  2. Reduces Overhead
  3. Single Point Responsibility
  4. Work Entrusted To Industry Expert
  5. Hassle Free 24×7 Operation
  6. Increases The Life Span Of Equipment
  7. Zero Down Time
  8. Reduced Maintenance Cost
  9. Reduced Energy Cost
  10. Zero Accident
  11. Reduced Recruitment Cost
  12. Reduced Training Cost
  13. Focus On Core Production
  14. Reduced IR Issue
  15. Value for Money

All the above is achievable when a customer buys outsourced Facility Management Service. The customer on appointing an industry expert for the work can focus on core issues. The responsibility reduces to the extent of one man interaction and monitoring.

An industry expert is best suited to operate, maintain and trouble shoot any equipment.

Apt handling has all the good effects as mentioned above which otherwise is not possible. There is considerable reduction in energy, time and cost and at the same time gives extended life to equipment.

100% plant is available and adequate safety measures taken. The customer gets its value for money and is in a better position to further its business.

How to Make Your Air Compressor System More Efficient

Compressed air is an important medium for transfer of energy in industrial processes. Proper operation & regular maintenance of Air Compressor can help to improve the system efficiency and reduce operational cost.

Preventive Maintenance of Compressor System:

  • Reduces losses
  • Improves energy savings from compressor system

The Following Should be Maintained:

  • Turn off your air compressors when not needed.
  • Identify and fix air leaks.
  • Eliminate inappropriate uses of compressed air.
  • Apply proper controls to multiple-compressor systems. Master system controls to maintain a stable system pressure. Ensure only the required compressor units are brought online and they are operating at peak efficiency.
  • Ensure that piping and storage are adequately sized.
  • Change compressor inlet air filters on a routine basis to eliminate pressure drop. Every 2 psi in pressure drop reduces compressor horsepower efficiency by 1 percent.
  • Consider automatic, zero-loss condensate drains. Capacitance-sensor-operated drain traps don’t need to be monitored. In addition, they discharge only condensate, not valuable compressed air.
  • Apply variable-speed-drive compressors where appropriate. Variable-speed drive is not a one-size, it fits all solution. However, if demand varies, it can have a huge monetary saving on electricity costs each year.
  • Reduce operating pressure to the lowest possible setting. Every 2 psi reduction in system operating pressure saves 1 percent in compressor efficiency.

Regular maintenance of air compressor includes:

  • Clean inlet air filters, coolant filter
  • Check coolant level
  • Check interlock and condensate drain system

Clean coolers maintain good compressor health.

Energy Plus provides Air Compressor Operation and Maintenance solutions. They are ever ready for assistance.


Safe Operation of a Boiler

IBR Steam Boilers are closed vessel exceeding 25 litres capacity and 1kg/cm2 pressure that are used exclusively for generating steam under pressure. It includes any mounting and or fittings attached to such vessel that is wholly or partly under pressure when the steam is shut off. This causes the boiler to be an extremely dangerous equipment which must be treated with utmost care.

Boiler Maintenance is essential to obtain maximum boiler efficiency. Regular maintenance helps to avert any kind of major break-downs. It is a big savings on overall costs. It is advised to entrust the maintenance work to licensed experts, for a commendable solution and to avert possibilities of mishaps. A scheduled maintenance program extends the life span of the boiler. Below are some important tips to safely operate a boiler:

Tips to Safely Operate a Boiler

  1. Keep A Daily Log For Smooth Operation – The daily log records is very useful to monitor the health of a boiler. Records on operating conditions that includes temperature, pressure, water quality, fuel consumption etc, help to monitor the boiler. These recorded parameters indicate the condition of the boiler, the kind of maintenance required, if any.
  2. Water Level of the boiler is vital and needs to be checked every fortnight or so. Should the boiler operate without adequate water, this can easily damage it beyond repair. Shortage of water in the boiler can lead to serious mishaps and endanger the lives of people. It is to be ensured the pilot light is on as you check the water level. If the water level is below minimum, you need to check the plumbing and correct faults if any. Sometimes, all that is required is a few minor adjustments in the set-up.
  3. Leaks may occur during normal usage of boiler. Gas or fuel leak is serious and calls for immediate attention. This usually indicates some adjustments are necessary in the system. If you detect damaged or worn out parts, it should be replaced or repaired, as the case may be, immediately.
  4. Regular Feed Water & Boiler Water Quality Check and monitoring is important to avoid scale formation in the boiler. Feed water & Boiler water’s TDS, PH & Hardness are critical factors to keep a boiler healthy. Scale formation due to hard water reduces boiler efficiency, increases fuel consumption, leads to heat loss and the possibilities of a mishap.
  5. Burner Maintenance is very important for boiler fuel efficiency. Fuel nozzles, Blower, Fuel pump, Fuel filters are important factors that improve efficiency. If fuel solenoid fails then chances of a mishap is high.
  6. Boiler Tube Cleaning is an important factor to improve boiler efficiency.
  7. Testing of Boiler Safety Mounting and Interlocking to prevent mishaps and increase the boiler health.
  8. Blow Down at regular intervals helps maintain boiler water quality and prevents scale formation.
  9. De-scaling, hard water usually gives rise to excessive lime-scale in the boiler. This prevents the boiler from functioning smoothly. If left to accumulate, lime-scale will hamper the heating capacity of the boiler. You will need to de-scale your boiler should you notice too much lime-scale inside the boiler.
  10. Annual Check & Overhauling is a mandatory practice to have your boiler checked at least once a year by a registered engineer. This ensures the safety and efficiency of the boiler. Any emerging problems can be noted and dealt with accordingly. The license to operate the boiler is issued after inspection.

