Category: Blog

Moving Towards a Cleaner Future

Posted on by Thermaxqaz

Humans have heavily relied on fossil fuels for far too long to meet their energy demands, impacting the environment adversely and ushering in a plethora of issues ranging from climate change to deterioration in air quality.

As of today, human activities have triggered global temperatures to rise by about 1 degree Celsius above pre-industrial levels (1950-1900). Record pollution levels are causing a paradigm shift in climatic conditions, and governments around the world are trying to stop the disastrous effects of climate change.

Green Energy – Need of the Hour

The problems caused by the use of fossil fuels can be solved by using renewable energy. Renewable energy resources are clean, inexhaustible, and environmentally conservative forms of energy that are harnessed from sources that are naturally replenished. They are much different from fossil fuels principally in their diversity, abundance, and potential for use anywhere on the planet. These sources are infinite and inexhaustible, but above all, they do not emit greenhouse gases – which cause climate change. There has been a global impetus on clean energy implementation with government incentives, encouraging industries to opt for clean power. They are feasible energy sources due to low lifecycle cost in comparison to fossil fuels that are increasing quite steeply on the back of global demand and volatility in the market.

Renewable energy includes sources such as sunlight, wind, rain, tides, and geothermal heat. According to the International Energy Agency (IEA), renewable energy sources represented nearly half of all new electricity generation capacity installed in 2014. Renewables constituted the second biggest source of electricity worldwide, behind coal.

Advantages of Adopting Clean Energy

Clean energy sources also provide a unique advantage to local economies because of their abundance in nature. Unlike the restrictive nature of fossil fuels, renewable energy sources are present everywhere in the world – whether in the form of wind, sun, water, or biomass, for countries to produce clean energy.

Renewables, specifically solar and wind, are more viable than their conventional counterparts. They are the most economically efficient way to generate electricity in a growing number of markets. Renewable energies are fast becoming the most sustainable solution not only environmentally but also economically for a better future.

Leading the Transition to Green Energy

Since 1980, Thermax has been focussed on sustainable energy and environmental solutions. It has developed several innovative technologies and unique offerings in clean energy, which are more pronounced today with an increased focus on climate change and are in line with the COP26 agreement. Thus Thermax has a long history of extensive engagement with diverse sectors and tie-ups with technology majors, which has empowered the group to deliver unmatched solutions to its clientele.

Thermax’s offerings in waste heat recovery, biofuels, solar, bio-CNG, waste to energy etc., show their commitment towards delivering clean energy. Thermax continuously introduces and innovates environment-friendly and carbon-neutral solutions capable of replacing most fossil fuels with commercial benefits, also helping us achieve Sustainable Development Goals (SDGs).

Thermax’s Renewable Energy Solutions

Solar Energy

With solar PV installations spread across industries and geographies, Thermax is helping customers generate green energy and minimise electricity costs. Thermax’s solar PV solutions reinforce the brand’s reputation in offering clean energy solutions trusted by organisations across Asia, South East Asia, the Middle East, and Africa.

Solar Rooftop

Solar energy offers an excellent return on investment while utilising the rooftop space of the customer’s facility. Solar rooftop solutions can generate free electricity for more than 25 years, resulting in substantial savings and carbon footprint reduction.

Solar Ground Mounted

Thermax has an excellent track record in the installation of ground-based solar power projects. Ground-mounted solar installations deliver unbeatable ROI during the lifecycle of the project, taking the customer’s manufacturing facility towards self-reliance for its power needs.

Battery Energy Storage System

Thermax provides specially designed battery energy storage systems with Li-ion technology to provide reliable and long backup. It also forms a hybrid system with solar PVs and solar power grid.

Biomass-Powered Boilers

Thermax offers various boilers with the capability of using biomass as the source of fuel instead of fossil fuels like coal/oil & gas without compromising on the quality of the output. These boilers have various benefits, including fuel flexibility, low maintenance, high efficiency, high availability, and reliability.

Travelling Grate Boilers

These are a highly efficient and reliable range of boilers that can run by combustion of a wide variety of biomass. They also allow precise control of grate speed and an over-fire air system. This system provides turbulence and thorough mixing of volatile gases, assuring complete combustion of biomass fuel.

Pinhole Grate Boilers

Pinhole Grate Boilers have a stationary inclined water-cooled grate design with no moving parts for avoiding any mechanical failures thus reducing maintenance costs for the furnace.

Pusher Grate Boilers

A unique boiler designed by Thermax for combustion of low calorific value in high moisture fuels with low maintenance requirements and high operational reliability.

Waste to Energy Boilers

Thermax has rich experience in providing clean and green solutions for converting waste products to generate clean energy.
Thermax offers a wide range of solutions for combustion of various fuels like – agriculture waste, spent wash, paper sludge, non-recyclable solid waste, refuse derived fuel, segregated municipal solid waste and other industrial process wastes.

