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We are preparing our 2009 Editorial Calendar.  I want to make sure we are covering all the topics that keep you up at night!  What issues are you faced with everyday at your plant or facility?  Have you had a time this year when you thought, “I wish Pumps & Systems would cover this more.” If so, please let me know so I can discuss it with our editorial team.  We want Pumps & Systems magazine and pump-zone.com to be your information source.  This is your opportunity to ask. 

Some very influential people seem to think so.  Wind is a key energy source critical to our power shortage and will play a vital role in reducing our dependency on fossil fuels, but is it really the answer?  Let’s take a look at the big picture, fuel and energy used to generate electricity is only part of the equation, we must take into account transmission, distribution, sustainability as well as public sentiment.

It seems everyone has a “Pet” energy source that is going to solve our energy crisis be it nuclear, wind, coal, natural gas, solar or bio-mass.  If we step back and take an objective look at what is going on in the world today perhaps we can make sense of the world (not just North America) energy crisis and come to a rational solution to this global issue. 

I’m going to go out on a limb here and make a broad statement, most Americans react only when a situation is in crisis mode or when it directly impacts their life style.  We go into panic mode and look for a quick fix, hence the single energy source solution.  In order to resolve this world wide problem (think global) we need to look beyond current technology.  Existing technology does not fit our future energy needs.  Does it make sense to continue building massive coal fired power plants when we do not have the rail capacity to deliver the coal or the capability to control emissions?  Not to mention public sentiment, there are quite a few environmental groups that will respond with a resounding no.  The same can be said for nuclear, while nuclear is emission free we still have special interest groups that feel nuclear power is dangerous.  Other special interest groups appose wind because of the noise, danger to birds and general appearance.  I can go on and on with other energy sources, no matter what some special interest group will have reason to object (that is their right).

Reality check, we are in a crisis situation and we still can’t seem to agree on a primary energy source.  A few people have offered up “conventional / singular” solutions all of which have come under fire.  The longer we wait the greater the impact on our economy.  Other countries are moving forward with solutions right or wrong, they are committed to meeting their countries need for additional power generation.  In my humble opinion we have “too many cooks in the kitchen” and we are not thinking beyond current conventional power generation technology.   

Is the answer blowing in the wind?  Only part of the solution lies in wind, the remainder will/should be a mix of other energy sources, some renewable, fossil, biomass and nuclear.  It makes little sense to gobble up our natural resources simple because it’s there, plentiful and perceived to be inexpensive.  This is short sighted thinking, smaller localized plants using renewable and bio fuels can make up a bulk of the power needs.  Main line generators can be used for the load cell regions of the country.  Wind is a key player but not the ultimate solution to our energy crisis.  Until we as a nation agree on the recipe we will be hard pressed to stabilize our economy.   

Sustainability is the biggest opportunity and challenge that industry faces.  Developing a strategy to take on sustainability is vital for the long term survival of industry. The motivation for industry is clear however the change in thinking required and the associated challenge for industry is significant. How can industry get past first cost and the paralyzing fear of change?  One thing we can’t get past is rising energy cost.  Since 1999 average energy rates have increased 50% for industrial and 30% for commercial businesses in the Northwest, other regions of the U.S. have experienced similar cost increases. 

The U.S. power industry must build at least 150 gigawatts of new generating capacity to meet electricity demand by 2030, at a cost of about $457 billion, according to preliminary findings of a new study being prepared by the Brattle Group on behalf of the Edison Foundation.  An additional $900 billion will need to be invested by 2030 in transmission and distribution facilities to modernize the national grid.  The additional capacity and transmission will come at a significant cost to the customer.  We have established this fact in my earlier blogs.

Three-fourths of U.S. electricity–69% of which is used in buildings, nearly all the rest in industry can be saved for less than the price of just running a coal or nuclear plant. This energy potential is not just in smarter motors, lights, appliances, etc., but even more in their larger systems. For example, three-fifths of the world’s electricity runs motors, and half their shaft power runs pumps and fans. Designing friction out of pipes and ducts can save 10 times as much fuel at the power plant and sizing equipment properly can save even more.

