Looking back at a long and blessed career, Walter Hyde often returns to his faith and the many people who have helped him along the way
By
Colin Gregory-Moores, EA Contributing Writer
Electric Avenue
21 Hydrogen fuel cells vs. battery EVs
Batteries are ahead in the race, but hydrogen fuel cells are quickly gaining ground
By Maura Keller, EA Contributing Writer
Conventions & Trade Shows
24 Heating up and cooling down in sunny Florida
Thermostat bullies, rejoice: The HVACR industry’s main event just capped another banner year
By Charlie Barks, EA Managing Editor
26 A world of automation
Automate 2025 promises to bring to its international audience an exciting vision of the future
By Kevin Jones, EA Senior Editor
Energy
29 A new nuclear age
Improved safety measures and concerns about oil and gas are spurring a re-evaluation
By Bill O’Leary, EA Contributing Writer
43 Four-wheel drive
Electricity generation by source in 2025: Natural gas, renewables, coal, and nuclear
By Charlie Barks, EA Managing Editor
Motors & Generators
35 Resin-rich vs. VPI
Which is the better method of insulating motor coils?
By Michael Mitten, EA Contributing Writer
Finance & The Workplace
41 Top financial challenges in selling a business
For sellers, exercising proper due diligence can pay off By William H. Wiersema, CPA, EA Finance Editor
Electrical Manager
The outlook for OSHA s new for 2025 from the Occupational Safety and Health Administration
By Bill O’Leary, EA Contributing Writer
Training & Education and, air, and sea
Initiatives being launched nationwide for workforces of all kinds
By Charlie Barks, EA Managing Editor
Pump It Up
Pumps and the ‘energy transition’
Increased efficiency, retrofits, and renewable energy sources could ease the way toward a global objective
evin Jones, EA Senior Editor
COVER PHOTO: From the Carol M. Highsmith collection of the Library of Congress.
The Editor’s Comment
The energy sector powers forward
Coming next month in Electrical Apparatus:
Low-voltage switchgear; Behind a financial statement’s numbers; EV charging loses funding; Automate and PEARL show reports
The energy sector is a bit like the Wild West. Almost any idea can break through and capture hopes and investments, and many competing energy sources deploy a ruthless approach to their rivals.
Around this time last year, the energy sector could be described as “in limbo.” We discussed in this magazine how the highly impactful energy sector has never been more influential: extremely lucrative but also sometimes appearing to be at a standstill.
It’s difficult to say with conviction that the optics have changed, as we mentioned last year at this time, things appear to get done (such as progress on emissions reduction and decarbonization) only to witness oil and gas companies report record profits. Energy in 2025 still appears to be in the midst of a game of tug-o’-war.
As Bill O’Leary analyzes in this month’s cover story (“A new nuclear age,” page 29), one of the latest “breakthrough” ideas is actually a reconstruction of an old idea: nuclear power. This era’s nuclear wave focuses on microreactors that are viewed as much safer and more efficient. The global energy transition is undergoing a seismic shift. A surging demand for electrification is colliding with aging infrastructure. Nuclear microreactors have emerged amidst this Wild West shift that is often open to adopting anything with potential.
Elsewhere in this month’s EA, we have two familiar trade shows to mention. Senior Editor Kevin Jones handled this year’s preview for the Automate 2025 show set to take place May 12-15 in Detroit (“A world of automation,” page 26). With more than 800 exhibitors, Automate will continue its focus as the premier show for all things automation and robotics.
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Barbara Goetz Barks
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We also have an AHR Expo report from Orlando (“Heating up and cooling down in sunny Florida,” page 24). Recent regulations have steered the industry towards a focus on decarbonization, electrification, new standards, commissioning, and energy management. However, there are pain points. HVACR workers are adjusting to the transition to A2L refrigerants, compliance requirements, and incentive programs.
Elsewhere within the energy theme (“Four-wheel drive,” page 43), the U.S. Energy Information Administration released its Short-Term Energy Outlook, which contains the ever-useful energy pie chart showing shares of U.S. electricity generation. Natural gas accounted for about 43% of the pie in 2024, with estimates to drop to 39% by 2026. This was followed by renewables (23%), nuclear (19%), and coal (16%). The U.S. is currently running on a four-wheel drive method of power sources.
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Let’s Solve Your Problem
Leads determine the positioning of winding
In rewinding multispeed motors having two windings, our practice has always been to start the rst A-phase group in the same slot for both windings. One of our new people had not followed this practice and does not believe it should make any di erence how the two windings are positioned relative to each other. We see so few of these that we’re not sure whether any particular pattern is important. What are your comments?
Normally, the only reason to orient a winding in a particular way around the stator circumference is to be able to easily bring the leads out at the most convenient place to reach the terminal box. Otherwise, no electromagnetic reason exists to maintain any special relationship. (Note that this is true only of two-winding, two-speed motors.)
Rewinding to lower hp doesn’t help e ciency
When we rewound a 60 hp 1770 RPM motor, the customer wanted us to see if we could maximize the e ciency. He claimed the actual load was constant at only 49 hp. There were 14 turns per coil in the original winding, with no slot room for any more copper. So to match the load better, we put in 15 turns of smaller wire (same slot ll). Now, the customer claims he’s not measuring any better performance than before. Were we on the wrong track? Without knowing the exact distribution of this motor’s internal losses, the e ect of the change is uncertain. But probably the net result was to increase the load-dependent motor losses by the square of the turns ratio (15/14), or 1.15 times what they had been. The core loss should have decreased by about the inverse of that same ratio, or 0.87 of the original value. Friction & windage
didn’t change. For a typical loss distribution, this rewind would have increased total motor losses at 49 hp by about 6%.
Remember that for most motors, peak e ciency occurs at less than nameplate horsepower, so redesigning the winding to suit a lower horsepower load can back re insofar as e ciency is concerned. The optimal load point for e ciency is approximately 80% of the rated horsepower, although power factor at this level decreases.
Comparing lap windings against wave windings
Could you comment on the relative merits of lap versus wave windings in slip-ring rotors?
In form-wound machines, wave coils are usually easier to insert. Any wave winding eliminates many interconnecting jumpers. Another advantage is that it inherently results in three outgoing leads that are equally spaced around the rotor. This minimizes mechanical unbalance. In smaller machines, where neither coil insertion nor unbalance presents major problems, random windings of the lap type are usual. An un-taped, random-wound wave coil would be di cult to handle.
Tight-bolted connections for demanding duty
What would be a reliable method of maintaining tight bolted connections in the secondary resistor bank for a 700 hp slip-ring motor that sees heavy starting and speed-changing duty? The bolts keep coming loose, leading to sparking and jerky operation, and some are not easy to get at for frequent re-tightening.
Along with lock washers, try putting Belleville washers in the joints. Available from a number of hardware suppliers, these are slightly cone-shaped, to atten out when
the joint is properly torqued. By spring-loading the joint, they maintain fastener tension while allowing for expansion and contraction of the fasteners as the assembly heats and cools. Liquid thread locking products should not be used to secure conductive connections.
Three-phase rewind using larger wire
We would like to be able to put a value on a three-phase motor rewind in which larger wire can be used, with the same turns, to add stator copper and thereby increase motor e ciency. Not knowing the exact losses, and being unable to do any before-and-after load testing, there’s no way to do this exactly. Can you suggest a reasonable approximation?
There is one, but it must be based on a couple of assumptions. First, you must assume what portion P of total motor loss is in stator copper. Second, you must assume some average dollar value D for a kilowatt of loss reduction. Also, you need a number for the existing motor e ciency E in percent, although there’s some leeway there.
Reasonable values are 0.35 for P and 2,000 for D. In such a case, every 1% increase in stator copper can be valued at about $6 times the motor rated horsepower times the fraction (100-E)/E. This gure applies only if the motor runs at its nameplate horsepower and must be proportionately reduced at lighter loads.
This rewind will result in only small eciency increases, as you did not reduce losses by using higher-grade steel in the stator and rotor. If you’re hoping to obtain greater energy savings, a premium-e ciency motor is a better solution. If the motor is driving a centrifugal load (pump, fan, or compressor), adding an adjustable-speed drive could save 30%-40% in energy use. — Edited by the EA sta EA
Steady but uneven growth for electrical manufacturers
Now that we’ve closed the books on the rst quarter of 2025, we’re hearing of steady, if unequally distributed, growth throughout the electrical industry. Supply chain kinks are being worked out, and industrial output is strengthening. The generally upbeat news, however, is tempered somewhat by global geopolitical and trade tensions.
Roland Busch, president and CEO of German industrial giant Siemens, said Feb. 13 that the company had made “a promising start” to the year, having “signi cantly exceeded the prior-year performance and created an excellent foundation for a successful scal 2025.” First-quarter revenue grew 3% to 18.4 billion euros, while orders rose in all industrial businesses except Mobility, which in the rst quarter of last year had recorded a “sharply higher volume” from large orders, the company said. As a result, orders for Siemens declined 7% overall to 20.1 billion euros. Net income rose sharply, bene ting from an after-tax gain of 2.1 billion euros from the sale last year of motor and generator manufacturer Innomotics to KPS Capital Partners
For the quarter most recently ended, South Korean industrial manufacturer HD Hyundai saw revenue growth of 50.6% year over year in its Power segment, to 815.7 billion Korean won, or about $565 million. The impressive growth was driven by what the company
characterized as “favorable market conditions and exchange rates.” Transformers in particular saw sales growth in all regions, with the Americas increasing its share of the total. The Rotating segment, on the other hand, recorded a year-over-year sales increase of “only” 1.3% and a decrease from the prior quarter of 6.2%.
Please turn to page 8
— Illustration by Bing generative AI
For the nine months ended Dec. 31, 2024, Japanese electrical manufacturer Nidec Corp., meanwhile, reported that net sales were up 11.5% compared with the same period the prior year, to the equivalent of about $12.79 billion. Although several factors and business units contributed to the increase, the company noted that “there is a rapid expansion in the demand for generators essential for data centers, battery energy storage systems due to the growth of green-innovationrelated demands, and large motors associated with the renewal of social infrastructure.” In response to this demand, the company is expanding production capacity in India, France, and North and South America.
Regal Rexnord of Milwaukee, the manufacturer of motors, drives, and other power transmission components well known for its Century, Marathon, and Leeson lines of electric motors, reported quarterly nancial results Feb. 6 that might be described as “steady,” although the company chose to describe them, less charitably, as “ at.” Net sales edged down a negligible 1.4% from the same quarter the prior year, to $1.46 billion. The company pointed to weakness in the machinery, factory automation, general industrial, and general commercial markets but strength in HVACR, food and beverage, aerospace, and energy.
In its quarterly nancial report released Feb. 10, Milwaukee-based Rockwell Automation, a provider of products and systems for industrial automation and digital transformation, reported that earnings per share
8.4% year over year and orders rose about 10%. First-quarter reported sales were $1.88 billion, down from $2.05 billion in the rst quarter of scal 2024. The disparity between sales and earnings per share may have been explained by chairman and CEO Blake Moret when he referred to the company’s “renewed focus on operational excellence and cost discipline.” Among the business units that underperformed was Intelligent Devices, which saw sales decline 13% for the rst quarter compared to the rst quarter of 2024, to $806 million.
Automation and process control provider Emerson of St. Louis saw earnings per share and operating cash ow increase signi cantly during the rst quarter of the current scal year even as orders and sales remained essentially at. Net sales, at $4.17 billion, were up 2% compared with the same quarter the year before, while underlying orders were little changed, up 1%. Free cash ow, by contrast, was up 89% to $694 million, while GAAP earnings per share rose 252% to $1.02.
“Accelerated execution” is how French electrical manufacturer Schneider Electric described its performance in 2024, when fourth-quarter revenue rose 12.5% over the same period the prior year, to 38 billion euros, compared with revenue for all of 2024, which was 8% over 2023’s, or 11 billion euros. Reported growth for the quarter was especially strong in North America, where revenue grew 25.3%, compared with Western Europe and the Asia-Paci c region, where revenue grew a more modest 7.2% and 7.9%, respectively.
Turning from manufacturers to the retail and distribution side of the industry, W.W. Grainger of Lake Forest, Ill., maintained steady growth in the fourth quarter and full year of 2024. Sales of $4.2 billion in the fourth quarter increased 5.9% over the fourth quarter the year before, while fullyear sales of $17.2 billion represented a 4.2% increase over 2023’s sales. Grainger’s net earnings for the quarter, at $475 million, represented a 13.9% increase over the year before. Grainger forecasts 2025 sales growth in the range of 2.7% to 5.2%. — Kevin Jones EA
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Associations
One association’s snapshot of the U.S. energy industry
A figurative snapshot of the U.S. energy industry captured last summer by the Edison Electric Institute reveals an industry that, at the time, had shifted decisively toward renewable energy and scaled back on the use of coal and other traditional energy sources. Generating capacity was on the rise as the nation’s thirst for electric power appeared unquenchable.
Whether or not the trajectories traced in the report will continue under the new regulatory regime in Washington remains to be seen.
The Statistical Yearbook of the Electric Power Industry, published by the institute last July, presents a detailed analysis of the industry’s performance. It provides insights into generation capacity, energy use, financial performance, and environmental impact. The annual yearbook is based on data that was the most recently available at the time of the yearbook’s publication, so it provides a view of the U.S. electric power industry frozen in time. The next edition is expected to be published this July.
According to the 2024 yearbook, total installed generating capacity in the U.S. had reached 1,190 gigawatts by the end of 2023, up from 1,175 gigawatts at the end of 2022. “This growth reflects the industry’s efforts to expand capacity and meet the rising demand for electricity,” the report noted. Natural gas remained the dominant source of electricity generation, accounting for 38% of the total mix.
Renewables, including wind and solar, contributed 21% to the total generation mix, with wind power alone accounting for 10%, solar power for 9%, and other renewables, such as biomass and geothermal, making up the remaining 2%. Coal’s share declined to 19%, down from 21% in 2022, while nuclear power stood at 19% and hydroelectric power at 7%.
At the time of the yearbook’s publication, new capacity additions, especially in wind and solar, continued to dominate installations, with a combined total of 35 gigawatts of wind capacity and 30 gigawatts of solar capacity added over the two-year period. This trend underscores the industry’s commitment to expanding renewable energy sources and reducing reliance on fossil fuels. “The shift toward cleaner energy sources is evident in the substantial investments made in wind and solar projects,” the yearbook noted.
The electric power industry’s total revenue reached $400 billion in 2023, up from $380 billion in 2022, reflecting increased demand and higher electricity prices. Operating expenses totaled $290 billion in 2023 compared with $285 billion in 2022 — an increase driven by rising fuel costs along with investments in grid maintenance and modernization. “The industry’s financial health remains robust, supported by strategic investments and prudent management,” the yearbook stated.
The yearbook also provided data on the participation and effectiveness of demand response programs, in which 25 million customers were enrolled in 2023, up from 22 million in 2022. These programs resulted in a reduction of peak demand by 20 gigawatts. Meanwhile,
energy efficiency initiatives led to an additional 5% reduction in electricity use. “Demand response programs and energy efficiency initiatives are critical components in maintaining grid stability and reducing overall energy consumption,” the yearbook’s authors wrote.
Technological advancements, not surprisingly, played a critical role in attaining these benchmarks. More than 80 million advanced metering infrastructure devices had been installed as of 2023, up from 75 million in 2022. By enabling real-time monitoring and better data on energy use, these technologies provided utilities with improved tools for managing the grid and responding to outages.
Emerging technologies such as energy storage, electric vehicles, and distributed energy resources, or DERs, were examined for their potential to transform the industry. Energy storage capacity, the yearbook’s authors found, had reached 10 gigawatts, up from 8 gigawatts in 2022. The number of electric vehicles on U.S. roads had surpassed 2 million.
The policy and regulatory environment at the time was conducive to the development of renewable energy, with tax incentives for renewable energy projects, emissions reduction targets, and mandates for utilities to procure a certain percentage of their electricity from renewable sources. Average electricity prices remained stable at 13 cents per kilowatt-hour, with increased competition and the growth of independent power producers contributing to market efficiency. “Federal and state policies continue to shape the landscape of the electric power industry, driving investment in renewable energy and grid modernization,” the report said.
The 2024 yearbook highlighted the need for continued investment in research and development, workforce training, and infrastructure upgrades to meet future energy demands and achieve sustainability goals. As the report concluded, “The future of the electric power industry lies in its ability to adapt to changing technologies, regulatory landscapes, and market dynamics while maintaining a commitment to sustainability and reliability.”
Perhaps we should consider all of these statistics an average from which deviation, given the current regulatory environment, is inevitable. Since the publication of the 2024 yearbook, much has changed in the federal government’s attitude about how best to generate energy and how best to use it. The next edition of the Statistical Yearbook of the Electric Power Industry, typically a rather dry read, should be very interesting. — Kevin Jones EA
— Illustration by Bing generative AI
Keeping the lights on for the renewable energy industry
American Council on Renewable Energy
Founded: 2001
Headquarters: 1150 Connecticut Ave. NW, Suite 401, Washington, D.C. 20036
Annual Dues: Varies by membership tier Website: https://acore.org/
Renewable energy is one of the world’s fastest growing energy sources and has grown exponentially from its roots. In 1839, the first solar panel was invented and got the ball rolling on early renewable energy innovations. Though the process of honing these innovative energy sources has taken twists and turns, there is no doubt that renewable energy sources continue to be at the core of conversations surrounding sustainability and climate change.
One of the organizations at the forefront of fostering these conversations about meeting the existential challenge that climate change poses is the American Council on Renewable Energy, also known as ACORE.