Waste Heat Recovery Boilers

Thermax provides energy solutions to utilise the excess heat from various processes and applications to improve overall energy balance in ferrous metals, non-ferrous metals, cement, refinery, chemical, oil & gas, glass, and other sectors. These offerings include a variety of customised, turnkey solutions to generate steam and power.

Spent Wash Fired Boilers

Thermax offers a unique solution for spent wash incineration to convert distillery waste to produce energy. This helps to adhere to the ‘Zero Liquid Discharge Regulatory Compliance’ and also helps in meeting the entire steam and power demand of the distillery industry.

Additionally, we provide outsourced utilities such as steam, heat, chilled water, treated water, power, and solar through the Build-Own-Operate (BOO/T) business model. We also undertake its comprehensive operation & maintenance along with supply chain management of all consumables, including biomass fuels.

As global emissions are reaching an alarming level, a shift to renewable sources of energy is inevitable. Thermax is also significantly investing in Research and Development (R&D) to tap new energy opportunities and devise unique applications focussed on creating a mark in the evolving sphere of energy transition, anchored towards a zero-carbon future.

Why Regular Boiler Repair and Maintenance Services Are Crucial for Long-Lasting Performance?

Posted on by Thermaxqaz

Boilers are an essential component of industrial operations, used as a source of process heating and to improve the operation of an enterprise by generating power. Its demand is rising with the market expected to reach USD 19.3 billion by 2025, at a CAGR of 5.7. An industrial boiler’s efficient operation and maintenance is complex and requires specialised attention. Solution providers such as Thermax Babcock & Wilcox Energy Solutions

(TBWES) takes a holistic approach to improve operations and maintenance, providing expert boiler repair and services.

A proper action plan is recommended to reduce asset downtime and increase production efficiency. Through engineered solutions, plant operations can be optimised to deliver intended performance. Proactive visits and customer interaction to provide preventive maintenance schedules help to minimise costly breakdowns and production loss.

Long-Term Benefits of Industrial Boiler Repair and Service

Regular boiler repair and maintenance will have added benefits like:

  • ● Having an authorised expert from an established boiler repair and maintenance company evaluate your equipment, you may avoid fires, explosions, and hot flue gas leaks from the boiler.

  • ● Annual or semi-annual boiler maintenance through a good boiler repair and maintenance company can help keep your boiler functioning effectively for longer periods. An expert can prevent a boiler from generating excessive waste, lowering your carbon footprint, and reducing your energy bills.

  • ● Furthermore, frequent boiler maintenance keeps your system running well for a longer period. This means you are less likely to have to pay for future boiler repairs.

  • ● Continued operation of a unit with defects may lead to a hefty repair bill or an expensive boiler replacement service. You can avoid that with regular boiler repair and maintenance.

Why Should You Service an Industrial Boiler Regularly?

You can save a lot of money on repairs if you get your boiler serviced regularly to ensure that it is running properly. Regular boiler maintenance reduces repair costs by detecting issues early before they become costly. Unrepaired problems might create substantial damage or malfunctions that will cost a lot more money in the long run.

Few other benefits of boiler repair service include:

● While servicing your boiler, specialists run a variety of safety tests. These inspections must take place regularly since they can eventually save lives.

● When boilers are maintained regularly, they are less prone to break down, function more effectively, and are therefore considered safer. Regular boiler servicing will lower your energy expenses and extend the life of the boiler and its key components.

● Switching to an efficient thermostat, adjusting your building controls, or adjusting your boiler setpoint are other ways to minimise your expenditures. These techniques will save the amount of energy your present boiler uses by up to 40%.

● When you have your boiler serviced as per the plant maintenance schedule, your expert from the boiler repair and maintenance company will be able to discover any problems and treat them before they cause serious harm. Any problems you experience, no matter how little, will only worsen as time passes and the environment begins to degrade your equipment.

Therefore, for such an important task, you should only rely on experts like Thermax Babcock & Wilcox Energy Solutions – who know all about boiler repair and service.

What is Thermax Babcock & Wilcox Energy Solutions (TBWES)?

Thermax Babcock & Wilcox Energy Solutions (TBWES) is an engineering company that specialises in heating, cooling, water and waste management, as well as specialty chemicals. In addition, the business develops, builds, and commissions large steam and power production boilers, turnkey power plants, industrial and municipal wastewater treatment facilities, waste heat recovery systems, and air pollution control projects.

TBWES’ technologies, products, and services assist the industry in increasing resource productivity and improving bottom lines while preserving a cleaner environment. TBWES has been one of the pioneers in building innovative solutions for complex problems of industries.

TBWES Services division offers a one-stop-shop for all types and brands of boilers, fired heaters as well as boiler repair and maintenance services in India. These solutions are increasing process efficiency in a wide range of sectors, including power utilities, petrochemicals, refineries, fertilisers, steel, cement, sugar, and paper, to name a few.