How to Improve Chiller Plant Efficiency

Chillers are the single largest energy-using component in most industries and can typically consume over 50 percent of the electrical usage. Department of Energy estimates that chillers expend up to 30 percent in additional energy through inefficiency. Chillers running inefficiently also results in decreased equipment reliability, increased maintenance intervals, and shortened lifespan. The slightest decrease in chiller performance can have a major impact on efficiency. For instance, every 1 degree C increase in condenser water temperature above full load design can decrease chiller efficiency by 1 percent to 2 percent. A failing or neglected water treatment program can reduce efficiency 10 percent to 35 percent or more in extreme cases.

What Is Maximum Chiller Efficiency?

Contrary to popular belief, running the chiller at full load design and achieving the design kW/ton does not necessarily mean the chiller is running at maximum efficiency. Maximum chiller efficiency is producing the greatest tonnage at the lowest kilowatt usage. Maximum efficiency occurs with most chillers running at approximately 70-75 percent load and the lowest entering condenser water temperature (ECWT), based on design. Knowing a chiller’s efficiency and the effects of load and ECWT will help the facility determine the most efficient chiller configurations, saving the maximum on energy costs.

Tips to Improve Chiller Plant Efficiency

  • Keep tubes clean for efficient heat transfer: – Heat transfer has the greatest single effect on chiller performance. Large chillers can have more than five miles of condenser and evaporator tubes, so high heat transfer is fundamental to maintaining efficiency.
  • Treat condensate water: – Proper water treatment is required for all condenser water loops. This treatment eliminates scale, corrosion and biological growth. If these elements are found in the system, increase the amount of chemical treatment to the water.
  • Analyze compressor oil: – Once a year, send a sample of the compressor lube oil to a laboratory for a spectrometric chemical analysis that will provide details about moisture content, metals, acids and other contaminants that affect performance. Oil should be replaced only if necessary. High moisture levels can indicate a purge unit problem, which has a significant effect on efficiency. Pull samples from low-pressure chillers more frequently, using a schedule based on purge run hours. Replace oil filters when they exhibit a high pressure drop and when the oil charge is replaced.
  • Reduce entering water temperature: – Lower temperatures of water entering the chiller condenser system will improve efficiency. When cooler water comes into a system, less energy is required to cool the water to a normal operating temperature. Also, if the regulated temperature rises, surging may occur.
  • Maintain a leak free system: – Compressor leak tests should be performed 3-4 times a year. A leak-free system is essential to the performance of a chiller system. Leaks in a system let in non-condensable in the form of air and moisture, which create stress on the system and lead to corrosion. Leaks also release harmful refrigerants into the environment.
  • Install VFD/VSD drive in chiller motor: – The motor in a chiller often draws the single highest electrical load in a facility and variable speed drives minimize energy consumption by syncing the work load and motor efficiency. Variable speed drives also serve as a sort of soft starter function that lowers the initial inrush current. This role is especially important when a chiller is running on emergency backup power systems. LG chillers provide the option to add inverter specifications.
  • Maintain proper water flow rate: – Flow rate must be regulated closely, because too low a flow rate reduces chiller efficiency, leading to laminar flow. The minimum flow rate is typically around 3 ft. per second. However, too high a flow rate leads to vibration, noise and tube erosion. The maximum recommended flow rate is typically around 12 ft. per second.
  • Proper Insulation on chilled water pipeline: – Proper insulation increase the chilling plant efficiency. If insulation is not proper or pipeline is not insulated the heat loss will occurs and overall chilling plant efficiency will comes down.
  • Maintain refrigerant charge: – The amount of cooling that any chiller can provide depends on how much refrigerant it moves through the compressor per unit time. It’s important to maintain the proper level of refrigerant. Leaks, as well as air and moisture, decrease efficiency and system reliability. Low refrigerant charge, usually resulting from leaks, causes the compressor to work harder and achieve less cooling effect.
  • Purge non condensable gases: – Air and moisture are two non-condensable that can leak into low-pressure chillers. Non-condensable can reduce chiller efficiency by as much as 4% at 60% load and 7% at 100% loads. Air insulates tubes, preventing exchange and elevating condensing temperatures, which also makes the compressor work harder. Moisture promotes acid formation, which can damage motor windings and bearings. Installing purge units on low-pressure chillers minimizes the effect of non-condensable. Modern, high-efficiency purge units minimize both air ingress and refrigerant loss. Eventually, positive pressure chillers using HFC-134a, HFC-410a and HCFC-22 will replace low-pressure chillers. The newer units don’t require purge units because non-condensable can’t enter them.