Introducing MachineEdge

AI-driven optimization, edge intelligence and automation to advance pump system reliability, reduce energy consumption by 50% and drive down CO2 emissions.

MachineEdge patents pending

The most common and most costly pump system problems that have affected the process industry for nearly 100 years stem from operating fixed-speed motors and pumps with throttling control valves. The detrimental effects of this unstable configuration – severe reliability problems and enormous energy waste – are well known, but an affordable solution has been elusive, until now.

MachineEdge Solution

MachineEdge uses a unique holistic approach to solve an old and familiar problem. MachineEdge optimizes the combined performance of three critical machines that are the life-blood of process control loops: the electric motor, the pump, and the control valve. These control loop ’machine sets’ power and control the network of 500, 1,000, even 3,000 control loops that drive process plant production. Although these three-machine sets are highly interdependent, each machine is traditionally operated as if it were totally independent and therefore operated in counterproductive ways. MachineEdge’s intelligent optimization synchronizes how the machine set interacts to minimize the combined machine set energy consumption while maximizing electric motor, pump and control valve reliability. MachineEdge works independent of the process control system, uses existing infrastructure, and installs next to the pump with a simple plug & play retrofit. As a result, brownfield installations are inexpensive, enabling a MachineEdge ROI payback in only one year or less.

Unlocks Energy Savings

MachineEdge can routinely save 50% of energy costs because of pump oversizing and the speed vs power relationship.

About 75% of fixed-speed process pumps are oversized, resulting in enormous energy waste as they require excessive control valve throttling. MachineEdge addresses this problem by periodically lowering the baseline speed to allow the control valve to automatically open, assuming a less restrictive, more energy efficient position.

MachineEdge leverages the centrifugal pump speed vs power relationship (power is proportional to the cube of the speed), meaning that a relatively small 20% reduction in speed results in a power / energy cost savings of about 50%.

Advance Reliability – Less Wear and Tear

MachineEdge can detect if a pump is oversized (about 75% are) and is operating far to the left of the its Best Efficiency Point (BEP) on its performance curve. Operating in this off-design state not only reduces energy efficiency but also causes significant wear and tear due to excessive vibration, significant internal recirculation, low-flow cavitation, and high radial shaft loads.

When MachineEdge recognizes this problematic operating state, it automatically repositions the pump operating point as close to BEP as possible, within the Preferred Operating Range.

  1. Anchor MachineEdge
  2. Reroute the power cable
  3. Give it air (for Class 1, Div 2 only)

Easy Plug and Play Retrofit

Allows for seamless integration with the existing electrical system and operates independently of process control.

Retrofitting MachineEdge to an existing pump system is easy and low cost. Installation directly next to the pump eliminates long expensive cable runs required by a centralized location. Additionally, it is seamlessly integrated with the existing electrical system by simply rerouting the motor power cable through MachineEdge.

MachineEdge comes preprogrammed and is intelligent enough to operate independently of process control system, without any changes or connections.

Because retrofitting MachineEdge is easy, it is designed not only for critical pumps but also for mainstream pump applications within a facility to significantly improve reliability and achieve enormous energy savings.

MachineEdge patents pending

Optional Data Sets for Predictive Analytics

Predictive analytics are highly dependent on the quality of the data set generated by the sensors. However, retrofitting legacy pumps with high-end sensors has been too complicated and too expensive for mainstream pump applications. Wireless sensors have provided a simpler and lower cost solution, but the selection of technologies is limited and the preferred high-frequency sampling rate drains battery life. 

Robust and Comprehensive Datasets Affordable for Mainstream Pumps

MachineEdge’s digital infrastructure, located directly next to the pump, enables integration of a sensor platform that is capable of generating unprecedented datasets at a price affordable for mainstream pump applications.

MachineEdge combines a microcomputer edge device, a DC power source, short sensor cables and contextual data into a holistic sensor platform that is capable of monitoring the complete pump system (including the motor, pump and mechanical seal), across a broad set of electrical and mechanical parameters.

MachineEdge patents pending

“Many companies talk about breaking the frame but PeopleFlo has done it with innovative product designs that optimize both first cost and life cycle costs.”

Mr. Richard Labrecque, Retired CEO, ITT Industries, Fluid Technology