In 2001, ACORE was formed as a dedicated player in expanding the “pan-renewable economy” in the U.S., which refers to an economic system in which the leading energy source is from a renewable source. Today, ACORE’s mission stands as uniting “finance, policy, and technology to accelerate the transition to a renewable energy economy,” and a vision of “an electrified economy powered by clean energy that supports an improved quality of life for all,” according to the organization.
These three focus areas — finance, policy, and technology — are the dedicated centers of attention that guide ACORE’s work. The organization’s finance focus is maintained by leading discussions about investments in clean energy through its advisory councils. ACORE’s policy focus is maintained by working directly with Congress, lawmakers, and other branches of the fed-
eral government to “promote and defend policies that accelerate the clean energy transition,” ACORE says.
Initiatives in the policy sector include tax incentives to drive clean energy usage, supply chain and trade regulation involvement, and policy reforms to improve the status of a clean energy infrastructure. The technological division of the ACORE’s work focuses on finding ways to work around industry and market barriers to assist those invested in promoting clean energy usage.
“What is unique about our organization, compared to other non-profits in D.C. and around the country, is that we really bring together companies from all sides of the clean energy transaction space,” Colleen Pickford, ACORE’s executive vice president of corporate engagement, says. “If there’s someone who is playing a role in developing renewable energy, they’re participating at ACORE.”
Membership with ACORE is divided among different levels and distinctions, including leadership council membership, advisory council membership, and executive council membership, each of which provides opportunities for networking, insights, and impact, respectively. Leadership council membership brings together leaders for industry events and
A scene from ACORE’s Grid Forum last October in Washington, D.C. — ACORE photo
o ers opportunities for connection. This membership tier also includes tickets to invite-only ACORE dinners, member-only digital webinars, ACORE receptions at industry trade shows, and opportunities for promotion in the organization’s newsletters and on its social media pages.
The advisory council tier of membership gives members access to and involvement with the organization’s four advisory councils, which allow members to “access the latest insights on critical policy developments, contribute to educational materials and comment letters, and strategically engage with government agencies, congressional o ces, power markets, and standard-setters,” according to ACORE. Advisory councils span nance and tax (PREF), transmission and markets, corporate sustainability standards, and trade and supply chain.
adjective: compliant
ACTually
The third tier, the executive council membership, grants access to all of the organization’s advisory councils in addition to opportunities to participate in speaking engagements.
In addition to the standard levels of membership, the organization o ers the ACORE Accelerate Membership Program, which is a two-year application-based program giving smaller companies a foot into the door of the renewable energy industry. The program provides opportunities for these smaller companies to build connections, attend town halls, and participate in mentorship.
“The market intelligence that we provide is really unmatched out in the marketplace, because we bring together such a wide range of perspectives and we’re a trusted partner for so many companies,” Pickford says. “We’re able to glean information and insights that others aren’t. More than anything else, I think our market intelligence, our research, and our reports are what people are coming to ACORE for.” An array of these resources — including blog posts, annual reports, fact sheets, testimonies, and more — are publicly available on the organization’s website.
Inclined to agree with others or obey rules, especially to an excessive degree; acquiescent. “A compliant labor force” Meeting or in accordance with rules or standards.
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As time goes on and governmental administrations change, renewable energy’s importance remains vital. “If you look at the clean energy landscape, as a country, our energy needs and demands are rising like never before, and so our industry is there to help meet them,” Pickford says. “Americans need a ordable, reliable energy, and so we’re spending a lot of our time focused on making sure we can deploy an ‘all-of-theabove’ strategy.” — Avery Heeringa EA
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Perdido River Farms announced in February that it has opened a new $29 million meat processing plant, Perdido River Meats, in Atmore, Ala. The 23,000-square-foot facility houses a retail store and a meat processing operation that can process up to 125 head of cattle weekly. It will eventually process hogs and chickens as well as beef. Described as the largest facility of its kind in southwestern Alabama, the plant will allow ranchers to sell locally raised and processed beef to consumers without rst sending the cattle out of state for processing. Perdido River Farms is the agricultural branch of the Poarch band of the Creek Indians.
Pet food plant closes in Missouri
Royal Canin pet food manufacturing will cease operations at its Rolla, Mo., plant by year-end. Eighty- ve employees will be laid o by mid-April and the remaining 20 will be let go by Dec. 31, 2025, when the plant shuts down for good, unless they nd jobs elsewhere within Royal Canin. Based in France, Royal Canin also has plants in Lewisburg, Ohio, and Lebanon, Tex. The company is a division of Mars Petcare.
Container plant puts lid on operation
Ardaugh Glass Packaging will close its Dolton, Ill., plant in May, laying o 316 workers. The company produces “innitely recyclable” glass containers for the food and beverage industry. It is part of Ardaugh Group, which has 60 metal and glass production facilities in 16 countries and employs some 20,000 people, with sales of $9.4 billion. The Dolton plant is located south of Chicago near the Illinois-Indiana state line.
New truss plant in Pennsylvania
Pennsylvania-based 84 Lumber has acquired a truss plant in Bloomsburg, Pa., so it can build more trusses to meet growing demand from its residential and commercial customers in eastern and central Pennsylvania. The plant, formerly Tri-County Truss, is located in the Lightstreet Business Park, northeast of Harrisburg, the state’s capital. The 29,016-square-foot building sits on 8.8 acres. 84 Lumber started its operations there in early January with 15 associates who were already working there. It plans to hire a total of 30 associates by the end of 2025 and add another 50-60 in 2026, the company says. The new facility has advanced MiTek robotic technology that allows trusses to be built more quickly, accurately, and safely with a laser system that guides the wood. Founded in 1956 and headquartered in Eighty Four, Pa., 84 Lumber Co. is a privately held supplier of building materials, manufactured components, and industry-leading services for single- and multi-family residences and commercial buildings,
Giving back, paying it forward
Looking back at a long and blessed career, Walter Hyde often returns to his faith and the many people who have helped him along the way
By Colin Gregory-Moores, EA Contributing Writer
“What I’m hoping out of this is to be encouraging and exhorting to the readers, ‘Go help this young generation,’” says Walter Hyde, the founder of Hyde Consultants, Inc., Houston, as we begin our conversation.
Hyde Consultants is a small service company specializing in the engineering design of electrical and control systems, electrical safety auditing, hazardous area classification, safe work practices, and field incident and accident investigation.
At 77, Walter Hyde now views his role as helping young people to enter the skilled trades and technical professions. This is supported by his activities in Scouting America and the Exploring program run by Learning for Life, an affiliate of Scouting America. He has a degree in electrical engineering and is a member of various professional bodies, including the Institute of Electrical and Electronic Engineers, the Society of Petroleum Engineers, and the National
Society of Professional Engineers. He worked for a petrochemical company and several engineering, procurement, and construction companies (EPCs) before founding his engineering firm in 1980. Along the way, he also became a registered professional engineer (currently inactive) and a licensed master electrician.
Appreciation of the skilled trades
Walter was born in Woodville, Tex., in 1947. With its rolling hills, pine forests, streams, and lakes, it is hunting and fishing country. Its industries include forestry, agriculture, and tourism. Like Walter’s parents, the people there were hardworking and neighborly, getting by with what they had and looking out for each other. From his father, who was employed as a surveyor for the highway department, Walter got his love for the outdoors. To study engineering and work as an engineer, though, Walter had to move away.
After graduating from high school in 1965, he enrolled at Lamar State College of Technology in Beaumont, Tex., to study engineering. Situated in a major industrial area, the college, which is now a university, focused on supplying graduates who had the necessary skills to work in the local industry. Walter was taught a lot of practical things. After two years, he transferred to the University of Texas at Austin (UT Austin), from which he graduated in 1970 with a bachelor of science degree in electrical engineering.
During the summers, he earned money for school. While at Lamar, he worked two summers for the Texas Highway Dept. He particularly remembers the skilled tradespeople. The quick-thinking crane operator who pulled up on the boom while yelling, “Run!” for those under the load when the hydraulic hose for the cable ruptured. And the grader operator whose trained eye could get within an 1/8” the contour for the road being built. While at UT Austin, he jobbed during the summers at a large petrochemical plant. One year, he worked maintenance, going out every day with the technicians to tackle challenging electrical or instrumentation jobs. His employers were so impressed by him that he had a full-time job offer in his pocket two years before graduation.
Blessed and helped along the way
From 1970-1971, he worked full-time at the petrochemical plant in the utilities design department. After that, his career took him to several large EPCs, where his work involved many complex and colossal projects and traveling to Europe and North Africa. As he kept going, he always had the sense that he could do things better if he had his own firm. In 1980, he founded Hyde Consultants, specializing in the engineering design of electrical and control systems mainly for the oil and gas production industry. Not deterred by the fact that he had neither
Walter Hyde pictured with the Eagle Scout mascot at the National Jamboree 2023.
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customers nor marketing skills, he says, “We started with next to nothing and hung out the shingle to be in business.”
Early one morning, Walter got a call from a company for which he had previously done some work. The company’s plant, which generated its own electricity, had lost all electrical power. When he arrived at the premises, there was no guard and nobody up front. Driving to the back where the generator building was, he looked at it and thought, “I’ve never done a black start of a generating facility.” He quietly said, “Lord, you’re going to have to guide me, because I don’t know what to do.” It was bedlam inside. People were running everywhere, and senior managers were standing around with grim looks on their faces, their arms crossed. The main electrical worker had been shocked and was in the hospital. It took Walter two hours of grabbing people by the arm and asking questions before they finally got to the point that they were able to black start the first generator. He billed the company for half a day’s work. Within two weeks, Hyde Consultants had the continuing work contract Walter had been seeking from that company.
Looking back at a long and blessed career, Walter often returns to his faith and the many people who have helped him along the way: “As I went through my career, there were several coworkers who freely gave of their wealth of knowledge and experience to me. That’s priceless. And that again is why I’m looking to paying it forward.”
Repurposing, exploring, and jamborees
After running his own engineering firm for decades, Walter started reflecting more on where he had worked, how he got to where he was, and what the next step should be. “Retirement’s not in the Bible,” he good-humoredly says and adds, “I finally came to the word ‘repurpose.’” He decided to take his skills, “no longer using them for monetary compensation, but toward helping the younger generations.”
Like his faith, volunteering for Walter is about giving back. In the early 1990s, Walter, who had also been a Scout, started to volunteer at the Boy Scouts when his son became a Cub Scout. After his son went on to college, he continued to work in leadership in Boy Scouts of America and its successor, co-ed organization Scouting America. Working his way up, doing some work at the council level as well as lots of work at
the national level, he came to the opinion that “If it’s being done right, and you’re applying the methodologies that are there for Scouting America, it’s the best thing for any kid’s start in life.”
In 2015, the National Service Center asked him to help revitalize the program materials for the electricity and electronics section of the science, technology, engineering, and mathematics (STEM) materials of Learning for Life’s Exploring program. Exploring is co-ed and caters to young people from the ages of 10-20. As stated on the website (https://www.explor ing.org), its vision is “to shape the workforce of tomorrow by engaging and mentoring today’s youth in career and life-enhancing opportunities.” Most recently, Walter was lead for the electricity and electronics STEM exhibits and activities at the National Jamboree 2023, which were highly praised. They resulted in several groups replicating the main activity in different parts of the country, many leaders volunteering to help with organizing similar events, and 50 volunteers helping to rewrite the electricity and/or electronics merit badge.
Walter and both Scouting America and Exploring are seeking individuals, and other organizations or companies to help with STEM and skill trades events in order to introduce and encourage young people towards careers in these areas. Addressing the labor shortage in skilled trades, Walter says, “There seems to be an emphasis in recent times that you need to go to college. We’re not all made that way. And we badly need those skilled tradespeople. Just as we also need university graduates with technical skills.”
Readers who are interested in learning more about Walter Hyde and his team’s skill trades and STEM outreach efforts are encouraged to e-mail Walter at EA.Walter@yahoo.com. EA
Walter Hyde (fourth from left) at second exhibit at the National Jamboree 2017.
— Scouting America photo
EA READER PROFILE continued from page 16
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U.S. electric motor design software rm ECM PCB Stator Tech has tapped David Hartwell as chief sales o cer, the Needham, Mass., company announced. In this role, Hartwell will lead business development for ECM’s PCB Stator products and services. These services include electric motor development on ECM’s PrintStator design platform as well as advising about modeling, prototyping, production, and commercialization of products incorporating ECM’s patented PCB Stator technology. ECM pairs printed circuit board technology to advanced Motor CAD technology. The combination is said to enable innovators to produce electric motors that are lighter, smaller, quieter, and more energy e cient.
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Brent Hutto is joining Chattanooga-based Truck Parking Club, a network of instantly reservable hourly, daily, weekly, and monthly truck parking locations throughout the U.S., as its “chief relationship o cer.” Hutto has been a cornerstone gure in the trucking industry for decades during his time at Truckstop and, before that, at Randall Reilly. He remains a senior advisor to Truckstop. At Truck Parking Club, he’ll be focusing that same energy and expertise on tackling one of trucking’s most critical issues: the truck parking crisis. The Owner-Operator Independent Drivers Association reports that there’s a ratio of one parking spot for every 11 trucks, resulting in more than 40,000 truck drivers struggling to nd safe parking daily.
Siemens AG has appointed Christiane Ribeiro Guimarães Höfer as the new global head of communications. She will report to Roland Busch, president and CEO of Siemens AG. Ribeiro succeeds Lynette Jackson, who had held the role since October 2021 and decided to leave the company to pursue a new opportunity. Ribeiro is currently Siemens’s head of CEO communications, strategic messaging, and thought leadership. She also leads communications for the newly launched ONE Tech Company, a company program for accelerated growth. She joined Siemens Brazil in 2001 and has held various communications roles at the company.
After more than ve years as president and CEO of Westinghouse Electric Co., Patrick Fragman announced he intended to step down at the end of March to spend more time in Europe with his family, Electrical Apparatus has con rmed since the initial January announcement. Fragman was to continue supporting Westinghouse for a few more months after March 31 to facilitate the handover to the new CEO. Former operating plant services president Dan Sumner assumes the new role of deputy CEO and upon Fragman’s departure will serve as interim president and CEO until a new CEO is appointed. “A recruitment process for the President and CEO position is underway and the selected candidate will be announced in due course,” Westinghouse said in an announcement. — Charlie Barks EA
Brent Hutto
Christiane Ribeiro Guimarães Höfer
Hydrogen fuel cells vs. battery EVs
Batteries are ahead in the race, but hydrogen fuel cells are quickly gaining ground
By Maura Keller, EA Contributing Writer
In recent years, advancements in EV technology have taken the automotive industry by storm. With ongoing marketing and education efforts, marketers and consumers alike are vetting these vehicles and determining their use and viability for both commercial and consumer use.
More recently, attention is being paid to the best way to power all-electric vehicles: hydrogen fuel cells or batteries. While both produce electricity to drive the electric motor – eliminating the inefficiencies and pollution of an internal combustion engine – fuel cells derive their power from hydrogen stored in the vehicle, while batteries receive their energy from the electrical grid. So which is better?
Katrina Groth, associate professor and director of reliability engineering, University of Maryland, says fuel cell electric vehicles (FCEVs) are simply a type of battery electric vehicle (BEV), but they use hydrogen as a fuel storage mechanism rather than only storing energy in the battery. The electrons from the fuel cell can directly power the vehicle motor or charge the battery.
Groth says that FCEVs offer the opportunity to decarbonize critical sections within transportation. They are also part of a value chain using hydrogen as an energy carrier and energy storage mechanism. Hydrogen can also be produced using excess energy generated from nuclear, wind, and solar and stored as a fuel until it is needed.
“By using hydrogen as an energy carrier – for example, using pipelines to transport and store hydrogen – we have both an alternative (and backup) to the overtaxed electric grid and a mechanism for storing and transporting hydrogen in existing infrastructure in critical regions of the U.S.,” Groth says.
Drawbacks of batteries
BEV drawbacks include fueling time, weight, and lower energy density (which translates into range). FCEVs can be fueled in as little as a few minutes as compared to the multi-hour charging time of batteries.
“FCEVs can store significantly more energy onboard than batteries – this translates into longer range and less frequent fueling,” Groth says. “This faster turnaround time also means higher utilization of your assets. There are also weight advantages:
Large-capacity batteries are heavy; fuel cell energy systems can be up to 10 times lighter than battery systems.”
On the vehicle side, Honda just unveiled a plug-in hybrid hydrogen fuel cell vehicle in Japan, with a range of 621 kilometers on hydrogen and 61 kilometers on its batteries. On the research side, there are first-of-their-kind demonstration projects in aviation, maritime, and rail. For example, multiple companies are developing helicopter propulsion technologies using hydrogen fuel cells. Joby recently set a new record: a 523mile flight powered by hydrogen, and Piasecki and ZeroAvia are partnering on hydrogen helicopter flight.
“On the ground, there are also investments in using fuel cells as backup power. Data centers are starting to invest in these backup power units to achieve uninterrupted power supply – for example, Caterpillar, Ballard, and Microsoft just completed a 48-hour backup power demonstration,” Groth says. “Hydrogen production has been significantly enabled due to recent federal investments in hydrogen hubs focused on overcoming hydrogen supply issues. Plug Power just opened a clean hydrogen plant that can produce 15 metric tons of hydrogen per day – enough to fuel 15,000 forklifts – one of the largest electrolytic hydrogen production facilities worldwide.”