While it is important to negotiate the best price per kW/hr for electricity investment in energy efficiency is not only about obtaining the cheapest source of new power for business.  Cost savings through energy efficient systems, waste reduction, reduced risk, and increased workforce productivity will allow industry to achieve sustainability. Unfortunately many companies still focus on reducing staff, eliminating or reducing planned maintenance and in some cases run equipment to failure, all for the sake of increasing stockholder value.  This is a huge misconception that must change in order for U S industry to prosper.  Eventually equipment must be maintained, catastrophic failures typically cost more than a standard repair any perceived savings is eliminated when the equipment fails.  So who wins?  Maybe the pump repair shop but certainly not your company.

For the skeptics there is a very compelling business case exists for investment in energy efficiency.  According to the NPCC’s 5^th Power and Conservation Plan, costs associated with energy efficiency average about 2.4 cents per kW/hr.  I challenge anyone to come up with a better return on investment.

The U S Department of Energy Superior Energy performance Program is asking for 25% reduction in energy intensity (a measure of energy consumption per dollar of real gross domestic product) by the year 2017.  By working smarter, using the latest technology, thinking beyond 1^st cost and controlling your systems we can achieve the desired energy reduction. 

Don’t forget to think beyond energy savings, in many cases by optimizing the design of a new pumping system it is possible to lower construction cost and achieve better performance, the best of both worlds.

Sustainability through energy conservation is the best solution for our country.

Reference:  The Case for Efficiency by Amory B. Lovins

                    Energy Efficiency is Pro Business by Kevin Wilhelm

The recent economic news in the United States has not been encouraging. The failure of Bear Stearns, the collapse of IndyMac Bank. . . even the purchase of Anheuser-Busch by Belgian company InBev. The news is grim.

However, an article from Reuters last week provided some encouragement for the process industries. Familiar companies like Eaton, ITT, SPX and ABB are set to post positive gains in these tough times. Increased activity overseas and the devalued dollar certainly help. The demand for energy also means significant industrial activity, which helps these OEMs.

One state is also benefitting from increased energy demand. NBC Nightly News recently ran a story (see the video here) about how the increased energy demands have bolstered the Texas economy. For the first time, Texas surpassed Virginia as the state with the number one economy in the United States. (Anyone who has been to Houston recently can testify to how much it has benefitted from this new oil boom.) It’s good news for Texas . . . and since I was born and raised in Texas, I was especially excited to hear the news.

On the downside, of course, nothing is permanent. The rising gas prices have decreased the U.S. family purchasing power and, consequently, will decrease U.S. demand for oil, as Federal Reserve Chairman Ben Bernanke commented yesterday. Riding an energy wave, Texas won’t be number one forever. However, we can still maintain hope in the process industries overall, as international demand and the necessity of the process industries mean continued business for our industry. This hope and the recent news from industrial companies provide a nice silver lining in an otherwise grim economic picture.

We are living in dangerous times, no I’m not talking about hostilities with other countries I’m referring to making the wrong decisions when specifying new equipment or system upgrades.  Failure to consider all options could be a fatal mistake, for example, sticking with the old tried and true specifications your company has been using for the last 50 years.  You know what I’m talking about, the typical fixed speed oversized pump coupled to an oversized motor with a 1.15 service factor bolted to oversized piping (future capacity).  Yes I sound like a broken record I’ve already mentioned this in previous blogs.   It’s worth repeating we need to dispense with the status quo.

Now let me throw out a new catch phrase “OPSOP” other wise know as “Optimum Pumping System Operating Point”.  This term was developed and coined by a well respected member of the Hydraulic Institute.  What is “OPSOP”?  Simply stated it is the pump operating point, which when combined with the optimized pumping system yields the absolute lowest cost.  Did I get your attention?  Lowest cost!!!

On a new pumping system you have three variables that affect the system initial and recurring cost:

Pump

•         Operating points have costs by choosing different pumps the pump curve can be adjusted.  The pump efficiency and BEP also adjust.  The pump curve can also be changed by changing the impeller size or (fixed) speed.

Control and Operations

•         The pump curve can be adjusted using variable speed control.  The system curve can be adjusted (to a limited degree0 by decreasing pressure drop across high pressure drop components

System

•         The system curve can be adjusted by using different pipe sizes, layout,  pipe material, and components

For existing system cost reduction, opportunities are typically focused on the first two.  Changes to the system are typically not cost effective.  Opportunities typically reside in changing the pump curve i.e. repair pump, impeller size change, controls (VFD) or a new pump.