TBWES offers services such as integrity assessment, plant equipment evaluation, and reliability-based maintenance (RBM). Thermax Global provides complete boiler safety and inspection health checks through Condition Assessment (CA) and Remaining Life Analysis (RLA) in addition to determining boiler fitness for continuous operation and boiler repair service.

Why Choose TBWES for Boiler Repair and Service?

Here is what TBWES has to help you with your boiler repair and service:

● Provides one stop solution for all boilers and heaters.

● Engineering and feasibility studies, annual service and maintenance contracts, spares, condition assessment and remaining life assessment studies, O&M services, and other projects are undertaken.

● Has production capabilities in Pune, Baroda, and Shirwal, as well as the port facilities at Mundra SEZ.

● A dedicated service and construction management team committed to providing comprehensive solutions at the site.

For expert boiler repair and maintenance services in India, visit Thermax Global now or contact them via email – customer.support@thermaxglobal.com.

Posted on by Thermaxqaz

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Optimum integration of multiple energy sources

Posted on by Thermaxqaz

The world is increasingly moving towards renewable energy and solar PV plants are the first choice of industries to generate green power. While a solar PV plant can be easily synchronised with the grid, industries have other energy sources too which call for careful integration to achieve optimal solution.

Industrial process plants have requirements in terms of fluctuating load, reliability of power, steam consumption etc. which need to be managed seamlessly. When introducing renewable energy as a source of power, it is critical to design a solution that fulfils all the process requirements from multiple energy sources and at the same time maximises the use of solar power.

The case study below is a testimony of our engineering prowess where we helped integrate solar PV plant with the grid, multiple diesel generators and a steam turbine so as to maximise the utilisation of solar power and meet plant requirement under multiple operating scenarios.

The Requirement:

The customer receives  power supply from the national grid for a connected load of 2500 kVA. A 650 kW back pressure turbine (BPT) was installed and in case of unavailability of the grid, the customer is using a DG set of 1200 kW to support the load and provide reference to the BPT. All the resources are currently monitored by a controller.

The customer wanted to install a 1000 kWp solar photovoltaic (PV) plant to reduce their electricity bill and carbon footprint. 

The requirement was to manage the resources in sequential preference as mentioned under different scenarios. 

Scenario1 –  Grid is available, the following sequences of the electricity sources are to be maintained:

  • BPT –  as a part of the existing process
  • Solar PV
  • Grid

 

Scenario 2 –  Grid is off / unavailable, DG to provide the reference signal to BPT and solar PV. In this case, following sequences of sources should be maintained:

  • BPT – as a part of the existing process
  • Solar PV
  • DG

 

The Goal:

The power output of a solar PV system varies depending on the irradiance and temperature at a particular time. The team undertook the below steps for achieving the goal:

  • Maximise power from the solar PV plant 
  • Minimise power from diesel generator (DG) – the costliest power source
  • Avoid reverse power flow from solar PV to DG, to avoid damage to DG windings
  • Maintain system stability in absence of the grid

 

The Solution:

The Thermax team devised a solution using IoT controllers with smart algorithms and logic for dynamic ramp up / ramp down of solar inverters.

The IoT controller is the central component of the solution for hybrid systems consisting of solar PV and other resources along with the DG. It has the flexibility to write an application programme to ensure a demand-oriented control of the PV system that is a factor of the plant’s load and other resources’ characteristics. Thus the DG operates in a reliable and stable state even with high levels of PV power.

It is achieved through power sensing, power flow and measurement at various points in the client electrical network as per the below schematic.

The logic of operation is:

When the grid is on, BPT and solar PV will receive reference signals from the grid itself. However in absence of grid power, the DG has to supply the reference signals to BPT and solar PV. Inputs for the above control logic will be taken from meters installed on:

  • Grid
  • Load
  • DG
  • BPT
  • Solar PV

 

The logic is configured as per the requirement of two different scenarios. The controller will act upon solar inverters and DG in case of absence of the grid. However, there will be no controlling of the turbine in any situation. Cloud based remote monitoring was provided for accessing the system performance from anywhere. 

The Benefit:

With the implementation of this solution, the customer was able to reduce their DG operation by more than 30% leading to significant savings. Moreover, green power by way of the solar power plant enabled significant reduction in their carbon footprint.

With expertise in power generation, understanding of process plants as an OEM  for more than 50 years and with a rich O&M experience, we have the advantage of providing holistic solutions. Our solutions will balance multiple energy sources for fluctuating plant requirements and will save not only electricity cost, but also support sustainability.

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How a shift from Net to Gross metering will impact rooftop solar sector

Posted on by Thermaxqaz

Solar power has evolved as the fastest growing energy generation technology worldwide as it is one of the most sustainable energy sources which is abundantly available and can be easily installed on rooftop and ground. 