According to Joe Adiletta, vice president of battery commercialization at Sylvatex, hydrogen is a challenging fuel to work with. To put it simply, hydrogen has a tendency to escape from almost everything, and it’s not very energy-dense by volume.
“Creating hydrogen itself is problematic, and that’s only the start,” Adiletta says. “It then has to be compressed, stored, transported, and pumped, not once but multiple times – ultimately stored onboard a vehicle before being converted into electricity.”
This complex process demands a vast infrastructure and is reliant
Katrina Groth, associate professor and director of reliability engineering at the University of Maryland
Joe Adiletta, vice president of battery commercialization at Sylvatex
on either fossil fuels (typically cracked natural gas) or water, a resource that’s becoming increasingly scarce, through electrolysis.
“The energy density is poor, it is highly flammable, and not cheap. So why not just use electricity to begin with? Remember, H2 isn’t an energy generator, it’s simply an energy storage mechanism to be run through a fuel cell, to ultimately create electricity,” Adiletta says.
On the positive side of the H2 argument, Adiletta says there are situations where fixed-route heavy-duty vehicles that rely on a central depot could create H2 on-site with limited need for storage that might prove effective, especially if/where high-powered electrical infrastructure might be limited.
“And, of course, there’s the benefit of rapid refueling,” Adiletta says. “That said, many companies have been trying to deploy H2-powered EVs for decades with limited, if any, success at adoption.”
Batteries a mature market
Conversely, battery-powered EVs are here – now. Costs for batteries are continuing to drop, and it’s expected that battery-powered vehicles will soon be cheaper to manufacture than their internal combustion engine counterparts.
“Charging infrastructure is expanding at a rapid pace, making it easier than ever to power up,” Adiletta says. “Today’s battery-powered vehicles are not only practical but incredibly fun to drive, and they’ll only continue to improve as technology advances.”
Of course, battery charging times still aren’t fast enough for most consumers today. Some market segments, like apartment residents or on-street parkers in urban areas, especially need fast charging options.
“While many Americans have driveways and garages to charge at home, this isn’t the case globally,” Adiletta says. “Charging times need to improve, and range needs to increase. Fortunately, both of these challenges are being actively addressed – and it’s only a matter of time before they’re resolved.”
disadvantages when applied to a public transit (heavy-duty) fleet.
For example, the advantages of battery electric buses relate to their operational cost compared to that of diesel buses and hydrogen-fueled vehicles. As Petrunic points out, battery electric buses (BEBs) in Canada are typically cheaper to operate than the other two platforms. They are often cheaper to operate than compressed natural gas (CNG) buses as well.
When applied to the Canadian electrical grid context, they are usually the “cleanest” propulsion solution as well when judged from a purely operational standpoint – i.e., route-by-route and bus-to-bus.
“However, BEBs are more expensive from a capital perspective compared to diesel or CNG buses, and the combined capital expenditure (CAPEX) of these vehicles and their allied charging infrastructure and facility upgrade requirements can sometimes outweigh their operational savings over diesels,” Petrunic says.
Groth says FCEVs are mature; the challenge is in the infrastructure to support them. Costs – with any new engineering technology — are high initially, but Groth expects this to come down as technologies mature.
“We also have a shortage of hydrogen in certain regions, leading to competition for the available hydrogen. Another issue is reliability –an area I work in – which is critically important for these applications that require high uptime,” Groth says. “Right now, we’re seeing excess downtime for fueling stations related to limited supply and availability of unique parts needed for hydrogen equipment. This drives higher costs because fueling stations are overbuilt to address known equipment problems. Finally, we also need continued investment in safety to ensure that systems are designed and operated to the highest safety standards.”
Mass transportation & EVs
When it comes to mass transportation, the battery and hydrogen-electrified transportation are both part of the decarbonization spectrum of solutions as we march towards a zero-emissions world, says Josipa Petrunic, CEO and president of the Canadian Urban Transit Research & Innovation Consortium. However, they have differing benefits and
Hydrogen-propelled buses are also battery-electric powered vehicles. Their propulsion system is composed of a battery pack that energizes the motor. As Petrunic explains, the hydrogen onboard is converted through a fuel cell stack into electricity that feeds that battery pack. This results in the main advantage of hydrogen fuel cell electric buses (FCEBs) – they have longer ranges than purely battery-powered buses because the hydrogen onboard carries more energy than a battery pack alone. The range extension associated with FCEBs can allow a transit agency to decarbonize with fewer vehicles and — sometimes — with nearly a 1:1 replacement with fossil-fueled counterparts.
“The main disadvantages of FCEBs, however, come from the up-front price point (FCEBs are about 30% more expensive than BEBs and twice as pricey as diesel or hybrid buses) and their operational expenditures are more expensive too, because hydrogen (whether electrolyzed hydrogen or steam methane reformed (SMR) hydrogen) is more expensive than diesel or gasoline at this time,” Petrunic says. This may change as volumes increase and supplies increase, resulting in price reductions through competition. However, the benefits of a longer range come with a price point increase today, which makes it difficult for agencies to purchase FCEBs as decarbonized solutions at a large scale presently.
The other disadvantage associated with FCEBs is the limited supply of “green” or electrolyzed hydrogen. This industry is just starting to grow, so volumes
Josipa Petrunic, CEO and president of the Canadian Urban Transit Research & Innovation Consortium
are low, and prices are high. For SMR hydrogen, there is more supply. But, according to Petrunic, those supplies have not historically served transit, so producers are just now starting to price out the cost of shipping hydrogen by tube trailer or pipeline for future delivery to public fleets.
The future for hydrogen busing in Canada is one of growth. “The technology benefits from longer ranges, and with recent federal and provincial investments in the build-out of regional hydrogen hubs, the supply is growing – slowly, but it is growing,” Petrunic says. “There is currently enough green hydrogen supply in Toronto to support a total of 30 FCEBs so that allows for some agencies to deploy first fleets of FCEBs without having to wait.”
Ongoing advancements
For batteries, the future is already here, Adiletta says. And, increasingly automotive manufacturers will move to completely electrified product portfolios with broader vehicle offerings than exist today – everything from 4H4s to minivans.
“Battery development will continue to focus on cost reduction, scale, and new technologies to enhance performance – faster charging, low temperature performance, energy density, etc.,” Adiletta says. “These improvements will likely lead to EVs that outperform internal combustion engine (ICE) vehicles across every vehicle performance metric.”
The future of H2-powered vehicles is much murkier. As Adiletta explains, today’s focus on clean H2 production from companies like Electric Hydrogen and others is geared towards sales into the industrial market rather than transportation.
Groth says the key near-term areas for market expansion include fuel cell buses and heavy-duty trucks.
“We also have an exciting horizon ahead of us – new technologies in aviation, maritime, backup power, and off-road equipment over the next decade,” Groth says. The major characteristics of these markets are a need for high uptime and extended range. Hydrogen has transformative potential for our energy and fuel ecosystem – flexible, clean, and produced in the U.S.”
“Ultimately, however, certain transportation niches may be able to take advantage of very specific benefits that hydrogen might have over batteries – at least in the near to medium term,” Adiletta says. “Whether battery powered or H2 powered, the future of electric vehicles is bright –and is going to be fun.” EA
A Honda associate at the Performance Manufacturing Center in Marysville, Ohio, sub-assembles hydrogen tanks for the 2025 CR-V e:FCEV. Fuelcell electric vehicles, or FCEVs, employ a type of power source that shows promise, but the infrastructure needed to support their widespread use still needs to be built out.
Feature | Conventions & Trade Shows
Heating up and cooling down in sunny Florida
Thermostat bullies, rejoice: The HVACR industry’s main event just capped another banner year
By Charlie Barks, EA Managing Editor
ORLANDO, FLA. — The days of mercury measurement and manual adjustment are long gone. Our modern “built environment” involves everything from remote monitoring to on-site technical skills, and it’s all interconnected now.
At AHR 2025, held in the Orange County Convention Center in Atlanta Feb. 10-12, the premier heating, ventilation, air conditioning, and refrigeration trade show — organized by the respected organizations of ASHRAE and AHRI — was on full blast.
The range of topics at this year’s event continued to sprawl for an industry getting massive in scope. Standardization and incentive programs, coupled with the LEED (Leadership in Energy and Environmental Design) establishment, keep drawing in companies that might’ve had no prior interest in how energy specs affect their downlines. Supply chain uncertainty and workforce turnover remain flash points, as with almost any trade.
New tech, data analytics, automated systems? Sounds cool. Hardware, software, supply chain, energy efficiency? You’re getting warmer.
Taking stock of an industry
AHR’s 2025 Trend Report for the HVACR industry, published prior to the expo, prepared attendees by explaining the current state of the industry as well as the challenges and opportunities to be found there.
The report emphasizes the industry’s diversity and the importance of aligning goals for continued growth. Key themes include regulation updates, the evolving built environment, supply chain issues, workforce and training needs, product adoption, and expansion.
Recent regulations have steered the industry towards a focus on decarbonization, electrification, new standards, commissioning, and energy management, the report explains. In terms of the “built environment,” advancements in AI, energy efficiency, sustainability, smart technology, automation, IoT, data analytics, and cybersecurity have created a buzzing of opportunity.
However, there are pain points. HVACR workers are adjusting to the transition to A2L refrigerants, compliance requirements, and incentive programs. This has the potential to compound a preexisting issue of the need for a skilled workforce.
The associations and workers at AHR don’t sound concerned, though, as they continue to tap into the wellspring of internet marketing to promote HVACR career paths and revitalize training efforts. The HVACR industry might be the best example of an industrial sector with an outstanding online presence.
Voices from the field
Case in point: this year’s AHR Expo featured a new component called “From the Field,” which used the show’s popular Podcast Pavilion along with interviews and the many opinions of X (formerly Twitter) to reflect some of the assets social media brings to this hands-on industry.
“I find myself in social settings talking about the trades, and how fondly I enjoy working as a tradesperson,” said Jason Norman, a general foreman from British Columbia who works mostly in the Lower Mainland and the Fraser Valley. “It’s really interest-
ing to me to see people’s reactions when I talk about how it’s not working in ditches and dingy construction sites; it’s so much more than that. There is a never-ending career path that can lead in so many different directions. From apprentice, journeyperson, manager, business owner, technical sales — the fact is the skills you learn will last a lifetime. The more that one applies themselves and continues their education while in the trades, the greater their opportunities.”
Norman’s stance on the energy transition will surely resonate with some:
“Everyone loves to use words like ‘decarbonization’ and ‘electrification’ to move away from fossil fuels. However, where is their electricity coming from? I live in an area where 89% of our electrical energy comes from hydroelectric dams. Stating that we have an abundance of ‘clean energy’ is great, but the infrastructure to support the distribution of that power is grossly undersized considering future growth in the province. Let’s continue this trend but embrace the safe use of natural gas burning appliances.”
An industry in flux
As we saw in the March Electrical Apparatus cover article (“HVACR training today”), the HVACR industry is undergoing a significant transformation, primarily driven by the shift towards more sustainable and efficient refrigerants.
A prime example is the transition to lower-GWP refrigerants such as R32, mandated by new U.S. regulations. (GWP stands for global-warming potential.) R32, a single-component refrigerant, not only enhances product performance but also simplifies recovery and recycling processes, contributing to reduced environmental impact. It’s an exciting time as we witness these changes fostering a more environmentally conscious future for the industry.
Product adoption in HVACR professions includes the increased use of heat pumps, hybrid solutions, building automation systems, and SaaS (Software as a Service) platforms. Most of the workforce views these elements as a plus, even if it presents some new challenges. From the entry level to the C-suite, there is a focus on managing growth, educating the workforce and end-users, adopting cutting-edge technology, and attracting and training new talent.
According to the professionals, the HVACR industry (and heat pump technology more specifically) could be in a unique position for market growth as residential electrification increases the demand to offer products that can assist in battling the effects of climate change, all while providing opportunities to increase the resiliency of residential power.
Heat pump technology is poised to be a critical component to aid in decarbonization efforts, so the HVACR industry has an opportunity to bring solu-
tions to market that can help benefit the environment while satisfying owners’ comfort expectations and educate contractors on the transition to a cleaner energy future.
Refrigerants and other issues
“Because of the focus on decarbonization and electrification, every refrigerant-based HVACR system needs to maximize efficiency without sacrificing costs, aesthetics, or comfort, both of which variable-speed compressors and heat pump technology offer to consumers,” said Doug Bougher, director of applied sales for LG Electronics USA. “LG is already a leader in [the combined new products using] inverter-compressorheat pump technology and will continue to expand the reach of this technology to more products in the U.S. because we know it is already aligned with where the market is headed.”
And just where, one might ask, is the market headed? In short:
> Various associations, including AHRI, ASHRAE, AABC, ASHB, BSRIA, ESCO Group, HARDI, IAPMO, NCI, NEBB, PHCC, RSES, and Women in HVACR, are contributing insights about industry trends, challenges, and workforce development.
> Trending topics in the HVACR industry today include decarbonization, AI and controls, energy efficiency, sustainability, smart technology, electrification, indoor air quality, and workforce development.
> Standout challenges and opportunities, as discussed above, can be found in things such as regulatory changes, labor shortages, technological advancements, and the need for ongoing education and training.
> Some key innovations in HVACR include AI-driven diagnostics, predictive maintenance, heat pumps, low-GWP refrigerants, and smart building integration.
Looked at this way, the industry’s challenges appear more than manageable. EA
Recent regulations have steered the industry towards a focus on decarbonization, electrification, new standards, commissioning, and energy management, a recent report explains
The new technology on display at this year’s AHR Expo represented an industry for which efficiency and sustainability are high priorities.
Feature | Conventions & Trade Shows
A world of automation
Automate 2025 promises to bring to its international audience an exciting vision of the future
By Kevin Jones, EA Senior Editor
The transformative power of automation in reshaping industry will come under close examination May 12-15 when the annual Automate Show and Conference is held at Detroit’s Huntington Place. The event is said to be North America’s largest automation trade show, as it brings together an international crowd of industry participants. Attendees will consider how automation technologies — from artificial intelligence and robotics to machine vision and logistics — are revolutionizing manufacturing and supply chains. (Information about Automate 2025 may be found at https://www.automateshow.com.)
The conference sessions — emphasizing practical implementation, emerging technologies, and the integration of automation systems — will offer attendees a thorough look at how these advancements address real-world challenges and present new opportunities. With a mix of foundational guidance for newcomers and new insights for the more experienced, the agenda reflects a commitment to building a future in which automation is both easily accessible and broadly influential.
Conference sessions will be organized around several topics: AI & Smart Automation; Automation Systems Design & Integration; Robotics: Applications, Systems & Innovations; and Logistics & Supply Chain, to name a few. This breadth is intended to ensure that attendees can tai-
lor their days to their specific interests, whether their thing is integrating automation into existing workflows or optimizing material-handling processes.
One of the dominant themes woven throughout the conference will be the roles AI and smart automation play in enhancing operational efficiency and adaptability. Sessions will delve into how AI can automate complex tasks, improve decision-making, and transform traditional manufacturing into more agile, “data-driven” processes.
The conference won’t just be about technology for its own sake. It will also address technology’s application in solving real-world problems — problems like reducing downtime, optimizing resource use, or enabling predictive maintenance. The agenda is the expression of a perspective in which AI is not a standalone tool but a critical component of broader automation ecosystems. This integration is evident in the variety of scheduled speakers, who represent companies pushing the boundaries of what automation can achieve. Many will blend AI with other, more narrowly defined disciplines.
The place of robotics
Another prominent theme of the conference will be the evolution of robotics and its applications. Sessions on robotics will cover everything from collaborative robots (cobots), which work alongside us, their biological collaborators, to advanced finishing applications that refine manufacturing precision. The focus on particular robotic applications, such as material removal and autonomous mobile robotics, will demonstrate how these technologies are being tailored to meet specific needs. The agenda will also emphasize systems, such as motion control and endof-arm tooling, that support these robots.
The design and integration of automation systems will also be explored in depth. A number of sessions will tackle the nuts and bolts of implementing automation; they’ll address such challenges as system compatibility, safety, and return on investment. Speakers from diverse industries will share case studies and methodologies, explaining how integration is as much about people and processes as it is about technology. This conference isn’t just a
Given the subject of the event — and the relative ease with which many robots can be transported and then demonstrated on a trade show floor — the Automate Show stands out as a highly kinetic event. Expect to see a lot of robots in action.
Pictured here is a scene from last year’s Automate Show, which was held at Chicago’s McCormick Place.
— Electrical Apparatus photo by Charlie Barks
showcase of futuristic ideas but a road map for applying automation in tangible, profitable ways, whether in small businesses or in sprawling operations that touch all corners of the world.
The interplay between automation and logistics will also come under close scrutiny, particularly as the resolution of supply chain kinks remains a global priority. Sessions in this area will explore how automation can streamline materials handling, enhance warehouse efficiency, and integrate with broader logistical networks. The focus on emerging applications — such as autonomous mobile robots and advanced vision systems — will bring to life the manner in which these technologies are redefining logistics, making the moving of things faster, more reliable, and less demanding of scarce resources than our current practices.
Automation’s transformative power
Four sessions chosen from the schedule might serve as examples of the way in which the conference figures to demonstrate automation’s transformative power:
> “Understanding the Benefits and Challenges of Implementing Automation,” presented by Joseph Gemma, chief revenue officer of Wauseon Machine and Manufacturing in Wauseon, Ohio, will delve into the practicalities of adopting automation. Gemma’s session will offer a balanced look at ROI, workforce impacts, and technical hurdles.