Doesn’t this make more sense then following the same inefficient methodology that has been in place for the last century?  It’s time to step out of the “box” there are better ways to design new and upgrade existing pumping systems.  Your companies’ bottom line depends on cost effective, energy efficient systems the status quo is not the solution.

For more information on System Optimization and “OPSOP” go to www.pumps.org and purchase “Optimizing Pumping Systems a Guide for Improved Energy Efficiency, Reliability and Profitability”.

California’s state legislature is expected to pass a water softener ban.  After reading this, I am concerned that it could cause major problems for everyone involved.  It seems to me that this would only increase our energy costs.  An issue we are already struggling with daily!  

The only time a lot of us think of “Hard Water” is when you wash a new shirt and it comes out looking ragged or you have a bad hair day. But, this is a big deal.  There are many people involved in keeping our water clean and efficient.  We have already spent many funds developing greener softening technologies.  Will this bill send us backwards?

The press release states “Under the bill, water boards – which are not answerable to the voters – would be able to simply issue a “finding” that they believe bans would be helpful.”   

Should a “water board” be deciding on the most efficient way to run our water systems?  

How will this affect our water treatment plants?  How will this affect Maintenance Costs?

Superior Energy Performance Program

This month the federal government will launch the Superior Energy Performance Program.  SEP is a partnership between industry and government to accelerate US industry’s energy efficiency by:  

• Delivering tools, training, technologies & standards to all types of manufacturing plants
• Facilitating recognition and incentives for effective industrial energy management and energy efficient technology adoption

Partners 

• U.S. Industry
• U.S. Department of Energy Industrial Technologies Program
• U.S. Environmental Protection Agency ENERGY STAR Program
• U.S Department of Commerce Manufacturing Extension Partnership
• American National Standards Institute

Objective 

U.S. industry improves energy intensity by 25% over a 10 year period:  from 2007 to 2016

The big question, how do we achieve this lofty goal and an even bigger question, what are the ramifications if we don’t?  The government has a viable reason for pushing this initiative; if we continue down our current path we can expect rolling blackouts and perhaps extended periods without electricity.  Why?  Because the power industry infrastructure is antiquated, we have an aging fleet of power plants (the average coal plant is over 40 years old).  Even if we had the generation capacity we lack adequate transmission lines to distribute electricity efficiently. 

Our government is making every effort to motivate the consumer (residential, industrial and commercial) to reduce energy consumption however unless we all take an active role we will never achieve the desired results. 

Needless to say we will make the greatest impact within the industrial sector.  The challenge, as I have stated repeatedly, is to audit/review your existing pumping systems, most pumping systems are inefficient. Studies have shown that a majority of pumping systems operate at less then 40% efficiency.  If a pump system is inefficient it is most likely unreliable and significant maintenance.  Such systems should not be difficult to identify, track your maintenance look for the “bad actors” systems requiring frequent motor repair, pump repair.   When walking through the plant listen for noise at the pumps and valves, severe cavitation is quite easy to identify. 

For new construction and improving existing systems, think “Life Cycle Cost”, review your current specifications require energy efficient pumping systems. 

Consult Hydraulic Institute and Pump Systems Matter, HI and PSM have excellent web sites containing the necessary tools and resources to guide you through the system assessment process as well as developing specification for new and energy efficient systems. 

Pump Systems Matter TM (PSM) is a market transformation initiative created to assist North American pump system users gain a more competitive business advantage through strategic, broad-based energy management and pump system performance optimization. A primary objective of the initiative is to change the decision-making process for the purchase of pumping systems (motors, couplings, base drives etc).  Pump Systems Matter will promote educated decision-making based on life cycle costs (TCO), thereby accounting for energy, maintenance and other significant costs factors of operating a pumping system. PSM seeks to transform the market by changing owner and operator decision-making (END USER) on pumping systems from a focus on first cost to a focus on life cycle costs, while helping pump users capture significant energy-savings and performance improvements.  

No single organization can achieve the objective of the Superior Energy Performance Program we need the combined efforts of PSM, HI, and most important OEM’s, end users and engineering firms.

The government is asking for help in reducing energy intensity the SEP program provides the incentives for implementation.  Don’t wait until your energy bills put you out of business. 

REFERENCE 

Hydraulic Institute – www.pumps.org

Pump Systems Matter – www.pumpsystemsmatter.org