India is chasing an ambitious target of 100 GW solar power by 2022, out of which 40 GW is to be installed on rooftops. With rooftop installed base totalling to just 6 GW presently, it is critical to maintain consistent supportive policy to achieve this ambitious target. 

One of the key enablers for growth of rooftop solar has been the “Net Metering” policy. However, the Ministry of Power has recently introduced regulations to implement ‘Gross Metering’ instead of ‘Net Metering’ which has raised serious concerns for rooftop solar power plant owners.

For most of industrial and residential customers, the Rooftop solar power plant generates power during sunshine hours and is consumed by electrical loads which directly offsets the net intake from Grid,  leading to significant saving in electricity bills. However, in some cases when there is no consumption of power generated by the Solar PV System or when the plant is not consuming any power during holidays, the excess power can be fed back to the grid on a metered connection called Net Metering. This ensures that the excess power transmitted to the grid can be adjusted from the net billing units in subsequent electricity bills. 

Net metering uses a single, bi-directional meter that measures the current flowing in two directions. Most states in India use the net metering framework to promote rooftop Solar PV power plant that has enabled a wide adoption of this solar technology. 

This was certainly an advantage to the industrial customer who pays high tariff but on the other side was a loss to the state DISCOMS (Distribution companies) who have to part with a share of their revenue coming from energy intensive customer. 

Considering the above challenges, the Government has introduced Gross Metering. The new rules prescribe net metering for rooftop solar projects up to 10 kW and gross metering for projects with loads above 10 kW. Under Gross metering, a consumer is compensated at a fixed feed-in-tariff for the total number of units of solar energy generated and exported to the grid measured by a separate unidirectional ‘gross meter’ and must pay the DISCOM at retail supply tariff for the electricity consumed from the grid. The feed-in-tariff is decided by the respective state nodal agencies for the electricity injected into the grid.

The typical feed-in-tariff is expected to be in the range of INR 2.5-3.5/KWh whereas the market prices for PPA (power purchase agreement) signed by customer with renewable energy companies is in the INR 3.5-4.0/KWh range. The significantly lower realisation per unit will drive down the return on investment and deter investors and organizations from setting up further rooftop solar capacity. Commercial and industrial customers have been the key drivers of rooftop solar power growth. In the absence of a net metering policy, they would not find it lucrative to set up such projects. 

One proposed solution is net feed-in arrangement where the units generated by the customer for self-consumption are deducted from the total units used from grid and the surplus power exported to grid is credited at the feed-in-tariff determined by the regulators. This helps the customers in lowering their energy cost whereas DISCOMs are not forced to purchase surplus power at a higher rate from rooftop power plants. 

There is a need to achieve balance between the twin objectives of increasing share of renewable energy and improving the health of DISCOMs. The industry and the regulators need to come on a common ground and adopt a mutually agreeable solution. To meet our climate objectives, a shift to future dominated by renewable energy is unavoidable. However, it is equally important to manage this transition well so that solar energy companies and all other stakeholders of the energy sector emerge profitable and sustainable.

Advantages of outsourced O&M for solar plants

Posted on by Thermaxqaz

Systematic operation and maintenance of solar power plants are critical in ensuring that the plants perform to the best of their designed parameters, delivering maximum uptime and generation.

Outsourcing of O&M for your solar power plant provides multiple advantages to the customer:

  • Allows you to focus on your core business and reap the benefit of low-cost power
  • Guarantees system availability and response time
  • Facilitates real time monitoring and analysis of plant performance
  • Provides access to the knowledge base of O&M contractor developed by serving multiple plants

The building blocks of a good O&M service are regular monitoring and analysis, preventive maintenance practices and rapid trouble shooting. 

Thermax solar power plants are provided with remote monitoring system that provides continuous  plant performance parameters and minimises person dependency by generating data on failures modes, types and details of equipment/components that need preventive maintenance.

Preventive maintenance helps to keep the plant running by minimising avoidable downtime. A planned schedule of comprehensive preventive maintenance practices can reduce the dual loss of unplanned downtime and repair costs. Thermax supports customers with a standard operating procedure for preventive maintenance which includes type of inspection, type of maintenance, frequency of the inspection/maintenance and other crucial aspects. 

In case of an unplanned breakdown, it is essential to respond quickly to resolve the failure and restore regular operation of the plant. The speed of response depends on the availability and strength of a dedicated service team as well as an established network of associates who can reach the customer on demand. With its dedicated O&M team and country wide dealer network, Thermax can promptly address any plant breakdown.