> “There Is No Silver Bullet: How to Use Multiple End of Arm Tooling for a Robotic Finishing Application,” presented by Matthew Dockstader, product manager at ATI Industrial Automation of Apex, N.C., will explore advanced robotic applications. This session will examine how versatile tooling can enhance robotic precision in finishing tasks.
> “Pushing Boundaries: Industrial Cameras vs. Smart Cameras,” presented by Frank Jakubec, head of global market segment at Balluff, Inc., of Florence, Ky., will tackle the evolution of machine vision within automation. Jakubec plans to contrast traditional and intelligent imaging systems, highlighting their roles in improving quality control and process efficiency.
> “Expect More from Your Automation: Transforming U.S. Manufacturing,” presented by Del Costy, president and managing director of Siemens Digital Industries, with U.S. operations headquartered in Plano, Tex. This session will offer a strategic perspective on automation’s role in revitalizing manufacturing.
Given its emphasis on AI and smart automation, the conference lineup exemplifies a shift toward intelligent, adaptive systems, while the focus on robotics brings to the fore the physical tools bringing these ideas to life. Systems design and integration
One of the dominant themes woven throughout the conference will be the roles AI and smart automation play in enhancing operational efficiency and adaptability
provide the blueprint for making it all work, and logistics extends automation’s reach across industries. What unites these threads is a commitment to transformation — not just incremental improvement but a re-imagining of how work is done.
The Automate Show conference, with its diverse sessions and expert speakers, presents automation as a collaborative, integrative force — one that empowers industries to innovate and thrive in an increasingly complex and interconnected world. By blending practical guidance with insights into current trends, the conference promises to offer a glimpse of automation’s potential, making this conference a useful event for anyone looking to shape — or be shaped — by the technological revolution we find ourselves in. EA
Products and services on display at Automate 2025
This year’s Automate Show will host more than 800 exhibiting companies presenting a cross-section of the automation industry. The companies signed up to display their wares represent numerous sectors. They include established giants, innovative startups, and everything in between, all converging to demonstrate products and services designed to enhance efficiency and precision.
Companies such as AAEON Electronics, Inc., based in Irvine, Calif., will bring embedded computing platforms, while Bosch Rexroth Corp., with operations in Charlotte, N.C., will display advanced drive and control systems. Dorner Manufacturing Corp. of Hartland, Wis., will exhibit conveyor systems designed for streamlined material handling. Meanwhile, AGILOX North America, Inc., of Atlanta will demonstrate autonomous mobile robots, and Banner Engineering Corp., of Minneapolis, will showcase sensors and machine vision systems critical for automation accuracy.
This diversity within the exhibit hall will extend further, with firms such as Dassault Systèmes Americas Corp., based in Waltham, Mass., offering software for digital twins and system simulation, and Micropsi Industries USA, Inc., from San Francisco, presenting AI-driven robotic control technologies. Hardware manufacturers, such as Chieftek Precision USA Co. Ltd., from Ontario, Calif., will highlight linear motion components, while CENIT North America, Inc., of Auburn Hills, Mich., will provide integration services and software for optimizing automation workflows.
There’s wide variety among the products and services expected to be displayed, and yet among them can be discerned a certain interconnectedness. Attendees can expect to see robotics systems, such as those from AGILOX and ATI Motors, designed for tasks like material transport and warehouse automation. Vision technologies, such as those from Banner Engineering and Lucid Vision Labs, will focus on quality control and process monitoring. Software from Dassault Systèmes and CENIT will enable digital transformation, while components from Chieftek and Bosch Rexroth will power the physical infrastructure of automation. These products span the automation lifecycle, from design and integration to execution, catering to such industries as automotive, e-commerce and general manufacturing.
What ties these exhibitors together — indeed, what ties together the conference sessions, the exhibitors, and Automate 2025 as a whole — is the pursuit of smarter, integrated automation as a catalyst for industrial transformation. — KJ
Update your calendar with these upcoming trade shows, conferences, and other events.
• April 3-5, 2025 — PEARL 2025 Conference & Exhibition, Sheraton Charlotte Hotel, Charlotte, N.C. Professional Electrical Apparatus Reconditioning League, https://pearl1.org/conference-details.
• April 6-8, 2025 — Electrical Generating Systems Association Spring Conference, Sheraton Le Meridien, Charlotte, N.C. Electrical Generating Systems Association, https://spring.egsa.org.
• April 29-May 1 — Facility Fusion, Renaissance Austin Hotel, Austin, Tex. The International Facility Management Association, https://facilityfusion.ifma.org.
• April 28-30, 2025, 2025 — NECA Legislative Conference, Salamander Washington DC, Washington, D.C. National Electrical Contractors Association, www.necanet.org/legconf.
• May 18-21, 2025 — Electrical Equipment Representatives Association’s Annual Meeting, Ojai Valley Inn & Spa, Ojai, Calif. Electrical Equipment Representatives Association, http://bit.ly/3BzYtMP.
• May 19-22, 2025 — Cleanpower 2025 Conference & Exhibition, Phoenix Convention Center, Phoenix, Ariz. Ameri-
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can Clean Power Association, https://clean power.org/expo.
• May 20-22, 2025 — NAED 2025 National Meeting, JW Marriott Marco Island Beach Resort, Marco Island, Fla. National Association of Electrical Distributors, www.naed.org/national-meeting.
• May 21-23, 2025 — Europump’s Annual Meeting and General Assembly, Hilton Prague, Prague, Czech Republic. Europump, http://bit.ly/4dt8TM2.
• June 3-5, 2025 — CWIEME Berlin, Messe Berlin, Berlin, Germany. Hyve Group Ltd., https://berlin.cwiemeevents. com/home.
• June 11-12, 2025 — Coiltech North America 2025, Suburban Collection Showplace, Novi, Mich. QUiCKFairs, www. coiltech.us.
• June 16-20, 2025 — Turbo Expo: Turbomachinery Technical Conference & Exposition, Renasant Convention Center, Memphis, Tenn. American Society of Mechanical Engineers, https://event.asme. org/Turbo-Expo.
• June 21-25, 2025 — ASHRAE 2025 Annual Conference, Sheraton Phoenix Downtown and Phoenix Convention Center, Phoenix, Ariz. American Society of Heating, Refrigerating and AirConditioning Engineers, www.ashrae.org/ conferences/2025-annual-conferencephoenix.
• June 25-26, 2025 — AEE East Energy Conference & Expo, Huntington Convention Center, Cleveland, Ohio. Association of Energy Engineers, https://aeeeast.org.
• July 19-22, 2025 — EASA Convention 2025, Gaylord Opryland Resort and Convention Center, Nashville, Tenn. Electrical Apparatus Service Association, https://easa.com/convention.
• July 22-24, 2025 — Safety25 Conference & Expo, Orange County Convention Center, Orlando, Fla. American Society of Safety Professionals, https://safety.assp.org.
• August 6-8, 2025 — NSPECon, InterContinental Kansas City at The Plaza, Kansas City, Mod. National Society of Professional Engineers, www.nspecon.org.
• September 12-15, 2025 — NECA 2025 Convention and Trade Show, McCormick Place, Chicago, Ill. National Electrical Contractors Association, http:// bit.ly/4f9BWoN.
• September 17-19, 2025 — AEE World Energy Conference & Expo, Georgia World Congress Center, Atlanta, Ga. Association of Energy Engineers, https:// aeeworld.org/conference.
• September 29-October 2, 2025 — Canadian Manufacturing Technology Show, Toronto Congress Centre, Toronto, Ontario, Canada. Society of Manufacturing Engineers, www.cmts.ca.
• October 13, 2025 — Hydraulic Institute Fall Conference, Kansas City Marriott Country Club Plaza, Kansas City, Mo. Hydraulic Institute, www.pumps.org/ event/2025-fall-conference.
• February 2-4, 2026 — AHR Expo 2026, Las Vegas Convention Center, Las Vegas, Nev. The Air-Conditioning, Heating, and Refrigeration Institute, www.ahrexpo. com/sales-floor-plan-2026.
• June 13-16, 2026 — EASA Solutions Expo, Rosen Shingle Creek, Orlando, Fla. Electrical Apparatus Service Association, https://easa.com/conven tion/future-easa-conventions. Edited by Kevin Jones EA
The Renaissance Austin Hotel in Austin, Tex., will be the setting April 29 through May 1 of the International Facility Management Association’s Facility Fusion conference.
Marriott International, Inc., photo
A new nuclear age
Improved safety measures and concerns about oil and gas are spurring a re-evaluation
By Bill O’Leary, EA Contributing Writer
Like sands through an hourglass, so flow the energy sources of our lives. The U.S. energy mix has undergone a number of seismic shifts since the advent of electricity — steam and coal power dominating the day as first movers, then oil and gas with full control. It’s a throughline that has continued today, as other renewable sources harnessing the very elements of our planet such as geothermal, wind, water, and solar jockey for supplementary positions.
But perhaps the energy source that has undergone the most erratic evolution is nuclear energy. Once considered an absolute game changer as a power source that is repeatable, sustainable, and with a conceivably endless supply, a variety of headline-grabbing accidents, deaths, and irradiating wastelands rendered nuclear energy a footnote in the vast article of energy, the source of trivia questions centered on the 70s and 80s. Now it’s rising from the energy ashes as technologies have evolved and knowledge has grown on how to properly harness it.
And with that, electromechanical manufacturers, distributors, and repair companies, which have been involved in nuclear energy generation to varying degrees in the past, along with new players that have emerged after its downswing, stand to benefit once again. But how and to what degree? Will it be the “same old, same old” for these companies? Or will nuclear energy generation emerge as the ultimate victor for power, expanding at a rate and to such a degree that it provides a vast, lucrative market for years to come?
This is a story in two parts:
1. The rise of nuclear energy in the U.S.
2. The fall of nuclear energy in the U.S.
And it is the story of how electromechanical manufacturers, distributors, and repair companies were there to ride those peaks and drops but, more importantly, how they stand to benefit from recent innovations and growth in the space.
Commencing with a bang
It started with a bang — one that we’re all very familiar with. The Manhattan Project and the bombing of Hiroshima and Nagasaki brought
Commercial nuclear reactors like these, at the Alvin W. Vogtle electric generating plant in Burke County, Ga., generate close to 20% of total electricity and almost half of the clean energy in the U.S.
— U.S. Dept. of Energy photo
nuclear energy to the main stage but it was in the late 1950s when its commercial life began. In 1958, the first large-scale nuclear power was built and operated in Shippingport, Pa. That same year, construction began on the first merchant ship powered entirely by nuclear energy, the NS Savannah.
That ship was launched a year later, which was also when the tendrils of nuclear power expanded to Illinois. Without government funding, the Dresden 1 Nuclear Power Station achieved a self-sustaining nuclear reaction. This helped pave the way for stations both large, such as the Yankee Rowe Nuclear Power Station, and small, as remote nuclear power generators were used to both light buoys for sea navigation and power weather stations.
The 70s were a decade of rapid growth, as 1971 saw 22 commercial plants operating across the U.S., producing 2.4% of U.S. electricity — still minuscule, but nothing to sneeze at for an energy source that didn’t exist a few decades past. The party kept rolling into 1973 as big utilities ordered 41 nuclear power plants. A single year later, the first 1,000 MW electric nuclear plant came online in 1974 - Commonwealth Edison’s Zion 1 plant in Zion, Ill., serving at the time the U.S.’s second most populous city, Chicago.
To match this mass acceleration, and to attempt to add a layer of safety and responsibility over this volatile energy source, the regulations came a-rolling in - the Energy Reorganization Act of 1974, which created the Energy Research and Development Administration to conduct research and development across a variety of dimensions, and the Nuclear Regulatory Commission to oversee and set initial guardrails
around nuclear energy production. In 1977, the air of hesitancy drove President Jimmy Carter to defer plans for reprocessing spent nuclear fuel.
That caution almost seemed to function as foreshadowing. In 1974, the U.S. saw the worst accident in commercial reactor history with the Three Mile Island nuclear plant meltdown in Harrisburg, Pa. - the same state where commercial nuclear power generation was born nearly 20 years prior. The cause of the accident? A dangerous combination of technological malfunction and human error. A pressure relief valve in the Unit 2 reactor failed to close, causing coolant water to escape, leading to the reactor’s overheating. Operators misread the control room reading and, believing that there was too much water in the system as opposed to the reality of there being too little, shut down the emergency cooling pumps.
The result was a partial meltdown where fuel rods melted and released radioactive gases. Luckily, the contamination structure of the facility largely prevented widespread radiation across the surrounding area. And while no direct deaths or serious injuries were reported, the incident created deeply felt public fear and stricter regulations that slowed nuclear power expansion in the U.S. but not completely.
In 1991, 111 nuclear power plants operated in the U.S., with a combined capacity of 99,673 MW and
Uranium like that shown here is mined from the earth and processed into pellets to be loaded into fuel rods. Those rods are placed in the reactor core, eventually releasing energy and producing electricity. — Kristina Postnikova / Shutterstock photo
accounting for nearly 22% of commercially generated electricity in the U.S. This was the peak number of nuclear reactors in the U.S. The majority of nuclear power plants were built in the U.S. between 1970 and 1990. It hasn’t reached that level since. The following year saw the rst downtick in nuclear energy investment, with one less power plant operating in the U.S. than a year prior.
This presaged a decline that spread further in the following century, when safety concerns were joined by competition from new players. In 2008, the discovery of abundant shale gas added a cheaper alternative to nuclear energy, which carries high capital construction, operation, and maintenance costs. The emergence of wind and solar created more economically viable and signi cantly safer options as “green energy” and a focus on tackling climate change took hold in the 2010s.
Also, complex regulations and licensing considerations led to construction delays and colossal cost overruns. Nuclear project cancellations and eeing investment dollars soon followed.
U.S. nuclear electricity generation was virtually at from 2019 to 2020 at 19.7%, but it experienced a relatively sizable drop in 2021, accounting for 18.9%. Another nearly comparable drop came in 2022 with 18.0% of electricity being generated from
nuclear power — a dramatic downward trajectory that seemed without end — until 2023, when the nuclear generation number bumped a full percentage point back up to 19%.
That same year, nuclear power plants generated 775 billion kilowatthours of electricity, a vast supply that could power more than 72 million homes. Today, there are 94 nuclear power reactors in the U.S. providing a fth of the country’s electricity. So the most important question in regards to the longevity of nuclear power is this: Are these numbers a random occurrence or a glimmer of hope?
Where electric machines fit in
Let’s take a look under the hood and see how electromechanical technology across the spectrum is involved in the nuclear generation process — and how the events described above have impacted those industries.
A smorgasbord of familiar components and systems play o each other, serving crucial roles for power generation. Motors are in turbine-driven generators to power auxiliary systems such as starting the turbine, regulating the ow of steam, and controlling cooling systems. Larger synchronous motors that operate at a constant speed (in tandem with power grid demand) drive fans, pumps, and other components found in high-power applications. These applications include cooling systems and feed water pumps, which move water into the reactor core or steam generators for e cient power generation.
Induction, or asynchronous motors, power systems instrumental for heat management, such as reactor coolant pumps, which circulate
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coolant such as water through the reactor core to move heat away from fuel rods, and cooling tower fans, which remove unnecessary heat from the nuclear plant’s cooling system and evaporating water in the atmosphere.
D-C motors drive control rod mechanisms that insert, remove, and adjust control rod positions. This helps manage reactor power by controlling the number of free neutrons for nuclear fission, a form of nuclear generation in which an atom’s nucleus is split into smaller particles that release a massive amount of energy. The control rod mechanisms are pivotal for safe operation, as they provide emergency shutdown capabilities.
D-C motors of the brushless variety are also involved in nuclear power generation. The low maintenance needs and reduced wear from the lack of brushes tees up the brushless d-c motor as a strong mechanism for torque control and precise speed regulation in reactors and auxiliary systems. That smooth, controlled movement doesn’t just allow for continuous operation in the incredibly sensitive and potentially volatile nuclear core; it also integrates with magnetic latching systems for accelerated emergency shutdown.
Brushless d-c motors also work in concert with reactor coolant pumps to monitor and measure flow rates, pump conditions, and valve actuation systems, where they provide precise and swift valve movements for fail-safe system shutoffs along with steam and coolant flow. The BLDC has also been paired with more modern innovations such as robotic and remote handling systems. Here, the motor powers the robotic manipulators (i.e., the arms) necessary for fuel handling in high-radiation areas.
Then we have the stepper motor. This motor rotates in precise steps and angles, typically around 1.8°, making it a strong match for the exacting control and movement necessary for nuclear applications.
The high stopping accuracy is another advantage when one false move can lead to outsized harm or even a meltdown. So similar to the BLDC, stepper motors are often used to drive robotic systems, valve actuators, and control rod mechanisms. The unique, distinguishing advantages come from its “microstepping” ability, which assists in sensor calibration and automated monitoring.
The precise movements also allow for reduced energy use compared to other motors and smoother integration with automation and AI. The stepper motor is also being tested with radiation-strengthened materials that provide advanced insulation and coating. With this hardened, resistant shell, stepper motors have heightened endurance to operate in the harsh environments of nuclear reactors.
And we are just talking about motors. There is an expanded assortment of electromechanical products involved in nuclear energy generation and which component or system is applied often comes down to one key decision: fission or fusion?
How fission works
Nuclear fission is the process of breaking apart a large, heavy atom into lighter, smaller atoms, which releases a great deal of energy. For fission, the starting atom, as it were, needs to have an unstable nucleus such as uranium. As the schism occurs, energy is unleashed because the mass of the remaining nucleus is smaller than the mass of the resulting nuclei.
