Certain topics continue to surface during recent expert discussions on energy efficiency in machines and plants. The topics include variable frequency drives (VFDs) for optimum drive solutions and increasing efficiency in low-voltage induction motors. However, low-voltage controls rarely enter the debate—which is an injustice. Low-voltage controls can increase energy efficiency in three primary ways:

Automatic optimization for pump design is a primary focus for many companies. Efficiency levels for several turbomachinery applications have been maturing in recent years. The introduction of computational fluid dynamics (CFD) in the design process led to some significant improvement in performance, but further improvements are increasingly more difficult to achieve.

The motor industry, represented by the National Electrical Manufacturer’s Association (NEMA), continues to expand motor scope and improve electric motors. Since the early days of the Energy Policy and Conservation Act (EPCA), the electric motor has played a key role in providing a catalyst of energy savings options.

Lawmakers in Washington are talking about it. Operations teams are thinking about it, and CFOs are losing sleep because of it. A plant’s energy costs are on multiple stakeholders’ minds.

Plant managers especially want to increase uptime and throughput without sacrificing goals for reduced production costs. These two competing issues can be dealt with simultaneously, but not through piecemeal efforts. A systems approach to pump system efficiency is required to accomplish both.

A thrust bearing can run hot for many reasons—such as excessive load and/or speed, inadequate oil supply or an axial clearance that is too tight. Typically, the reason a thrust bearing runs hot is because, for whatever reason, the load has increased. Time could be spent trying to address the root cause of the problem (the increased load, and indeed that task should be undertaken in parallel) or a redesigned bearing could be installed to address the symptom (a hot running bearing).

After nearly six years of intensive work, the American Petroleum Institute (API) 682 mechanical seal standard is soon to be adopted. Since its introduction in 1994, API 682 has become “the” standard that sets the global tone for the procurement and operation of seal and supply systems for centrifugal pumps in the oil and gas sector as well as in the petrochemical industry. API 682 is a “living” standard that directly incorporates diverse practical experience in its regular updates.

Magnetic drive and canned motor pumps are two types of sealless pumps. The difference between them is how energy is transferred to the impeller. A magnetic (mag) drive works on the principle of attraction and repulsion of two permanent magnets. A canned motor is an electric motor in which the rotor winding is encapsulated and is immersed in liquid. The rotor shaft has the impeller at its end. In the past, canned motor pumps had some features that made them technologically more developed than mag drive pumps.

Flow meters are necessary in the municipal world because utilities require accurate flow measurements for everything from chemical dosing to customer billing. The types of flow metering technologies are vast and depend on the accuracy required, water quality and line sizes.

New standards are emerging in maintenance operations across the U.S. Under enterprise-wide pressure to increase productivity, maintenance managers are responding by finding new ways to maximize uptime, extend equipment life and eliminate human error.

Given the realities of modern manufacturing, the recent movement is only expected to grow. While some new solutions may be difficult to integrate into current practice, one is simple, economical and delivers maximum impact—color coding.

Kids usually master new technology quickly. They use Facebook, iPhones, iPads, Xboxes—all things digital. Common to all these devices and technologies is the integrated chip (IC). Pump users, on the other hand, have not been as quick to adopt this new technology.