Thermax has built a competent team for maintenance of rooftop solar plants and provides regular trainings through the experts. Major maintenance activities of the solar plant are 

  1. Ensuring safety equipment are in place and are in good condition 
  2. Regular cleaning of glass of the solar PV modules during low/no sunshine hours  
  3. Checking components for higher temperature conditions
  4. Checking earth resistance  
  5. Checking for cable terminations
  6. Cleaning inverter filters and LT panels

All the above activities are scheduled under preventive maintenance and are important not only for smooth operation of the plant but also to ensure safety of the plant, uptime, and better performance. Any laxity in proper maintenance can impact the plant in multiple ways. For example, 

  • dust accumulated on the modules will reduce the DC power leading to reduction in solar generation
  • non-usage of proper cleaning kit will lead to scratches on glass of the modules 
  • frequent ground faults may be observed in case of higher earth resistance values
  • loose terminations/non cleaning of inverter fans may result in local heating and may damage the equipment/component   
  • excessive consumption of water while cleaning will lead to wastage of natural resource 

Thermax provides tailormade O&M solutions to customers with the flexibility to choose from

  1. Annual Maintenance Contracts 
  2. Operation & Maintenance 
  3. Remote Service Support

As an O&M service provider with EPC background, Thermax has the strong engineering expertise to tackle any technical issues and the procurement strength to engage with various OEMs for spares and warranty issues. Further, our design team ensures that O&M requirements are addressed right at project conceptualisation stage for easy maintenance.

Get in touch with us to know more!

What are Boilers? How do they Enhance Production Processes?

Posted on by Thermaxqaz

Firstly, What is a Boiler? 

Before we begin with all the uses of the boiler, let’s define what a boiler is and how it works.

A Boiler is a closed vessel in which water or other suitable liquid is heated to generate steam or vapour.The steam/vapour is then exited and is used for various purposes like heating applications (water heating, central heating), boiler based power generation or even for cooking and other purposes which could be domestic or industrial.

It basically follows the concept of a pressure cooker but in a bigger way. The boiler concept is used across places from domestic purposes to industrial activities. The fluid is generally incorporated into a system and it works to provide steam through connecting combustion products and the water. 

There are many types of boilers based on their uses. While domestic boilers are small and are used for daily household chores, the industrial boilers today play a magnanimous role in the production process. 

Industrial boilers can also be environment friendly if the fuel used is natural gas or other types of non-harming fuels. They not only deliver the desired performance but also help industries to keep a check on the toxic emissions that are harming the environment in the worst possible way. 

For centuries we have been using boilers in various forms to heat water or to produce steam. Household boilers and Industrial boilers though have different purposes, but the operational aspect is similar. Good Industrial Boilers are known for their energy efficiency and massive heat production that has the capability of running your production processes. From steam-powered locomotives to external combustion engines to power plants, for various purposes, industrial boilers are used. 

Heat is vital for life. Without it, we cannot sustain. From cooking to styling your hair, we need heat for almost everything. Our pressure cookers can explain the basic concept of steam boilers where steam is pressurised and used for cooking. Heat energy also reduces the reliance on fossil fuels like petrol, diesel and more. 

Ever thought of enhancing your production efficiency without wasting money on electric energy? Did you know Industrial Boilers are powering many industries? Did you know Industrial Boilers are of various types and have different utilities? If not, here’s everything that you must understand about Industrial Boilers. 

The importance of Industrial Boilers is not unknown to manufacturing companies. They use industrial boilers for their many advantages; one of them is saving the cost of using electric energy for the entire process. Electric power becomes extremely expensive if used on a large scale, but Industrial Boilers help in keeping the extra expense in check.  Boilers offer maximum efficiency and minimum menace like fewer hassles of handling and depending on electric energy. 

Basic Industrial Steam Boiler

Image Source: https://electricalengineering123.com/steam-boiler-diagram-parts-dummys/boiler-room-schematic-diagram/

In today’s time, efficient boiler technology is way more important than before. Heat energy will also improve equipment efficiency. Many industries are now using pressurised steam to run machines.  It is not only efficient in enhancing your production but also is environment friendly in many ways. 

First, it saves the companies from using gallons of electric energy which is expensive and harmful, according to an article published in 2015. Industries wasted three billion units of power. Imagine what the number for the amount of energy that was consumed would be! Appalling! Isn’t it? Here are the latest statistics of power consumption in 2020

The fuel used for the boilers is often natural gases and various other fossil fuels, coals and more. Thus, it is crucial to choose the right boiler that does not waste the heat produced,  ensuring more delivery than other sources of energy. 

Some of the best boiler manufacturers, Thermax, for example,  offers waste heat recovery solutions as well. Thermax ensures that all the heat that usually is lost as exhaust gas is utilised to its maximum potential. Advance designs and constant innovations help in bringing out the best in the boilers.

Necessary Parts of an Industrial Boiler:

Parts of Industrial Boiler

Image Source: https://www.tradeindia.com/products/high-strength-waste-heat-boilers-6320393.html

Burner: The burner is the starter of the combustion reaction inside the boiler. There is a mechanism that sends the message to start the process of producing heat. A nozzle in the burner that turns the fuel pumped from the fuel source ignites it to create the combustion. 