In order for this to happen, fission reactors rely on electromechanical components, such as control rod drive mechanisms. The aforementioned stepper or traditional electromagnetic motor powers actuators to insert or remove control rods, which causes the nuclear chain reaction. After this occurs, highprecision position sensors such as linear variable differential transformers control neutron flux, a measurement of the amount and speed of neutrons moving within a system. In nuclear reactors, neutrons move in a number of directions at a number of speeds. A proper neutron flux calculation determines the behavior of neutrons in a reactor, allowing for closer monitoring of the entire system.
Large centrifugal pumps driven by 5-10 MW motors are implemented to maintain coolant flow throughout the core. Taking a step back, those paired motors are then driven by variable frequency-drives that calculate motor speed based on the thermal load of the reactor. In some pump designs, magnetic bearings are included to conversely increase efficiency while reducing internal mechanical wear and tear.
For conversion of electromechanical energy, turbine-generator systems are often used for nuclear fission. Here, high-pressure steam moves an impulse-reaction turbine with that shaft, which is combined with a hydrogen-cooled synchronous generator. Also, in the realm of cooling are emergency core cooling systems that use high-speed electric motors, pumps, and solenoid-actuated valves to inject coolant into the core for emergency overheating events. These cooling systems also typically have diesel generators to provide backup power.
Much of the involvement has been in the sensitive inner workings of the reactor, but electromechanical devices also have external applications. Cranes and other electrical material-handling systems move used fuel rods and other nuclear waste to shielded storage pools. Controlling airflow in outer containment structures and other radiation shielding is provided by electrically actuated dampers.
Today, most commercial nuclear power plants use fission technology, and fission has been the sole nuclear generation process over its storied history. However, a new challenger has emerged, mostly residing in early research and development stages.
Fusion in the most simplistic sense is the opposite of fission. It occurs when two or more small, light atoms or molecules are combined to form a much heavier helium nucleus. A reaction takes place in plasma, an effusively hot and charged gas, and the resulting nucleus has less mass than in the original nuclei. That remaining mass converts to a large amount of energy.
Fusion reactors, often called tokamaks or stellarators, need components not just for energy conversion
Nuclear Regulatory Commission branch chief Matt Young inspects an emergency diesel generator at the Beaver Valley Nuclear Power Plant in Shippingport, Pa. A well-designed and tough pipe system is needed for producing nuclear energy. Young is attempting to determine if a leak on service water piping that provides cooling to an emergency diesel generator has affected the system’s operability. — U.S. Nuclear Regulatory Commission photo
like fusion but unique applications such as plasma containment. For plasma containment, magnetic coils with superconducting abilities are needed to generate magnetic fields to contain plasma. Electromechanical switches are needed to control capacity banks and pulsed power systems that create the magnetic fields. Rotating flywheels operating at high speeds stabilize power input to those electromagnets.
For efficient temperature regulation, cryogenic vacuum pumps with electromechanical compressors to maintain low pressure inside the fusion chambers and gate valves have motors to regulate gas flow and sustain the necessary plasma conditions.
Enter nuclear fusion
Nuclear fusion potentially provides a more abundant, cleaner, and potentially inexpensive alternative energy because the quantity of waste and greenhouse gases created is smaller than fission. However, this is ultimately a newer process that deals with the building blocks of our planet so building a safe and continuously operating plant that can
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withstand necessary, oppressive pressures and temperatures. At this moment, nuclear fusion plants have enough technological and engineering challenges that prevent building at scale.
So opportunities for manufacturers, distributors, and repair companies are massive and some firms are already in on the action. Major players, like Siemens Energy manufacture electrical systems, turbine generators for fission reactors and advanced reactor types, and digital control products that reduce downtime. GE’s Hitachi Nuclear Energy is a provider of electromechanical systems such as emergency core cooling systems and backup power products. They also offer digital control systems and software to manage reactor parameters. Schneider Electric is another large corporation that provides products and services in similar categories, particularly automation systems.
Mitsubishi Heavy Industries designs and manufactures steam turbines along with motor-driven pumps that are used in reactors throughout Japan, while Westinghouse Electric Co. provides large nuclear components such as reactor coolant pumps and control rod drive mechanisms along with modular reactor systems. Curtiss-Wright manufactures precision motors and actuators for control rod mechanisms along with valve positioners for controlling the flow of cooling and other fluids. And robotics and maintenance systems are built and distributed by a number of large companies in the sector including ABB Ltd. These robotic arms and integrated systems are being used to
manipulate and monitor a number of reactor components.
You may be noticing a trend here. Currently, “big” is the name of the game for nuclear energy - the energy created, the reactors, the potential and the groups involved. Yet as innovative methods such as nuclear fusion and other approaches potentially solve the problems and break through the barriers that have been erected about traditional nuclear energy generation, is it not possible for more to join the party? More electromechanical companies of various sizes and specialties?
This was a story in two parts:
1. The rise of nuclear energy in the U.S.
2. The fall of nuclear energy in the U.S.
And how electromechanical manufacturers, distributors, and repair companies were there to ride those peaks and drops but, more importantly, how they stand to benefit from recent innovations and growth. The story of nuclear energy has been littered with unfettered excitement at the possibilities and cold dashes of water in the form of “maybe someday, but not today.” But could that “today” come sooner than we expect? EA
A Nuclear Regulatory Commission inspector is ensuring that this reactor on the Savannah
place to connect to the grid and become the second AP1000 reactor designed by
River in Georgia has the electrical infrastructure in
Westinghouse Electric Co. to operate in the U.S. — U.S. Nuclear Regulatory Commission photo
Resin-rich vs. VPI
High Voltage Coils
Which is the better method of insulating motor coils?
By Michael Mitten, EA Contributing Writer
ELECTRICAL TESTING
Resin-rich and VPI are the two most prominent technologies used in the repair of HV electrical machines. Both methods involve the impregnation of insulating materials into the windings of the electrical machine, but they di er signi cantly in their approach and the results they produce. Understanding these di erences, bene ts, and concerns is crucial for choosing the appropriate repair method for a given application.
If you are involved in the repair of medium- and high-voltage machines, you’ll likely have an opinion on this matter informed during your time in the trade, especially if you operate a VPI tank that ts larger machines: You need a return on your investment, and to keep turning over your resin. In my years as CEO of a repair shop and international coil vendor, I often encountered engineers with rmly entrenched opinions, who when challenged were unable to present any validity of why they held such views, nor even a cursory appreciation of the alternative technology.
Throughout my career, I have found that engineers without VPI as an asset often had very little understanding of its bene ts and risks; equally, and especially in North America, engineers often wouldn’t consider using resin-rich coils, often because they’d spent their time convincing their customers of VPI’s bene ts, so changing wouldn’t look great. Equally as often, it was because they’d never considered the bene ts of an alternative method. Rarely was anyone able to articulate clear bene ts and a way of measuring them, but with some exceptions. I found I had at rst to challenge rmly held beliefs, then o er an evidence-based counterpoint. And with very mixed degrees of success!
The scope of our inquiry
Given the breadth and depth of this subject, to narrow things down I’m referencing the repair and life extension (not original manufacturing) of HV electrical machines, both motors and alternators, up to roughly 30 MW in size. In this context I’m de ning HV as voltages equal to or greater than 6000 V at 50 Hz, because during our research we consistently found evidence of corona discharge activity (see sidebar on page 38 for de nitions of corona and partial discharges, or PD) at and above 6000 V.
Typically, for cost purposes, corona discharge protection is speci ed for coils equal to or greater than 6600 V at 50 Hz. However, we found evidence of discharges in much lower-voltage machines. For example, many thyristor drive powered motors can exhibit insulation deterioration from corona discharge at signi cantly lower voltages due to the dy/ dt rise times of the voltage waveform, which was frequently prevalent in older AC traction motors operating at only 1000 V. In advanced stages, the corona activity presented as having turned the endwinding insulation into white powder.
I’m also assuming repairs will be carried out using IEC 60034 – the entire suite of documents – and that
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A pair of high-voltage coils being subjected to a voltage endurance test.
As CEO of a repair shop and international coil vendor exporting coils to all populated continents of the globe, I spent years of my life visiting repair shops, convincing them to buy not only resin-rich HV coils but specifically our resin-rich HV coils. I learned, especially in North America where there is a uniquely strong belief that vacuum-pressure impregnation (VPI) technology is superior, that I needed to pack my A-game in my suitcase and be ready for an argument.
While we still sold HV VPI coils the world over, and in our own shop used VPI for both a-c (silicone) and d-c (epoxy) traction motor repair, our stance as a group of engineers was to always recommend the use of resin-rich coils for HV rewinds. Internally, we would never rewind an HV machine using VPI technology, even if we did have a tank large enough to do so. Which we didn’t. I never saw the benefit of such a big investment.
It remains my firmly held belief that resin-rich is the best technology out there for one-off HV machine repairs. However, Electrical Apparatus has asked me to impartially consider the pros, cons, risks, and rewards of both technologies, which I strive to do in this article.
There exists very little helpful, easily accessible, peer-reviewed academic work that’s available online informing this topic. Nor is this article an academic text. What I’m sharing are my experiences of over 30 years working on HV machine repairs: what we learned, what worked, what didn’t, and why. —
Michael Mitten
RESIN-RICH VS. VPI continued from previous page
shops have achieved or are working towards the Electrical Apparatus Service Association’s AR100 Standard, as an absolute minimum level of technical and quality management.
Note that given the constraints of EA’s word count, and my ability to stop you nodding off, spilling your mid-morning coffee across the copy of EA sitting in your lap, that this is not a comprehensive review of all aspects of both technologies. My aim is to provide an overview of the key factors to consider when specifying resin-rich or VPI technology for critical HV machine repairs so repairers and asset owners alike can make more informed, and better, decisions. If I can add something positive to this ongoing discourse, all the better for it.
The key word of note here is “critical” – every HV machine repair is critical. Frequently, asset owners do not have a spare machine, so will be losing production and incurring significant costs, while repairers get on fixing it. Time is of the essence but so, more critically, is quality. Get the job right first time, on time, and with a winding at least as good as the one replaced, you’ll have a very happy customer who in all likelihood will send their next job to you when it goes pop. Get the job wrong and the net cost for both repair shop and asset owner can be astronomical. Production losses can be massive, as can the warranty costs and loss of custom for the repairer.
Like many things in life, repairers only get one shot at rewinding or life-extending an HV machine. And for the reasons explained above, they simply must get it right first time. Moreover, and most importantly, the asset owner is paying their repairer not only to fix the problem, but to prevent it happening again any time soon.
Ensuring repairers are improving and life-extending their asset’s performance should be top of mind for asset owners, focused on high quality coil manufacturing, coil insertion, bracing and connecting and, when using VPI, stringent levels of process control. For repairers, this is your opportunity to add value against your competitors, because be damn sure someone else will be out there sniffing around like a dog at broth trying to win this work — and your customer — from you.
So, in a winding full of contradictions, what’s the best way to ensure you don’t just get this one shot right, but that you knock your customer’s expectations right out of the park? Which technology should you use, why, and when should you use it?
Resin-rich technology
Resin-rich technology involves the use of a high percentage of resin, typically epoxy but also acrylic and polyester, which is applied to the individual coils of an HV electrical machine as they are manufactured. This resin is either manually or, ideally, automatically applied, ensuring consistent coverage and overlap. The number of insulation layers required depends on an insulation system’s design and purpose, and also on each chosen material’s relative dielectric strength, but always increases with voltage.
Epoxy resin is applied into the tapes at the point of manufacture, either in uncured B-Stage or cured –but flexible - acrylic, which in turn are then applied to the copper wire coils in various arrangements depending upon specification, machine type, and environmental concerns as well as dielectric longevity.
A key characteristic of well-made resin-rich systems is that the resin fills the gaps created by the copper strand’s radiused edge within the coil windings, which provides an additional layer of insulation at zero build, reducing PD within individual coils, a process called consolidation. (Note: HV VPI coils can and should also be consolidated.)
The main wall insulation of an HV coil is then hot pressed to form a solid bar, which can then be fully tested for Tan (Tip Up) and PD according to IEC 60034:2022. (Note: there are many sub-documents within the 60034 Standard, so it’s worth fully familiarizing yourself with it prior to deciding what testing regime you want to work to for a given repair process. Your coil manufacturer should provide detailed test results compliant to this international standard and clear guidance on testing processes.)
Here’s how resin-rich works:
> The process involves producing a solid main wall (slot portion) of the coil with a flexible end winding to allow for coil insertion. The end winding can be both cured using an acrylic resin or uncured using a B-stage epoxy. B-stage material then needs to be cured in an oven following coil insertion, bracing and connection.
> The resin hardens in place, providing a robust and durable insulation layer.
> Once the resin is cured, the electrical machine is ready for final testing.
The benefits of resin-rich are:
> Guaranteed slot fill. High-quality resin-rich coils are manufactured to a fine tolerance, typically
less than or equal to 0.25 mm of the stator slot size for straight slots or less than or equal to 0.5 mm for skewed slots, to reduce corona discharge between main wall and the stator core. There is no proven benefit of using ripple springs or side packing in HV machines of this size. Moreover, it was our firmly held belief that such needless packing can increase corona activity by increasing air gaps.
> Enhanced durability. Hot-pressing a coil under pressure for a cycle of 45 minutes to 1.5 hours depending upon material spec and coil size helps to reduce air gaps. This capacitive content of each side of a two-sided diamond coil, or loss tangent, can be measured and assessed by Tan testing. Moreover, many high-quality coil manufacturers now offer PD testing for individual coil sets, usually for an additional price. This is especially beneficial in high-integrity assets that are critical to a plant’s production, and for hydro applications. Voltage Endurance (VE) testing is a condensed life-cycle test that helps verify a given insulation system’s life expectancy, and is often specified for many hydro machines equal to or greater than 5 MW.
> Improved dielectric integrity. The entirety of a fully cured (using acrylic rather than a B-stage epoxy) coil can be fully tested at the point of manufacture, with extended warranties offered by the manufacturer. This guarantees dielectric integrity at the point of manufacture. As insulation tapes and application processes have evolved and improved over time, so has the life expectancy of rewound HV machines, providing the coil manufacturer is following robust processes with multiple fail-safe checks within their processes. A comprehensive audit of your coil manufacturer will give confidence as to their true capabilities.
> Cost-effectiveness. For some applications, the resin-rich process can be more affordable than VPI, especially in smaller-scale repairs or when equipment is not exposed to extreme conditions. Cost is always a function of urgency and time, as well as size and specification. When engineering and procurement assess a resin-rich option
versus VPI, they often forget to add in the cost of their VPI resin per kilogram or pound required, process time, labor, and energy costs. To get a true cost, accurate assumptions of these elements should be added to the value equation, alongside delivery time and anticipated manufacturing quality.
> Lower thermal stress. Resin-rich materials offer good thermal resistance, minimizing the risk of thermal breakdown during operation. There are now Class H (180°C) rated resin-rich HV
Please turn to next page
Applicable standards
IEC 60034-27 is part of the IEC 60034 series, which covers rotating electrical machines. Specifically, IEC 60034-27-1:2017 focuses on off-line PD measurements on the winding insulation of rotating electrical machines. This standard provides guidelines for:
> Measuring techniques and instruments.
> Arrangement of test circuits.
> Normalization and testing procedures.
> Noise reduction.
> Documentation and interpretation of test results.
The standard aims to ensure consistent and reliable measurements of partial discharges, which are critical for assessing the insulation condition of electrical machine windings.
The standards are available at https://webstore.iec. ch/en/publication/29254 and at http://bit.ly/43e4kTx.
Figure 1. An example of partial discharge testing measurement of production coils.
Reducing corona discharge and partial discharge
High-voltage (HV) electric motors and generators are critical components in various industrial applications, and their reliability and efficiency are paramount. When these machines are rewound, it is essential to address and minimize corona discharge and PD to ensure optimal performance and longevity.
Corona discharge
Corona discharge is an electrical phenomenon that occurs when a high-voltage conductor ionizes the surrounding air, creating a visible glow and audible noise. This effect is particularly prevalent in HV systems due to the high electric field strength around conductors. While corona discharge is a natural occurrence, it can lead to several detrimental effects:
> Energy loss. Corona discharge results in power losses manifested as light, heat, sound, and harmful ozone production. These losses reduce the overall efficiency of HV electric motors and generators.
> Insulation degradation. The ionization process produces ozone and other reactive gases that can degrade insulation materials over time. This degradation can compromise the insulation’s effectiveness, leading to potential failures.
> Radio interference. The discharge generates electromagnetic interference, which can disrupt communication systems and other sensitive monitoring equipment.
To mitigate these issues, engineers employ strategies such as using larger or bundled conductors, adjusting conductor spacing, using stress grading tapes such as corona shields on end windings, and implementing corona rings. These measures help reduce the electrical field strength around conductors, minimizing corona discharge and its associated problems.
Partial discharge
Partial discharge, or PD, is a localized electrical discharge that occurs within an insulating material when a high-voltage stress is applied. Unlike a full discharge, PD does not completely bridge the space between two conducting electrodes. PD is often an early indicator of insulation degradation or defects in HV equipment, and its importance cannot be overstated.
PD is prevalent to some degree in all HV windings. In newly rewound machines, minimizing void content in main wall insulation is critical to longevity; however, it is worth considering that when full discharges do occur, those voids can then become inert and will no longer allow partial discharges to further degrade insulation.
Here are some matters to consider when confronted by PD:
> Prevention of insulation failure. PD is a sign of insulation degradation. Monitoring and addressing PD early can prevent full insulation breakdowns, which can lead to equipment faults or catastrophic failures.
