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.

How to Maintain a Cooling Tower System

Energy Plus has trained our site engineers with the operation of cooling tower systems and to improve their understanding of the water/energy nexus with the goal of reducing energy, water and chemical consumption of the cooling systems through improved operations. By reinforcing strong operational practices, introducing new concepts and raising overall awareness of cooling tower operations, it is expected that a system will more likely be operated at or near peak efficiency.

  • Our goals with respect to cooling tower operations is to:
  • Protect the health and safety of building occupants and technical personnel as related to the treatment of water and the handling of associated chemicals.
  • Maximize the efficiency of HVAC equipment.
  • Protect equipment from scale, corrosion, and deleterious micro-bio activity such that cleaning and repairs of equipment due to water problems are not required.
  • Achieving these goals will save energy, water, chemicals and costs while improving sustainability by reducing consumption of scarce resources.

Cooling Tower Operations Checklist

  1. Determine makeup water quality – Make up water quality is most critical factor for cooling tower system. This will enable the establishment of target Cycles of Concentration (COC).
  2. We Energy Plus team test the makeup water quality at site to ensure TDS, PH, Hardness of the system.
  3. Establish target Cycles of Concentration (COC) – Based on makeup water quality, set a practical COC goal using the Target Cycles of Concentration.
  4. Monitor COC and water performance frequently – Keeping the system running at peak COCs while staying within water performance levels will maximize efficiency and protect equipment.
  5. Automate where possible – Utilize automated monitoring and alarms when available and cost effective. Implement direct chemical feeds at the makeup distribution. Implementation of temperature controller is cost effective.
  6. Protect the equipment –We Energy Plus team maintain the regular chemical dosing as per requirement to ensure no corrosion, scale buildup or bio-fouling is occurring, which is important to protect the system and equipment’s.
  7. Water Flow rate- Water flow rate is a vital factor for heat transfer of a cooling tower system, as well as efficiency of cooling tower. We Energy Plus team carefully maintain pump flow rate and clean the strainers of system.

 

Installation of Boiler – IBR Regulation in India

Boilers are used in industries to generate steam and power. The food, beverage, jute, chemical-processing, pharmaceutical, paper, packaging, steel, and many more industries use boilers. To install boilers certain regulatory requisites are to be fulfilled and maintained for which only approved and authorized companies are entitled to undertake such skilled work.

Regulations to Keep in Mind

An unfortunate incident of boiler explosion, in Calcutta in 1863, led to the loss of several lives. This incident prompted the introduction of boiler inspection. In the year 1864, the Bengal Act VI of 1864 was passed which provided for the inspection of steam boilers and prime movers in the town and suburbs of Calcutta. This is the beginning of boiler legislation in India.

As per the Indian Boiler Act, boilers have to go through an in-depth inspection. The inspectors assess the design and materials used in the manufacturing of boilers for reasons of safety.

The method of installing a boiler is assessed as well. Prior to the installation of boilers, one should bear in mind the mandatory regulations required to be followed to install a boiler. A reputed Boiler Repairer, approved by Boiler Directorate, is authorized to carry out such installation work.

Why Should You Contact Us?

We are well-known Mechanical and Electrical Utility Solution Provider from Kolkata. We install Boilers/TF Heaters with all accessories. All types of mechanical and electrical utility equipment are installed in industrial and commercial sectors. We are 1st Class Certified, as Boiler Repairer, by the Boiler Directorate.

Our services range from installation of boiler, supply and installation of balance of plant, design, fabrication, supply & installation of industrial boiler chimney, pressure vessels, storage tanks including air receivers to operation and maintenance of boiler, chiller, hvac, cooling tower, treated and untreated water, air compressor, et al mechanical and electrical utility equipment. Our clients range from corporate and non-corporate sectors, government and private organizations.

We at Energy Plus are authorized boiler repairers and credited to install Boilers in India. Being the most reliable in the sector, our servicemen can visit your site on a regular basis for periodic maintenance and service. Get the best from us at an affordable price.

How Much Does an Industrial Chimney Installation Cost in India?

India is a land of industries. When you drive past by a factory, you must have seen tall chimneys which are installed within the precinct of an industry. Your eyes must have caught the sight of smoke which comes out of chimneys. The colour of smoke defines the emission of pollution. It is indeed a strenuous effort to build industrial chimneys for various industries. You need to have the expertise. It is important that you get the industrial chimneys supplied and erected from a trusted service provider. To install industrial chimneys for your industry, you should get in touch with renowned Industrial Chimney Suppliers in India.

Opt for the Best Industrial Chimney for Your Plant

Our Industrial Chimney, Design, Supply and Installation across pan India have notched immense reputation. The sturdy structure has stood many a wind and seismic test apart from being durable if well maintained.

We are one of the leading suppliers of Industrial Chimneys for Boilers, Furnaces and Generators. The design followed is as per structural design base IS 6533 Part I/Part II, Seismic Zone IS 1893, material IS 2062, wind speed IS 875 and IS 800 Part III. We also construct civil foundations post design, required for installation of industrial chimney.

Our Credibility

We have supplied and installed nearly 100 Industrial Chimney in various industries throughout India. The maximum chimney height supplied and installed is 48 Meters. The top and bottom diameter ranges from 200mm to 1500mm and from 1000mm to 3000mm respectively. We design, fabricate, supply and install Industrial Chimney for Process Boiler.

The chimney outer surface is painted with 400 degree centigrade heat resistant aluminum paint after adequate surface treatment. The inner surface of the chimney is painted with heat resistant black bituminous paint.

Our customers who have restored their trust in us – Coca Cola, Alembic Pharmaceuticals Ltd., BATA India Ltd., Britannia Industries,  CIPLA Ltd., Dabur India Ltd., Indian Explosives, Bihar Dairies, Keventer Agro, Parle Agro, GMP Technical (ITC Bangalore), Microlabs Ltd., Gloster Ltd, Ganges Jute Pvt. Ltd. to name a few.

Industrial chimneys are either self-supported or guy rope fixed that are designed by our experienced and trusted designers. Attention is given to every minute detail by our team of engineers who put in their best to install a strong and sturdy built self-supported industrial chimney that can stand the cruel test of nature.

Cost of Industrial Chimneys

The cost of the boiler chimneys vary due to its dimension, structural material, installation terrain, etc. The effective cost for a self supported MS Industrial Chimney ranges from 9 lakhs to 14 lakhs approximately depending on the above parameters.

Install an industrial chimney from the most trusted industrial utility service provider in India. We are a call away to assist you install a chimney in full or part, for painting or thickness testing, for aviation lamp or lightning arrestor at an affordable cost. Now, when you think of chimney think of Energy Plus.