Combustion Chamber: The combustion chambers are made of cast iron and can have a temperature of several hundred degrees in minutes. It burns the fuel and generates heat which is transferred to the heat exchanger.

Heat Exchanger: Also called the economiser, it is responsible for increasing the efficiency of the boiler. The heat exchanger is placed before the air heater in the fuel gas path.

Steam Drum and Mud Drum: The steam drum collects the steam while the mud drum is placed beneath the steam drum and collects the solid which is removed periodically. 

Fuel Sources used in boilers

 From coal, kerosene to natural gases, the fuel can be of various types. 

How does Industrial Boiler work? 

Industrial Boilers are water-containing vessels that generate heat with the help of a fuel source. It is then transferred to various tubes connecting to the various industrial equipment. The steam energy is used for running the machinery, giving industries a cost-effective way of powering their production.

Basic Functioning of Industrial Boiler

Image Source: https://ccpia.org/commercial-steam-boilers-a-primer/

The way the boilers work is not as complex one would think. It is a mix of basic science and the latest innovations. Separate parts of the system are placed at different points.

The heat source and the water vessels are placed in different compartments. The metal rods that connect to the water vessel and then the heat helps in steam production. The steam is then collected in a dome to condense it before releasing it from the boiler. This increases the pressure, and the energy produced helps in powering your production processes. 

Often for safety purposes, boilers come with a safety valve to ensure zero mishaps because of the increased pressure. There are different types of boilers, depending on the purpose of use. We will get into the details of the classifications as we go further in the article.

Boiler Care For Longevity And Better Performance

Here are a few things that one should always take care of to increase the lifespan of boilers.

  • General safety checks at regular intervals are crucial for maintaining the boilers.
  • Boiler temperature should be perfect as overheating can be a cause of the boiler’s breakdown. 
  • Avoid inefficiency by keeping a tab on the fuel levels, circulations and pressure.
  • A boiler should always have smoke detectors and alarms for low fuel and pressure for safer functioning.  
  • The Chimneys, vents and outlets must be cleaned for better productivity of the boilers. 

Types of Boilers: 

The type of boiler you need will depend on your production requirements. Different types of boilers serve different purposes. The classifications are based on the amount of pressure it can create, the capacity to hold the fuel and water and the type of fuel one will be using.

Boiler Classification

Image Source: https://www.researchgate.net/figure/Boiler-classifications-adapted-from-2_fig1_329358458

Fire Tube Boiler

Fire Tube Boilers are used widely in small and medium-sized industries. They are factory-made and come with pumps and control systems, all set to start operations as soon as connected to a fuel and water supply. They are often called the packaged boilers. These kinds of boilers are befitting for low to medium pressure steam requirements. Here, the combustion gases flow outside the water pipes.

They also have the capacity to produce steam with up to 2200 horsepower pressure but comes with a tremendous risk of explosion. It might be a little expensive for companies that do not need steam energy at all times.

Boiler Classification

Image Source: https://savree.com/wp-content/uploads/2019/07/fire-tube-boiler-cross-section.jpg

Water Tube Boiler

The Water Tube Boiler is multifaceted. They are significantly different from the fire tube boilers. The two types differ in the ways they function. Water Tube boilers are usually used in large manufacturing factories where there is a need for high-pressure requirement. There is a circulation of water between the mud and the steam drum, ensuring more control over the circulation by density differences.

They are perfect if you often need to change the steam quantity because of their lower water content. The water tube boilers are often built on sites and are usually not available in a packaged unit.

Image Source: https://3.imimg.com/data3/MR/EC/GLADMIN-41054/water-tube-boilers-500×500.jpg

Electric Boiler

The most popular boiler type. It is incredibly efficient and environment friendly as it does not require any kind of fossil fuel and hence leaves a smaller carbon footprint. The best part is unlike other boilers; there are no exhaust fumes. Rural users use them widely as the installation cost is lower, less noisy and requires less space than the others as well.

Though it looks like it is the most advantageous, it has its cons as well. It runs on electricity and involves heavy electricity consumption. Electric energy is not at all cost-effective.

Image Source: https://lh3.googleusercontent.com/proxy/fZETYEgc-Ux0S8psNPC19TJYBf5ZVuC9HzlGDM72FgNV1Y9H5IfjO5uKOI04XXUYpIO8hwlsB1qhABzGaCIV_ok7GIobwM6hhYY14QB5mBd3HKxkkTlM2rpDN821GD-O

Condensing Boiler

Condensing boilers are different and work differently. They use natural gases and two heat exchangers, making it the most efficient boiler. They extract heat from the exhaust or waste gases. This helps in reducing the wastage. They are capable of achieving 98% thermal efficiency and are now replacing other boilers for central heating. 