> Extended equipment lifespan. By identifying and mitigating PD, operators can manage the degradation of insulation materials over time, extending the effective lifespan of HV motors and generators.
> Increased system reliability. PD monitoring helps ensure continuous operation by reducing the likelihood of unexpected breakdowns due to insulation faults. This reliability is crucial for maintaining power quality and consistency.
> Cost savings on maintenance. Condition-based maintenance, driven by PD monitoring, allows for targeted repairs and servicing only when needed. This approach reduces maintenance costs, minimizes downtime, and maximizes resource allocation.
> Enhanced safety. PD can lead to dangerous conditions such as arcing, fires, and equipment explosions if left unchecked. Monitoring PD improves safety for both personnel and equipment by detecting and resolving issues before they escalate.
Reducing corona discharge and PD when rewinding HV electric motors and generators is vital for maintaining their efficiency, reliability, and safety. By implementing effective strategies and monitoring techniques, operators can ensure the longevity and optimal performance of these critical machines. — MM RESIN-RICH VS.
insulation systems coming to market, whereas previously only Class F (155°C) systems were available at voltages equal to or greater than 11 kV.
Concerns regarding resin-rich
Such are the benefits of resin-rich. Here are some concerns:
> Inconsistent application. Achieving uniform resin distribution can be challenging, which could lead to areas of insufficient insulation, potentially compromising the machine’s performance. Automated taping machines and kneading functions in hot-pressing cycles help to ensure uniform application and reduce PD effects. Adherence of the main wall and end winding insulation (known as the scarf joint, usually located at the end of the coil straight) is a frequent area of failure. Typically scarf joints don’t feature in VPI systems.
> Longer curing time. Hot-pressing individual coils takes longer than manufacturing VPI coils, meaning a VPI insulation system should be quicker overall. However, if problems are encountered after testing, a total rewind is required. We saw this all too frequently among our customers opting for global VPI solutions who then failed to follow necessary processes.
> Impact on cooling. There’s a strong evidence base supporting the notion that VPI has a better thermal dissipation than resin-rich systems.
> Delamination. There exists a risk of premature failure due to delamination of the main wall and end winding insulation if not properly manufactured.
Vacuum-pressure impregnation
Vacuum-pressure impregnation, or VPI, uses a vacuum to remove air from the windings and then applies pressure to force the insulation resin deep into the windings of the machine. This method can only be used where a repair shop owns or has access to a VPI tank and curing oven large enough to house the HV machine. VPI plants able to house machines up to 30 MW in size are very expensive to install and maintain, so only very well-equipped workshops tend to have them, which tend to be geographically located in areas with high densities of resident HV machines. A deep understanding of process engineering is required to consistently achieve repair standards comparable to resin-rich options for larger HV machines as defined by Tan & PD test criteria.
Here’s how VPI works:
> The windings are placed in a vacuum chamber and air is removed to create a vacuum.
> Once the air is evacuated, resin is introduced into the chamber under pressure, ensuring that it
thoroughly penetrates the windings and fills any voids.
> After the resin is injected, the windings are cured at high temperatures to harden the resin and form a solid, insulated structure. Rotational curing, when the machine is dynamically rotated during the curing process, ensures the resin doesn’t pool in one part of the machine due to gravity. Post-impregnation resin loss is a key factor in VPI processes being unsuccessful or not achieving optimum lifeextension due to inconsistent resin penetration throughout the stator slots during curing. These are the benefits of VPI:
> Complete insulation. Under controlled, engineered processes, VPI ensures that the resin penetrates deeply into the windings, which helps eliminate air pockets and voids. This results in a consistent and reliable insulation layer.
> Enhanced reliability and lifespan. VPI-treated windings are less likely to experience issues related to moisture, contaminants, or thermal cycling. This makes VPI an ideal choice for machines that operate in extreme or high-demand environments.
> Better thermal performance. With deep penetration of resin into the windings, VPI systems typically offer better heat-dissipation properties, which helps prevent overheating during prolonged operation.
European standard BS EN 50209. — IPS Newcastle / Houghton-International.com graph
Concerns regarding VPI
As with resin-rich, VPI brings with it a few concerns:
> Cost. VPI can be considered more expensive than resin-rich technology, both in terms of the initial setup (the need for specialized vacuum chambers and equipment) and the overall process. However, the more machines a company rewinds using this process, the lower the net individual cost. A fully informed commercial decision is required into what technology a repair shop should invest. Once that decision is taken, most repairers stick to it religiously, which is why I struggled to change their minds!
> No guarantee of slot fill. The VPI process, while highly effective, is unable to be full-tested by individual coils or slots, so there is no way of knowing, in a one-off repair, if each slot is fully impregnated, thus reducing the effects of corona discharges externally to the coil and PD within the coil.
> Complexity. The VPI process requires sophisticated technology and engineered process expertise, which may not always be readily available, especially in remote locations or for small repair operations.
The key differences between resin-rich and vacuum-pressure impregnation are outlined in the sidebar on the next page.
How to decide?
Having read all of the above and avoided spilling your morning coffee across your lap, you’re probably expecting me to conclude that the choice of which technology to use depends upon a range of factors. And
Figure 2. Typical HI Tan δ value for 13.8 kV HiFLEX resin-rich coils tested against the
you’re right! Annoyingly, you’ve read this far and there is no conclusion!
This is true to a point. Taking the decision to use VPI as a sustainable competitive advantage in large HV machine repair is one not to be taken lightly. The up-front investment cost is in a range of millions of dollars. The engineering and process management required to achieve high quality outcomes first time, every time, is considerable. But it is achievable. Once economies of scale are achieved by regular throughput, VPI is an excellent commercial option, and should improve your margins. You must have volume!
Many smaller shops can’t afford such an outlay. The decision is taken for you – you’re using resin-rich coils, or a benevolent competitor’s VPI plant. But why add risk, time and cost? My strong advice here is to learn about the range of insulation systems on offer and find a coil manufacturer you can develop a long-term mutually beneficial relationship with. This will provide competitive advantages that sit way beyond simple unit price and delivery time. All too often, repair shops focus on coil price and delivery as the differentiator, which I always found to be sub-optimal for both parties.
Our most successful long-term partnerships came from a decision by the repair shop to work with one partner, not chopping and changing between suppliers for any given job. Engineering is an iterative game. Nobody knows everything. Your coil supplier should be a technical partner who will help you understand the best solution to any given problem.
Aspect
Winders, ever a fickle bunch (I know, I was one), will learn to use the coils from your supply partner. As almost every job is different, each manufacturer has their own nuance as to how they finish a coil set. How they position leads. Where they stop the insulation. What materials they use, why, and how to get the best out of them. Sticking to the same partner for the long-term – sometimes through difficult challenges – builds trust, product familiarity and quality consistency through fruitful collaboration.
Hopefully you’ve found this article educational, illuminating, and interesting. You may disagree with me. That’s fine. There is no right nor wrong answer; asset owners and repairers alike must make their own choice. My best advice is to find the right coil manufacturer to help you make the right technical, and ultimately, commercial decision for your business. The wide set of both technical and commercial considerations that inform your
Penetration
Cost
Durability
Repair time
Applications
Your coil supplier should be a technical partner who will help you understand the best solution to any given problem
decision making will be far more optimal if you work alongside a highly competent technical partner who seeks to add value to your business.
Repair shops that chop and change suppliers depending upon which way the wind blows may gain a short-term extra dime in their pockets, but they risk losing out in the long run to a more competent competitor that’s chosen to form a deep technical and mutually beneficial partnership with their chosen coil vendor. I always thought it far better lose the odd battle – albeit through gritted teeth – and win the war.
In choosing the best technology, it’s a tight run race. For me, resin-rich wins it by a coil’s nose. EA
Resin is applied directly to the windings.
Complete resin throughout every coil’s main wall. End winding separately insulated.
Generally more affordable because the coil manufacturer invests in the critical hot pressing machinery, but varies massively from job to job.
Good, but can suffer from external influences such as chemical and moisture ingress if not properly manufactured.
Many variables dictate repair time. Coil manufacturing takes longer.
Typically good but not as effective as VPI due to thicker resin layers.
Consistent, high-quality insulation if produced by a high-quality coil manufacturer applying consistent, proven processes and testing. Risk of premature failure due to delamination of main wall insulation if not properly manufactured.
Suitable for less demanding environments.
Key differences between resin-rich and VPI technology.
is applied under vacuum and pressure.
Deep, thorough impregnation throughout the windings.
Considered more expensive due to VPI tanks required and up-front resin costs. Resin storage is a risk if not properly monitored.
Superior durability and longevity to resin rich, but only if slot penetration of main wall insulation is complete, for which there is no way of knowing down to an individual slot.
Many variables dictate repair time. Coil manufacturing quicker.
Better thermal performance due to deep penetration and method of impregnation.
Consistent, high-quality insulation if processes are fully understood. The risk with VPI is there is no way of knowing if you have achieved full resin penetration throughout the slot portion of the coil. Delamination far less of a risk.
Ideal for high-demand or harsh conditions.
Feature | Finance & The Workplace
Top financial challenges in selling a business
For sellers, exercising proper due diligence can pay off handsomely
By William H. Wiersema, CPA, EA Finance Editor
Business owners who are planning to sell their businesses have much to do. Enhancing a business’s value, planning personal finances, and considering tax implications are often top priorities. However, many sellers overlook the financial challenges that may arise once they’ve signed a letter of intent with a buyer. Unprepared sellers are often blindsided and disappointed, even to the point of withdrawing from the transaction. Most letters of intent do not close, causing significant wasted time and resources for everyone involved.
On the other hand, once under a letter of intent, buyers focus on due diligence. The financial portion entails a thorough review of the target company’s financial statements, accounting policies, tax aspects, proposed adjustments, and operational performance, among other things. Unlike sellers, many buyers have extensive experience in evaluating businesses. Buyers seek reassurance that the financial representations made by the seller are accurate and that they are not overpaying for the business. For buyers, the target’s earnings before interest, income taxes, depreciation, and amortization (EBITDA), as adjusted, is a key metric.
To forestall problems, sellers and their advisors should stay informed about the latest developments in due diligence. That way, sellers can identify potential issues and optimize their responses. Investment bankers note that these efforts can pay off handsomely, leading to an increase in the business’s selling multiple by one-half to a full turn. For instance, for a business generating $1 million in EBITDA, this could result in an additional $500,000 to $1 million in the selling price.
Let’s consider today’s top accounting, tax, and add-back concerns.
Apply accounting rules
Companies book sales at different times, often improperly. For instance, to incentivize its sales team, a kitchen remodeler recorded revenue when the company received a final order, even before scheduling the work or purchasing materials. This practice significantly inflated the company’s
financial performance. More commonly, middle-market companies recognize revenue at the time they invoice customers, following most accounting software.
However, since 2019, the new default method for revenue recognition is “Over Time” (OT). It resembles the percentage of completion method, which was used traditionally by contractors. Now, OT applies to almost every industry, including consulting, software, and custom manufacturing, promoting consistency.
OT recognizes revenue based on the ratio of costs incurred to the total budget. Because this method aligns with project progress, it is theoretically sound, although not in line with billing. For example, customer advance billings are regarded as liabilities and considered unearned until work is performed under OT. In contrast, if revenue were recognized solely based on billing, a company could record a deposit as revenue without incurring any costs, which would be misleading. Other examples where billing does not align with earned revenue include annual billing, retainer or progress billing, and timeand-materials work billed a month in arrears.
— Illustration by Bing generative AI
OT relies on estimates, making budgeted remaining costs a crucial element. Unfortunately, budgets are rarely accurate and always contain some degree of error. Budgeting can also be subjective. Inflating budgeted costs results in reduced revenue, whereas understating budgets can accelerate revenue. Additionally, OT can lead to increased revenue and profit in unexpected ways. For example, by adding payables to ongoing jobs, revenue is recognized with a budgeted margin added.
Inventory is the second top issue. For companies in trouble, a classic way to turn losses into profits is to raise inventory levels. This can be as simple as creating fictional inventory in the records, as happened in the Phar-Mor fraud case during the 1990s. Other ways of misstating inventory, whether intentionally or not, include practices such as capitalizing more overhead into inventory cost, failing to write off old inventory (or marking it back on), and even just adjusting upward to current costs in inflationary times.
The equation for computing cost of goods sold illustrates how. Ending inventory is deducted from purchases (or production) plus beginning inventory, meaning that overstating ending inventory leads to more income. Unfortunately for the fraud-minded, ending inventory this period is beginning inventory for the next. Inventory must continue to be overstated by the prior amount just to run in place.
Buyers are also wary of reserves mandated by accounting rules for excess and obsolete inventory. For example, an item costing $1,000 might be reserved to $750 down to a net realizable value of $250. Oftentimes, middle-market companies do not book reserves. Additionally, where reserves exist, buyers may suspect manipulation.
In one situation, buyers insisted on a deduction from EBITDA for a reduction in an inventory reserve, which caused ending inventory to increase. The seller became distrustful of the buyer and terminated the deal. When investigated subsequently, the decrease in reserve was actually reasonable and could be traced to negative margin sales, charitable donations of product, and disposals. Once documented, it became a non-issue in the next deal, which successfully closed.
Check on tax compliance
In its 2018 Wayfair decision, the U.S. Supreme Court ruled that sales of $100,000 or 200 transactions over twelve months was enough for a state to obligate an out-of-state business to register, collect, and remit sales tax. As a result, many companies are facing unexpected consequences. For instance, an Illinois distributor of repair parts for manufacturing equipment had no tax liability before Wayfair. However, about one-quarter of states do not provide exemptions for manufacturing, meaning the distributor now becomes liable for sales tax when shipping to those states.
Buyers are often hesitant to assume state tax liabilities due to the risk of successor liability, even in asset acquisitions rather than stock purchases. This often leads to complex negotiations, structures, and financial protections, such as voluntary disclosure filings, which can become an ongoing burden for sellers after the business is sold.
The Wayfair decision extends beyond sales tax, potentially affecting any non-income tax compliance. The landscape is complicated by politics, as there are 10,000 state and local taxing jurisdictions in the U.S., each with varying rules and timelines. Out-of-state businesses lack voting power, so their concerns tend to receive lower priority.
Payroll also presents due diligence concerns. Recent changes to the income tax law regarding the qualified business income deduction
Sometimes, measuring a company’s value requires more than just historical data
greatly impact owner compensation. In many industries, owners can deduct 20% of pass-through income, giving them a considerable tax advantage over their W-2 income, causing owners to revisit their compensation.
Owners influence related party transactions in ways that are not solely market-driven. For example, when a business rents a facility owned by its owner, the arrangements may reflect personal financial objectives. Complications may arise further when a company sells to an affiliate, who might purchase more than necessary to boost profits.
Compliance remains a critical issue. Early-stage businesses often misclassify workers as contractors to save on payroll taxes and benefits. However, the IRS and other government agencies apply complex and strict tests to determine worker classification. Employers who violate the rules face penalties and personal liability.
Adjust for non-recurring items
Sellers often take the time to identify nonrecurring items to add to reported EBITDA. Examples include failed products, nonproductive advertising, recruiting fees, severance pay, and employee bonuses. However, buyers are likely to challenge these items, arguing that they are standard parts of business operations. Additionally, buyers may analyze historical data to exclude any anomalies related to the post-pandemic period, such as government pandemic subsidies, abnormal revenue fluctuations or temporarily elevated profit margins caused by lags in changes in sale and purchase prices.
For sellers to effectively present their add-backs and defend against buyer deductions, the items must be quantifiable, justifiable, and supportable. For instance, an examination of historical data reveals that ocean transport costs peaked in 2021 but have since returned to pre-pandemic levels. Consequently, the costs that impacted profit margins were temporary and can be justifiably considered as add-backs to EBITDA.
Sometimes, measuring a company’s value requires more than just historical data. For example, when Encyclopedia Britannica published its last print edition in 2010, many believed this marked the end of its 240-year history. However, Crain’s Chicago Business reported recently that the company has undergone a technological turnaround through digital products, resulting in a current valuation of $1 billion. EA
Four-wheel drive
Electricity generation by source in 2025: Natural gas, renewables, coal, and nuclear
By Charlie Barks, EA Managing Editor
The U.S. is currently running on a quartet of energy sources to generate electricity. Natural gas remains the primary method, with seasonal fluctuations. Renewables, nuclear, and coal account for the rest of the grid, all with similar slices of the pie.
The U.S. Energy Information Administration (EIA) detailed this in its February report. EIA noted that it made a last-minute revision to its initial 2025 forecast of natural gas projections but left the remaining three energy sources largely unchanged.
EIA’s Short-Term Energy Outlook (STEO), published on Feb. 11, uses 2024-26 as a timeline. It factors in U.S. energy market indicators like Brent crude oil spot prices (projected to drop from $81/ barrel in 2024 to $66/barrel by 2026), gas prices, and oil production trends. While rates at the pump could stay relatively steady, natural gas is expected to spike in the next two years.
Shares of U.S. electricity generation are perhaps the most revealing. Natural gas accounted for about 43% of the pie in 2024, with estimates to drop to 39% by 2026. This was followed by renewables (23%), nuclear (19%), and coal (16%). In this case, the renewables category contains anything considered a source that doesn’t heighten CO2 emissions. Meanwhile, nuclear power is looking like the George Harrison of the four as it blossoms outside the group of traditional sources it used to work with. Thanks to new technology, safety developments, and more, nuclear power is resurgent. (See Contributing Writer Bill O’Leary’s article “A new nuclear age” in this issue, page 29.)
