Energy Plus India Blog

Managing the Risks of Industrial Pipeline Installations

Be it any sector or industry but the Industrial Pipeline often are the backbone of many. So for the efficient functioning of these industries smooth working of the pipeline systems is critical. So this is why you need the right installation and maintenance of these systems so that they function properly without any difficulty in the long run. Unfortunately, it is seen that utilities frequently experience failures in recently installed piping systems. The risks associated with improper piping systems are many.

Major hazardous operational risks

Improperly installed and poor quality piping systems offer significant operational risks. These could be all the more if the piping systems are used for carrying hazardous materials. Thus any leak or defect in these pipelines could lead to major hazards. Thus care must be taken so that these piping systems are installed properly. They must be carried out by experts in the field.

Improper installation lead to higher Repairing and Maintenance Costs

It is seen that if the piping systems have not been installed rightly, then soon it may lead to a significant escalation of repairing and maintenance costs. To keep the costs low for better profitability has become critical in the age of cut-throat competition. This is another major risk which is involved with the improper installation of piping systems. So the right installation of the piping systems initially would mean lower costs and thus better profitability in the long run, which is critical in this very competitive industrial scenario.

Meeting strict safety regulations

Certain industries have very strict safety norms and regulations. Failing to meet these strict industrial safety regulations may threaten the very survival of the plants. This is why proper installation, as well as maintenance of piping systems, is an essential requirement for any industry. This is why you need the experts in the field who can do the job of industrial piping systems well.

Energy Plus India: Experts in the field

For any industrial utility operation in India, Energy Plus India are the undisputed leaders in the field. We are an ISO 9001: 2015 Company based in Kolkata who been offering the best Industrial Utility Management Solutions and services under one roof, over a long period that begun way back in the year 2001. We offer a wide range of the industrial related key services like installation of the boiler in India, along with Industrial Chimney Installation in India, and much more. As a part of services, we are also experts in the field of Industrial Utility Pipeline installation which has become an essential requirement for various industries and sectors.

Being in the field of providing the best industrial utility management solutions and services since long we have a very rich experience and helps us provide the best services. Apart from this, we act as the single window for multiple industrial services. This means that you need not run around for availing the different industrial service providers. You can have all the most essential industrial services under one roof. It is this experience which helps us to stay updated with the latest safety norms and thus we can provide you with the best industrial services at all times.

So be it for industrial pipeline installation or any other industrial service make sure to Contact Us! for the best services in the field

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:

Improves Operational Efficiency
Reduces Overhead
Single Point Responsibility
Work Entrusted To Industry Expert
Hassle Free 24×7 Operation
Increases The Life Span Of Equipment
Zero Down Time
Reduced Maintenance Cost
Reduced Energy Cost
Zero Accident
Reduced Recruitment Cost
Reduced Training Cost
Focus On Core Production
Reduced IR Issue
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

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.
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.
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.
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.
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.
Boiler Tube Cleaning is an important factor to improve boiler efficiency.
Testing of Boiler Safety Mounting and Interlocking to prevent mishaps and increase the boiler health.
Blow Down at regular intervals helps maintain boiler water quality and prevents scale formation.
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.
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.