Many HVAC experts are of the opinion that this is the most sustainable boiler as its two heat exchangers help in the reduction of wastage and expenditure.

Image Source: https://www.atlanticboilers.com/products/ESB-3pass-steam-boilers.jpg

Oil Boiler

The efficiency of oil-fired boilers is usually 86% while oil condensing boilers are  90% or more efficient. The fuel used here is not natural gas but oil. The oil is ignited in the combustion chamber, and then the heat exchanger heats the cold water. It is usually used in the household to get warm water in showers, taps or radiators. 

Image Source: https://www.industrial-boilers.com/wp-content/uploads/2014/12/Fulton-Horizontal-Firetube-Boiler.jpg

Natural Gas Boiler

Natural Gas Boilers, as the name suggests, use natural gas as its fuel. A temperature gauge regulates it, and a thermoelectric device is used to reduce fuel wastage. The gas lights up the pilot which heats the coils in the boiler. Rural areas use propane gas most of the time.

It is essential to understand what your needs are, and this classification might be of help. It is always advisable to have a detailed discussion with experts from boiler manufacturers like Thermax or others. This will ensure you save your money and get the right one. Too small or too big, what type of fuels and more of such information you must always attain first before making a purchase decision.

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Solar PV Installation Guide by Thermax: Tips & Mistakes to Avoid

Posted on by Thermaxqaz

India has been one of the active proponents in establishing solar energy as the major source of electricity. Using environmentally friendly materials is one of the most considerate things industries can do to ensure sustainability of the environment. Many people have turned to solar energy to power all of their manufacturing and other activities through companies like Thermax Global and their expertise in solar PV installation.

Solar energy is currently used in a variety of critical activities ranging from air cooling to electric power to machine fuelling through solar panels. By 2030, the country hopes to have installed renewable energy capacity of around 450 gigawatts (GW), with solar accounting for roughly 280 GW (almost 60%). Below is a graph that talks about the growing demand for solar energy.

Now, if you are working on solar PV installation, you will need a guide that will provide you with all the necessary dos and don’ts. So, here is what you need to know about solar PV installation in India:

Pre-installation Checks – All the Things to Take Care of Before Starting

Since installing solar panels will require you to be focussed, it is better to go through everything before starting. Below is a basic concept of solar PV and its working:

  • Purchase supplies not included in your shipment

Ensure that you have wiring, toolbox, junction boxes, splicing devices and anything else you might need to install without hiccups.

  • Inspect your package to verify there are no missing or damaged items

Check all the items in the package and system thoroughly before starting. Any damage or missing parts will halt your solar PV installation.

  • Keep your system and yourself organised while unpacking everything

Ensure that everything is well organised before starting the installation. This will reduce confusion down the line and ensure smooth operation.

  • Examine and understand safety precautions before installing your system

Always check for safety ratings on all of your equipment and electrical systems. This will prevent any accidents. India has different ratings so ensure that you have the right ratings for solar PV installation in India.

  • Measure the needed angle and direction for your solar panel

The tilt angle of your solar panel should be determined by the latitude of your location anywhere in the globe using a solar tracker. It is often assumed that modules set at a tilt angle equal to the latitude of the location will produce the most energy.

Simple Tips for Installation to Make Things Easy and Mistakes to Avoid

  1. Choose the right type of mount for you. There are three types of mounts: pole, roof-ground and flush mounts. Each will help you install in a specific location.
  2. Take care of any sunlight obstacles before starting solar PV installation. Remove any unneeded obstacles, such as branches that may be blocking sunlight to your solar unit.
  3. To avoid fatigue, use the right equipment and remember to take pauses. Always use eye protection, gloves, and closed-toe boots.
  4. Always keep a multimeter on hand. Before proceeding, double-check the wires and terminators for zero volts.
  5. Before you begin, spend some time reading the manufacturer’s solar PV installation guide. Make a to-do list using the instructions. This will help you to organise your equipment, hardware, and tools as you progress through each task.
  6. The proper installation of solar panels is critical. Solar panels are set out and secured to a mounting framework such that they do not tilt or wobble. Civil work should be used to ground the solar panel mounting framework.
  7. Solar panels should always be placed at a 30-degree angle to maximise efficiency. In addition, solar panels should be installed towards the southwest.
  8. Earthing safeguards your solar system by preventing overload, directing surplus power to the ground, stabilising voltage, and preventing accidents.

How to Install the Solar Panels

Step 1 – Assemble all the tools you will need. It includes tape measures, ladder, chalk line, hammer, ink marker, wire stripper, screwdriver, multimeter and any other tool that the guide suggests.

Step 2 – First, measure out the mounts using a tape measure and mark them on the desired spot. Make sure there is enough space around it all, just in case. Make sure you double-check with the installation guide about the weight and check the sturdiness of your space.