As the energy transition slowly equalizes source distribution, all eyes are on black gold. The energy report predicts U.S. production of refined petroleum products will decrease by about 190,000 barrels per day in 2025 and by 180,000 barrels per day in 2026 as two refineries close operations (LyondellBasell in Houston and Phillips 66 in Los Angeles.) This could mean importing more gasoline and jet fuel while remaining a net exporter of distillate fuel oil. Of course, a lot of this is contingent on world affairs.
“EIA completed its January forecasts before additional sanctions against Russia’s oil and shipping sectors were announced, which created additional uncertainty in outlooks for crude oil supply,” the revised summary noted. “EIA does not expect the sanctions to have a significant impact on global oil production or prices, although trade flows could be affected.”
Residential electricity prices, despite inflation, may have good news in the future, with a forecast of 3% growth in 2025, which would be the smallest annual increase in residential electricity prices since 2020, according to this particular report. The modest price increase, similar to the expected rate of inflation growth, reflects relatively low natural gas prices over the past year offset by continuing expenses for improvements in grid infrastructure.
Regarding U.S. coal exports, another timely indicator stood out: EIA expects the U.S. to export about 100 million short tons of coal in both 2025 and 2026, about 2% less than EIA’s January forecast. EIA expects that China’s tariffs against the U.S. will affect U.S. coal exports, but exporters are likely to find customers in other markets, limiting the tariff’s impact.
— Illustration by Bing generative AI
Product Showcase
What’s new among products for service and plant operations
Emerson’s Type 84 pressure relief valves
Emerson has introduced the Anderson Greenwood Type 84 pressure relief valve (PRV), specially designed to protect tanks and vessels used in hydrogen and other high-pressure gas applications. PRVs are frequently used in traditional applications, but they are not designed to handle extremely small molecules at very high pressures. To address these and other issues, Type 84 PRVs are constructed for high-pressure gas applications, with a range of 6,000 psig (413 barg) to 20,000 psig (1,379 barg) for H2 and He, and a range of 6,000 psig (413 barg) to 15,000 psig (1,034 barg) for all other gases. It reaches full lift at less than 5% overpressure to protect the vessel or tank to which it is a xed, with zero leakage at 90% of set pressure. H
Long-life machine safety doors
EFAFLEX has released its EFA-SRT MS Performance machine safety door, which it claims o ers a service life of one million load cycles. The door is designed for adaptation to all requirements; attachments and fence connections can be exibly mounted in almost any position, and the door can be installed either as a free-standing unit or mounted on a wall. The EFA-SRT roll-up door is suitable for use as an interior door in logistics areas as well as for hall closure. The high-speed turbo door EFA-STT Clear opens at speeds of up to 3.2 m/s and is suited for logistics processes with high daily demands. The door blade with EFA-CLEAR transparent laths also ensures optimal lighting conditions in storage and production halls. Additionally, it o ers the advantages of the “Next Generation” spiral doors, such as high-customization options and extensive safety features, including the EFA-TLG door light grid.
New servomotors from Siemens
Siemens is introducing the new Simotics S-1FS2 line of servomotors, designed for the clean condition requirements of the food, beverage, sterile packaging, pharmaceutical, and other process industries. These new servomotors are o ered in a variety of power ratings, from 0.45 kW to 2 kW (0.60 hp to 2.68 hp) with torque from 3.1 Nm to 14 Nm (2.28 ft.-lbs. to 10.32 ft.lbs.). Crafted with housings of 1.4404 (AISI 316/316L) stainless steel, EPDM seals, and bearing grease with NSF H1 approval, the new servos are said to be highly resistant to corrosion and acidic chemicals found in the process industries.
WEG drives available from AutomationDirect
Certi ed supplier AutomationDirect has added general-purpose WEG CFW320 a-c drives and full-featured SSW900 soft starters to its catalog. The CFW320 series VFDs o er all the features of the existing CFW300, including a compact size, a built-in operator interface, and an embedded SoftPLC, but they provide support for 460 VAC and Ethernet communications. These drives support 230 VAC three-phase motors up to 5 hp and 460 VAC motors up to 10 hp. Dynamic braking is built in on many models, so no external braking chopper is required. The optional Ethernet module communicates over EtherNet/IP and Modbus TCP. The new SSW900 soft starters o er motor support up to 1,050 A and a voltage range of 220-575 VAC. These soft starters feature an advanced setup with parameter help and event history on the included interface. Software setup is optional using free WPS software, and the same software is used for all WEG drives and soft starters. Ethernet communication is optional on the SSW900.
Right-sized automated packaging systems
Packsize, of Salt Lake City, is unveiling its X6 automated right-sized packaging system at two upcoming trade shows. The company says the X6 “is the highest-capacity erected box machine available on the market today,” capable of creating up to 1,500 at-bottom boxes per hour from corrugated z-fold. The X6 has the exibility to produce both boxes with aps and corrugated trays, facilitating integration with leading goods-toperson and shuttle systems. Producing right-sized trays enables picking directly into shipping boxes and can replace the need for totes, as they provide enhanced ergonomics, are conveyable, and are usable with various operator workstations. The X6 will be available with both box-closing and lidding modules.
Megger’s predictive maintenance platform
Megger, the provider of electrical measurement and monitoring solutions, has launched its Megger Industrial Reliability platform in the U.K. and Ireland. The new division is dedicated to advancing reliability solutions within the industrial sector. Building on its expertise in un-energized electrical testing, the company has recently expanded into advanced monitoring and predictive maintenance. This latest o ering combines cuttingedge technology and a comprehensive software-as-a-service model. Megger Industrial Reliability is designed to reduce unplanned downtime and extend the lifespan of critical industrial assets. Using techniques such as vibration analysis and advanced monitoring tools, the division provides organizations with actionable data to improve decision-making and streamline maintenance. — Charlie Barks EA
Feature | Electrical Manager
The outlook for OSHA
What’s new for 2025 from the Occupational Safety and Health Administration
By Bill O’Leary, EA Contributing Writer
Keeping abreast of the latest safety happenings — legislation, regulations, certifications, infinitely more “-ations” — can be a full-time job. Unfortunately, most of us don’t have the 9-5 to devote to this, but we have you covered. Below is the 2025 outlook for the Occupational Safety & Health Administration. By continuing to deliver on the safety considerations of the past and preparing for the considerations of the future seen here, managers and workers should be well-positioned for a healthy and injury-free year.
Stricter rules on lead exposure
In order to address the still-common workplace hazard of excessive lead exposure, OSHA is implementing stricter regulations to protect those who work in high-lead areas. At the beginning of this year, OSHA began enforcing stricter air quality monitoring along with dust reduction measures and pushing increased ventilation.
More specifically, the action level has been reduced from 30 micrograms per cubic meter to
2 micrograms per cubic meter. Action level is a threshold of a pollutant’s concentration. When that action level is passed, an intervention or engaged response is required to protect an individual’s health or the environment. Examples of interventions include emission-reduction efforts in technology or building construction, health advisory warnings, or clear work restrictions.
These levels are set by OSHA and are based on scientific research on the various effects of pollutants. They vary, depending on the region and the specific pollutant in question. They are also often tied to Air Quality Index values, the major pollutant levels that are measured — groundlevel ozone, carbon monoxide, nitrogen dioxide, sulfur dioxide, and particle pollution.
Another key update is the lowering of the permissible exposure limit (PEL) from 50 micrograms per cubic meter to 10 micrograms per cubic meter. The PEL is a cap on the amount of hazardous substances that workers can be exposed to. It is based on the average concentration of a particular chemical that workers can be exposed to over a typical eighthour workday.
In addition to short-term measures, called the short-term exposure limits, or STELs, OSHA sets PELs with long-term considerations in mind as well, basing its decisions on whether workers can be safely exposed to a chemical over a lifetime without adverse effects. Other PEL types include time-weighted averages and maximum allowable exposure limits. OSHA has established hundreds of PELs for hazardous chemicals, all of which can be found in the OSHA 1910.1000 Z Tables.
Heat safety rules
In 2025, OSHA is launching a new heat safety rule with the goal of decreasing heat-related illnesses and injuries in high-temperature environments. The rule would apply to a variety of locations including outdoors in warm climates and enclosed factories and manufacturing facilities with excessive temperatures, such as foundries. It also would apply to a range of workplaces, such as general industry, agriculture, and construction.
Under this rule, employers must establish heat injury and illness
prevention plans along with heat emergency response plans — commonly agreed upon and easy-to-follow guidance that all workers are trained on that includes content covering additional requirements from the rule outlined below. Heat safety training in accordance with OSHA regulations and relevant to the specific workplace environments must also be built and delivered to all employees.
Along with preventative measures, companies must also document all heat-related incidents. Additional measures under this rule include continuous monitoring of workplace temperatures, scheduled rest and water breaks for hot outdoor work, and scheduled heat risk assessments.
But what qualifies as a “hot” environment? The designation applies to any employees who are exposed to heat indexes 80°F and above for more than 15 minutes in any 60-day work period. The rule would establish “heat triggers” at 80°F and 90°F. At the 80° heat index, required actions include easy access to potable drinking water and increased environmental monitoring of heat conditions. At the 90° threshold, more heightened protective measures are required, including at least 15 minutes of paid rest breaks every two hours and easy access to “cool-down areas” — essentially shaded spaces or air-conditioned rooms.
This new rule has not taken effect. The Notice for Proposed Rulemaking was published on Aug. 30 of last year in the Federal Register. The comment period was extended until Jan. 14 of this year. And an informal hearing on it will begin on June 16, when employers and other impacted parties can provide questions, documentary evidence, or oral testimony. But the wait might be even longer. In January of this year, President Trump issued a memorandum that immediately withdraws rules from the Federal Register that have not yet been published. Under the memorandum, a department or agency head appointed by the President must first review the rule before deciding whether or not to move forward with approval.
Lockout/tagout updates
Another ongoing effort this year for OSHA is updating the Lockout/ Tagout (LOTO) standard (29 C.F.R. 1910.147). The agency is considering the inclusion of control circuit-type components such as selector switches and push buttons as suitable alternatives to energy-isolating devices.
Control circuit-type devices rely on electrical control circuits to start or stop machinery by interrupting signals within the control circuit. This feature is different from more traditional LOTO, energy-isolating devices such as manually operated circuit breakers, line valves, and disconnect switches, which physically separate the equipment from the energy source.
OSHA is debating control circuit components because the current standard outlines that energy-isolating devices must physically prevent the release or transmission of energy. Simply put, control circuit devices do not do that, so they do not meet the current OSHA LOTO criterion of providing adequate protection against the release of hazardous energy. However, the technology has advanced and provides a basement of benefits such as improved operational efficiency, minimization of direct exposure to dangerous voltages, lower-voltage operation, and enhanced fault protection. Thus, OSHA is exploring adding these products as safe alternatives for energy control procedures.
Also under consideration for the proposed update is the integration of robotics, such as wearable robotic systems and collaborative robots in LOTO, potentially describing best practices in managing associated energy hazards. When the standard was finalized in 1989, robotics were
A department or agency head appointed by the President must first review unpublished rules before deciding whether or not to move forward with approval
essentially a glimmer in Mama Machine’s eye. Today, they are fixtures of so many industrial settings. But that gulf between this standard and the current technological landscape needs to be filled.
Robotics systems are more autonomous and “freemoving” than traditional equipment that LOTO is designed for, and shutting them down in a LOTO-safe manner is also very different. For example, completely de-energizing (i.e., shutting down) a robotic system can cause a loss of the precise calibrations needed for these intricate systems to operate effectively. De-energization can also lead to more costly shutdowns than other industrial machinery that LOTO is applied to. Because of this, many operators have robotics systems that can undergo maintenance without de-energizing them, which is a violation of the current standard.
Applying the current standard to robotics today, “serious” violations can lead up to a $15,625 fine per infraction. This is in addition to abatement requirements that have even more dire consequences — the required discontinuation of manufacturing or operating robotics systems. Because of these costly violations, many manufacturers have requested exemptions or, more officially, “variances” from the standard. Today, OSHA grants variances if an employer demonstrates the infeasibility of deenergization or can prove that maintenance of an energized system is safer than adherence to the current standard.
So where does that leave us? In the Spring of 2024, OSHA moved the standard update to the proposed rule stage. The Notice of Proposed Rulemaking, scheduled for release this August, will outline the desired changes and provide impacted parties the ability to review and provide feedback.
Lead exposure, excessive heat prevention, proper shutdown of industrial machinery - these are just a sampling of the potential changes that could impact you in 2025. In order to stay prepared and protected this year and beyond, continue to visit OSHA’s website and search “OSHA Outlook” and specific applicable standards to get the latest.
Because it’s better to be safe than sorry. EA
Land, air, and sea
Initiatives launched nationwide for workforce development
By Charlie Barks, EA Managing Editor
Training programs are being launched across the U.S. to address labor shortages in critical industries, including aviation, construction, and maritime operations. The following is a look at three programs set to launch in Alabama, New York, and Massachusetts in 2025.
To air is human
The aviation industry is facing challenges, from mechanical issues to staffing shortages and regulatory complexities. One area of consensus: the need for skilled technicians.
Embry-Riddle Aeronautical University’s Worldwide Campus is partnering with Airbus SE and its U.S. manufacturing facility in Mobile, Ala., to launch a 24-month training program aimed at strengthening the aviation manufacturing workforce.
The program, designed for structural and electrical assemblers working on A320 and A220 aircraft, will provide participants with opportunities to expand their expertise and career prospects. Graduates will be prepared to transition into broader manufacturing roles, including tasks typically assigned to manufacturing engineers.
“This collaboration aligns with Embry-Riddle’s mission to support the aviation workforce,” said Dr. Bill Muldoon, vice chancellor for business development and professional education at Embry-Riddle Worldwide. “We’re proud to partner with Airbus, a global leader in aviation manufacturing, to develop an innovative training initiative that prepares the next generation of industry professionals.”
The program, designed for structural and electrical assemblers working on A320 and A220 aircraft, will provide participants with opportunities to expand their expertise and career prospects
Training will be conducted online through Airbus’s onsite learning labs. The initiative is made possible by a collaboration with Flight Works Alabama, a nonprofit public-private partnership between Airbus and the State of Alabama.
With the aviation industry facing a shortage of skilled workers, programs like this one aim to provide a practical solution by equipping employees with advanced technical knowledge.
“This initiative gives our assemblers a broader understanding of the work we do while creating new career pathways they may not have otherwise considered,” said Michelle Hurdle, director of workforce and economic development at Airbus Americas, Inc.
Ramping up
New York City’s magnitude and influence are undeniable, but Upstate New York has its own legacy of hard work and innovation.
On Feb. 6, New York Gov. Kathy Hochul announced that the Capital Region, Finger Lakes, and Mohawk Valley were selected to advance to the planning stage of the $200 million One Network for Regional Advanced Manufacturing Partnerships (ON-RAMP) program. These regions join Central New York, where Syracuse was established as the program’s flagship location. The initiative will create a network of workforce development centers to connect New Yorkers with careers in high-growth advanced manufacturing industries.
The goal of these workforce centers is to equip New Yorkers with the skills they need, provide an “on-ramp” to training, internships, apprenticeships, and permanent employment, and capitalize on the state’s success in attracting and expanding advanced manufacturing companies such as Micron and GlobalFoundries.
$50,000 if by sea
Despite tariffs and trade disruptions, commerce and logistics remain heavily dependent on maritime transportation. Massachusetts is preparing the next generation of maritime workers to ensure the supply chain remains robust.
Massachusetts Maritime Academy (MMA) launched a partnership with Bourne High School (BHS) in late January to support this effort.
The academy and BHS were among 31 college and high school partnerships throughout the state to receive Early College grants. These programs are designed to support students traditionally underrepresented in higher education. Massachusetts Early College programs blend elements of high school and college to provide students with the opportunity to complete college-level coursework while gaining exposure to various career paths.
With support from a $50,000 grant, the Early College program will introduce BHS students to high-level coursework, hands-on instruction, and lab experiences at the MMA campus. EA
A regulatory shift brings uncertainty for electric utilities
The U.S. has long benefited from an abundance of natural resources that have fueled economic growth and secured the national defense. The newly dominant view in Washington, however, is that government regulations in recent years have hindered energy development, driving up costs and limiting job opportunities.
According to this view, these burdens have impacted nearly every aspect of American life, from transportation to manufacturing. The new administration is therefore seeking to reverse these policies as it emphasizes energy independence and economic revival. The effect on the U.S. electric utility industry could be profound.
On Jan. 20 — Inauguration Day — the White House issued a document, titled “Unleashing American Energy,” that outlines a new energy policy intended to encourage domestic energy production, reduce regulatory burdens, and safeguard consumer choice.
The administration plans to support energy exploration on federal lands and waters in the hope of positioning the U.S. as a dominant global energy leader. It also seeks to increase production of non-fuel minerals, including rare earth minerals. By ensuring a steady supply of resources, the administration believes it can strengthen national security and reduce reliance on “adversarial states.”
Consumer choice is another element of the new policy. The administration hopes to “eliminate the ‘electric vehicle (EV) mandate’ and promote true consumer choice,” arguing that regulations have unfairly promoted EVs over traditional gasoline-powered vehicles. This includes reviewing state emissions waivers and subsidies.
To implement these policies, federal agencies that answer to the President have been ordered to review their existing regulations to identify and remove barriers to domestic energy development. This includes oil, natural gas, coal, hydropower, biofuels, nuclear energy, and critical minerals.