Step 3 – Now install the solar panels and fix them in place. The panels will require precautions. So, be patient and take help from someone if needed. Ensure that you check for electrical wiring and their exits. It will make things easier for you in the next step.

Step 4 – The next stage is to complete the electrical wiring. During wiring, universal connectors such as MC4 are utilised since they can be linked to any type of solar panel. In a series connection, the positive wire from one module must be connected to the negative wire of another module. A parallel connection connects the positive to the positive and the negative to the negative leads. A parallel connection keeps the voltage of each panel constant, but a series connection raises the voltage to match the voltage of the battery bank.

Step 5 – Now connect the wiring to the inverter as instructed in the solar PV installation guide. Connect the positive solar panel wire to the positive inverter terminal and the negative solar panel wire to the negative inverter terminal. Other connections include the battery wire connection and the output wire connection to the inverter. To generate energy, a solar panel, a solar battery, and a grid input are all linked to a solar inverter. The inverter’s input is connected to the output of a series of solar panels. While making the connections, ensure the inverter is switched off.

Step 6 – A battery is required in an off-grid solar system since it is utilised to store backup power. This battery is linked to a solar inverter, which recharges it using a solar panel and the grid. The battery’s positive terminal is linked to the inverter’s positive terminal and negative to the negative terminal.

Step 7 – To connect the inverter to the grid, simply plug it into the main power switchboard and it will get electricity from the grid. The output cable is also linked to the board that supplies power to the house. A metering device must be installed to determine the surplus energy generated by the solar system. The positive wire from the metering device must be connected to the line terminal, and the negative wire must be connected to the inverter’s neutral terminal.

Step 8 – Turn on the mains when all the connections are completed. There is a digital display that indicates the total solar unit generated during the day, the supply voltage and current (amp) from the solar panel, and other information.

Thermax Global – Where Quality and Technology Goes Hand in Hand! 

It is important to choose a solar PV installation company in India that is known for efficiency and great practices. This ensures that you get the best solar panels for your investment.

Thermax Global has years of experience and knowledge in the construction of solar power plants. Thermax has assisted some of the industry’s largest companies in making the transition to solar energy with ease. It has been a pioneer in developing creative solutions to challenging issues.

Among other things, they are the leaders in industrial solar PV installations and innovators of more efficient technologies. Choosing Thermax Global is not just the right but the obvious choice!

So, visit Thermax Global now or contact us via email (customer.support@thermaxglobal.com) or call us on toll free number 1800-209-0115 for your solar PV installation now!

Balancing Power Availability With Sustainability – DG PV Controller

Posted on by Thermaxqaz

A DG-PV Controller 

Frequent power cuts are a grim reality faced by all industries and commercial establishments across the country. It forces businesses to rely on Diesel Gensets, thereby increasing costs as well as the carbon footprint of the organisation.

The effectiveness of generating clean and cheap power by installing GRID connected rooftop solar power plant gets marred by frequent power cuts as solar power plants use grid power for reference voltage and frequency. In the absence of grid power, the system is unable to function, causing dual loss to the owner. The owner not only loses the electricity that could have been generated by rooftop solar power plant but is also compelled to switch over to the costly DG set for full power back up.

DG-PV System controller is a unique solution that resolves this problem by interfacing with the grid and DG set simultaneously to provide a complete grid management solution. This controller makes it possible to use solar power even when grid power is not available, by using a diesel generator. It ensures maximum utilisation of solar power and minimum fuel consumption by DG set.

Smart communication between the photovoltaic system and DG set assures greater uptime of the system and up to 25-30% fuel saving with maximum grid stability.

A solar DG-PV controller automatically synchronises solar PV with DG set. All information related to grid properties, load requirement and minimum genset loading is considered while configuring the fuel saving controller, which defines the optimum PV power set point for secure and reliable operation at all times.

The fuel save controller enables the hybrid controller system to meet any dynamic load requirement. If required, the PV power can be throttled down to guarantee smooth genset operation for optimum grid stability.

Some of the other benefits of DG-PV controller are protection against reverse power current and dynamic monitoring of system parameters on the SCADA /monitoring software. Also, it will ensure zero power flow from PV to grid in case the load demand comes down, thereby maintaining system stability when running PV plant with DG generator in the absence of the grid. 

The hybrid control system is highly scalable and can be adapted to the specific requirement of the application, for example – communication with inverter over ethernet or serial (RS485/232), universal analog inputs/output module, thermocouple and RTD. The controller also ensures compatibility with all makes of solar inverters and diesel generators.

Thermax has set up DG PV controller for multiple customers over the years. Our experts can guide you to select a configuration that works best for your plant. As the world moves towards improving energy efficiency and conserving resources, DG PV controller can help in taking another step towards sustainability and reduce your cost of operation in the process.

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