In a sweeping reversal of previous environmental policies, the order revokes multiple executive orders from previous administrations, including those pertaining to climate change, emissions standards, and sustainable energy programs.
Another priority expressed in the order is streamlining the permitting of energy projects. Regulations under the National Environmental Policy Act will be revised to accelerate approvals, ensuring that infrastructure projects, including pipelines, move forward without delay. Agencies are being directed to use emergency authorities, if necessary, to fast-track critical projects.
The order also calls for eliminating the “social cost of carbon” calculation, arguing that it lacks scientific and legislative foundation. It puts forth the opinion that this metric has been used arbitrarily to justify regulatory slowdowns and places U.S. industries at a disadvantage against international competitors.
Funding for climate initiatives under the Inflation Reduction Act and the Infrastructure Investment
and Jobs Act will be halted for review, the statement goes on to say. This includes federal support for EV charging stations and other clean energy projects. Agencies have been directed to evaluate whether these programs align with the administration’s priorities before releasing funds.
Energy exports play a crucial role in national security, and the administration is seeking to expand liquefied natural gas exports. The U.S. Dept. of Energy will resume reviews of liquid natural gas export applications, giving priority to projects that benefit the U.S. economy and strengthen energy security for allies.
The policies outlined in the new energy policy are expected to have a significant effect on the U.S. electric utility industry. The order includes measures such as pausing funds that support renewable energy projects, halting new federal permits for large-scale wind farms, and rescinding various environmental regulations imposed during the previous administration. The order also reverses mandates related to electric vehicles and energy efficiency standards, which will likely shift focus away from renewable energy expansion and toward fossil fuel development.
For electric utilities, these changes will surely reduce incentives and funding for renewable energy projects such as solar and wind farms. Utilities that have invested heavily in clean energy and grid modernization may face uncertainty regarding future financial support. On the other hand, companies involved in fossil-fuel-based power generation, such as coal and natural gas, could benefit from regulatory rollbacks that make it easier to expand traditional energy production. Among electric utilities, in other words, there are sure to be winners and losers resulting from these policy shifts.
The emphasis on expanding domestic oil and gas production, along with reversing emissions-related restrictions, may also affect electricity markets by influencing fuel prices. Lower natural gas prices could make gas-fired power plants more competitive, potentially slowing the transition to renewable energy sources. And the removal of electric vehicle mandates could alter projected electricity demand growth from transportation, affecting utilities’ infrastructure planning. Already, Bloomberg and other news organizations are reporting, demand for electric vehicles is stalling.
In short, the electric utility industry appears poised to shift, in a big way, from clean energy investment toward fossil-fuel-based power generation. State-level policies and market forces may still drive renewable energy adoption to some degree, and already — as this issue of EA was going to press — the new energy agenda is being challenged in court. But even if the administration’s energy vision is not realized in full, significant changes in the U.S. electric utility industry appear inevitable. — Kevin Jones EA
— Illustration by Bing generative AI
Pumps and the ‘energy transition’
Increased efficiency, retrofits, and renewable energy sources could ease the way toward a global objective
By Kevin Jones, EA Senior Editor
The role of pumps in helping bring about the muchdiscussed “energy transition” has gained significant attention in recent years, particularly as the need for energy efficiency becomes more pressing.
Pumps, essential for moving and processing fluids across various sectors, have long been recognized as critical to reducing energy use. Only recently, however, has their potential to contribute to sustainability been explored in depth. The question of how to enhance the efficiency of fluid management through the wise use of pumps has become a matter of great interest, with industry leaders and manufacturers shedding light on innovative answers.
A notable contribution to this conversation comes from Sulzer, the prominent pump manufacturer, which released a document in February titled “Pumps to Empower the Energy Transition.” The report explains how advanced pumping technologies are supporting the shift to cleaner energy systems by improving efficiency in industrial, commercial, and residential settings.
Sulzer’s document highlights two primary ways in which pumps are driving this transition: by optimizing geothermal energy production, and by enabling retrofits for aging infrastructure.
In geothermal energy, specialized pumps designed to withstand extreme conditions — such as those found in deep wells — play a vital role. These pumps efficiently extract geothermal fluids, which are then converted into electricity via such processes as binary-cycle or flash-steam systems. By enhancing the reliability and output of geothermal power (a low-emission energy source), these pumps help expand renewable energy options.
Retrofitting older industrial systems with modern pump technology offers another means of improving efficiency. Many facilities operate with outdated, energy-intensive pumps that are expensive to maintain. Sulzer suggests that retrofits — such as upgrading materials to reduce wear, re-engineering pumps to meet current demands, or redesigning hydraulics — can extend equipment life and improve performance without requiring full replacements.
The broader impact of pump efficiency is substantial, particularly given their significant share of global energy use. Sulzer notes that industrial pumps account for over 20% of the world’s electricity
demand. Even a modest 1% improvement in efficiency could yield substantial savings — enough to power a country the size of New Zealand while cutting millions of tons of carbon dioxide emissions. Achieving such gains would require adopting high-efficiency pumps, refining hydraulic designs, and integrating digital monitoring systems.
Beyond renewables, pumps also contribute to decarbonizing conventional energy production. In thermal power plants, for example, advanced pumps and monitoring tools can streamline such processes as cooling water circulation and boiler feeding.
Pumps also play a crucial role in water management, an often-overlooked aspect of sustainability. Efficient pumping systems in water treatment, desalination, and wastewater recycling reduce the energy demands of these processes.
Complementing Sulzer’s insights is the perspective of Luboš Michlík, CEO of Sigma Group a.s. and president of Europump, the European pump association. In a December 2024 article published in World Pumps and Water Magazine, Michlík emphasizes pumps’ critical but underappreciated role in the “energy transition.” He echoes Sulzer’s point about their 20% share of global electricity use and argues that upgrading to efficient systems can significantly cut energy costs and emissions in industrial processes such as cooling and fluid transport.
Michlík extends this vision to urban sustainability, noting that pumps are integral to modern cities’ HVACR systems, water networks, and waste management. In “smart cities,” energy-efficient pumps can help balance environmental impact with the demands of growing urban populations.
The transportation sector also benefits from pump technology. In electric vehicles, pumps regulate battery temperatures to optimize performance, while in conventional vehicles they improve fuel efficiency. Public utilities such as wastewater treatment and power generation rely on pumps to manage resources. Michlík further highlights pumps’ indispensable role in renewable energy systems — circulating fluids in geothermal plants, cooling solar farms, and supporting wind turbine hydraulics. He argues that the scalability of these renewable energy sources hinges on efficient pump performance.
In residential settings, pumps quietly sustain our daily lives by powering heating, cooling, and water distribution systems. Their efficiency directly affects how much energy each household uses.
Europump, under Michlík’s leadership, has championed these advancements through such initiatives as Ecopump, launched in 2004 to promote energy-saving pump technologies. The organization reports saving 233 million megawatt-hours of electricity and reducing CO2 emissions by 163 million tons since 2016.
Together, Sulzer, Michlík, and Europump make the irrefutable case that pumps are far more than utilitarian devices — they’re pivotal in the transition to a world in which energy is more wisely used.
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*subject to Publisher’s acceptance
Equipment for Sale
GREAT WORKING BURN OUT OVEN
Neptune, NJ. Mfg/ Pollution Control natural gas well built burn out oven. Model VP-127134.Loads from top.
Call or text Marc at 1 609 709 0382. Can text pictures.
27” W x 39” D x 24” H.
Equipment for Sale
CSI FOR SALE
CSI 2110 with manual , case , pick,ups , cables , charger , etc..... $1K brinksindustrial@gmail.com 412.977.5938
Business for Sale
EXCITING BUSINESS OPPORTUNITY —
Established Motor Shop & Electrical Contracting Business for Sale!
Are you ready to own a thriving, wellestablished business with 66 years of success? Located in Long Island, NY, our reputable motor shop and industrial electrical contracting company is seeking a new owner.
• Ideal for individuals with a strong mechanical background, drive systems, and PLC knowledge
• Plenty of room for expansion and increased profitability
• Turnkey opportunity with a proven business model and established customer base
Owners are looking to retire and are open to mentorship and training for the right candidate. If you’re ambitious and ready to take on a successful, growing business, this could be your chance!
Serious inquiries only. Contact us today to discuss this incredible opportunity! Box 31, barbara@barks.com
Business for Sale
FOR SALE
Electric Motor business in Atlanta Ga area for sale. Inventory and equipment. No building or land. Contact Box #11, barbara@barks.com
Business for Sale
RETIRING
Electric Motor shop in the Houston TX area FOR SALE OR PARTNERSHIP. Shop, equipment, land, house 4-man shop 713-882-0999
Help Wanted
ELECTRIC MOTOR COMPANY IN LONG ISLAND, NEW YORK LOOKING FOR EXPERIENCED ELECTRIC MOTOR MECHANIC
Capable of rewinding AC 3 Phase and Single Phase Motors
Fraction Horsepower up to 300 Horse Power
Knowledge in Rebuilding various types of Pumps and Motors
$30 - $40 Per Hour Please contact: mpdpelectric@yahoo.com
Business for Sale
SERVO AND SPINDLE REPAIR BUSINESS FOR SALE… OR PARTNERSHIP WISCONSIN
Unique Opportunity. Very well-equipped facility with clients across the nation. In House Machine Shop, Precision Balancing, Rewinding, and more. Capability to do up to 500hp AC/DC but the focus is on servo/ spindle. Would also consider selling the “standard-motor” section of the business separately. Relocation or multiple locations could be possible. Owner/Staff available to stay on for training and smooth transition. Extensive testing capabilities, knowledge, and databases far beyond the average servo shop. We specialize in difficult repairs and find that we can often repair units deemed unrepairable by other servo repair shops. Email: servoshopforsale@gmail.com
COPYRIGHT 2025 ELECTRICAL APPARATUS
HANSOME ENERGY SYSTEMS
HANSOME ENERGY SYSTEMS, located in central NJ, is seeking a qualified electrical design engineer with a primary focus on the design of electric motors.
Requirements:
-Bachelor’s degree in Electrical Engineering (BSEE)
-U.S. citizenship
Benefits:
- Highly competitive wages
- Health insurance
- 401(k) plan and profit sharing
Send résumé to wendy.felise@hanenergy.com or call 908-862-9044
COMPETITIVE PAY, BENEFITS & OT!!
Prime Electric in Gorham, ME is looking for an experienced Electric Motor Technician. Relocation compensation, training program & advancement opportunities. Safe, friendly environment. Call 207-591-7800 or email résumés to dan@PrimeElectricMotor.com. Visit us at PrimeElectricMotor.com.
High-tech, low-tech
In the grid at left, find and circle the words listed below, which are taken from Contributing Writer Bill O’Leary’s article “A new nuclear age,” in this issue. The uncircled letters, arranged in order, will spell out a low-tech necessity for any high-tech nuclear plant.
The solution may be found online at http://barks.com/puzzles, or call (312) 321-9440. Happy hunting!
Help Wanted
ELECTRIC MOTOR & CONTRACTING CO., INC.,
founded in 1960, is one of the largest independently owned repair facilities for electrical rotating machinery, pumps, and switchgear in the United States. We are conveniently located in Hampton Roads, Virginia just miles from Virginia Beach and Norfolk.
Our company prides itself on:
• Maintaining a clean, state of the art facility
• Providing quality service to our customers
• Employing and retaining great people
• Our shop is AIR CONDITIONED!!!
We are seeking qualified candidates for the following positions:
• Electric Motor Mechanics
• Electric Motor Winders
• Machinists
• Switchgear Technician
• DC Specialists
• Reactor Coolant Pump Motor Technicians
• Field Service Technicians
First and second shift opportunities available. Employees receive 20% shift di erential!
EMC o ers competitive pay, full benefits package including 401K, insurance, uniforms, relocation assistance, and more!
Help Wanted
EASA SEEKS MOTOR ENGINEER
Join EASA’s world-renowned technical support team! EASA seeks an engineer with at least 5 years of experience in repair, service, maintenance and/or redesign of ac and dc motors. Must understand motor theory as well as application and be able to communicate e ectively in a fast-paced consulting role. Some travel required. For more info, see easa.com/careers.
Competitive salary; excellent benefits; team environment. Remote work option for the right candidate.
This is an exciting role with variety that impacts the entire indsutry. Send cover note and résumé to Linda Raynes; lraynes@easa.com.
Help Wanted
Electric Motor Shop in Wake Forest, NC, is looking for candidates for:
• Field Service Techs
• Manual Machinists
• Motor Mechanics
• Outside Sales Reps
• Field Service Manager
• Pump Mechanics
• Switchgear Specialist
• Winders
Visit our website at www.emc-co.com to complete an online application or email résumé to jobs@emc-co.com
Electric Motor Shop o ers competitive pay and benefits, including 401k. For employment consideration, please contact Kristine Larsen at 919-556-3229 or by email at Kristine.Larsen@emsnc.com
Help Wanted
ELECTRIC MOTOR WINDER
Relocation assistance available for the right candidate. Join Savannah Apparatus Repair, a trusted name for over 45 years, in the heart of Savannah, GA - a historic coastal city known for its charm, a ordability, and high quality of life.
We are seeking an experienced motor winder to join our team.
Responsibilities: Rewind various 3 phase AC/DC, random wound, form coil, stators, rotors, and armatures.
Requirements: Electrical experience and Baker testing up to 4160V. Must handle Start to finish work from strip and recording data to brazing and soldering.
What we o er: Competitive benefits, wages, medical, dental, vision, vacation, and much more!
Apply today! Send your résumé to ChrisB@savannahapparatus.com or call (912)925-8700
Bookmark these links to access our flipbooks
APRIL 2025 (this issue)
https://bit.ly/apr25poww
MAY 2025
https://bit.ly/may2025gogo
JUNE 2025
https://bit.ly/jun25upnx
EXPERIENCED SHOP FOREMAN
North End Electric in Wilkes Barre Pa, Shop overseeing all repair, field diagnosis, rewind and machine work progress. Must be experienced with AC/DC electric motors, gearboxes and other various rotating equipment. Contact cody.hendricks@ northendelectric.com to inquire.
ELECTRIC MOTOR TECHNICIAN
SUPERVISOR - 2ND SHIFT
10+ years exp w. industrial AC/DC electric motors, generators & electro-mechanical equipment repair. Must have previous supervisory exp. Pay based on exp. Excellent benefit package: 401k, medical, dental, vision, vacation, sick pay, paid holidays.
EEO
Apply at bit.ly/mti_jobs
Motor Technology, Inc.
515 Willow Springs Lane York, PA 17404
SHOP FOREMAN
Jasper Electric Motors, Inc.
Located in Jasper, Alabama
Experience in all areas of Electric Motor Repair.
Strong Mechanical and Load Test skills are a must. Must have good management and coordinating skills to advise and assist technicians in completing jobs in a timely manner. We o er competitive wages, health, dental, vision insurance, paid holidays and a retirement plan.
Please send résumé to jemi@bellsouth.net or call (205) 384-6071
ADVERTISING INDEX
Direct & Current
WATER BILLS UP.
The combined water and sewer bill for a typical U.S. household increased 4.6% from 2023 to 2024, according to Bluefield Research, a provider of global water market data and insights. This rise is being fueled by mounting operational costs, inflation, and necessary capital investments. Bluefield’s latest report, U.S. Municipal Utility Water Rates Index 2024: Drinking Water & Sewer, benchmarks a core set of water and wastewater utilities over the past five years (2019–24) and reveals a 24.1% increase in combined drinking water and sewer bills, reflecting the mounting cost pressures impacting U.S. households.
QUITE THE KATCH.
A titan of the industry is evolving as Westinghouse proceeds with its microreactor venture. The Westinghouse eVinci microreactor team recently hosted representatives from the Saskatchewan First Nation Natural Resource Center of Excellence at the eVinci Technology Hub in Pittsburgh. The Canadian eVinci engineering team now has more than 30 professionals, allowing Westinghouse to enhance nuclear component design, testing, decommissioning, and reactor tooling development locally. Additionally, Westinghouse has invested $3 million in expanding Canadian partnerships for design, testing services, and transportation logistics.
ALL ABOARD THE APPRENTICESHIP.
The Illinois Dept. of Commerce and Economic Opportunity recently announced up to $10 million in funding for the Apprenticeship Expansion Competitive Grant Program to support workforce programs that expand Registered Apprenticeship Programs and pre-apprenticeship programs. Grantees will be selected through a competitive notice-of-funding-opportunity process. Eligible applicants include community-based organizations, municipalities, education institutions, industry associations, state agencies, workforce boards, and non-profit organizations.
PFAS LEGISLATION.
The Water Environment Federation has expressed support for the reintroduction of the Water Systems PFAs Liability Protection Act. This bipartisan legislation aims to protect water utilities from undue financial burdens of cleanups associated with per- and polyfluoroalkyl substances — PFAs — under the Comprehensive Environmental Response, Compensation, and Liability Act. The bill ensures that producers of PFAs, rather than the public, bear the cost of remediation. — Charlie Barks Have the digital “Direct & Current” delivered each week, at no charge, to your e-mail in-box. Scan the code at right or sign up now at http://eepurl.com/dEkrB9.
Representatives from the Saskatchewan First Nation Natural Resource Center of Excellence at Westinghouse’s eVinci Technology Hub in Pittsburgh. — Westinghouse photo
Designed for industrial equipment manufactured overseas.
Metric Motors & IEC Worm Gears
Our aluminum frame metric motors operate at IE3 Efficiency at 50 Hz and are NEMA Premium Efficient at 60 Hz operation.
