Xylem TotalCare Energy Audit team members Gavin Westworth and Victor Carlson measure the efficiency of a customer’s pumping system – taking into consideration the interaction between pumps, pipes, controls and treatment equipment. All audit teams now use a tool developed by Westworth (right) to quickly and easily show possible energy and cost savings to the customer.
A New Energy Audit Service for Customer Sites
Beyond selling energy-efficient pumps, Xylem now offers customers energy audits of their entire pumping network – pumps, pipes, controls and treatment equipment – to find and fix inefficiencies in their systems.
There is no reason that wastewater treatment plants have to waste energy on their pumping systems. As part a new TotalCare offering from Xylem’s Water Solutions business, wastewater plants and other customers can bring in members of the Xylem Energy Auditing team to diagnose their entire system and recommend fixes that will reduce energy and other operating costs, plus increase asset life.
These two-day energy audits follow the flow of liquid through a facility – from source to destination – with the Xylem team testing and measuring pressures, flow rates, power usage and other key metrics everywhere along the way. During the audit, the TotalCare technicians inspect the performance of both Xylem and competitors’ products and look at the interaction between all the system’s pieces – pumps, pipes, controls and treatment equipment – to demonstrate how real savings can be achieved.
At the conclusion, the Xylem team provides the customer with recommendations about improving the overall pumping system design, upgrading or optimizing equipment, repairing leaks and blockages and making other process improvements.
A service that pays for itself
The audit team’s final report includes a cost estimate for the improvements and an estimated “pay-back time” that lets the customer know how long it will take for the energy savings and reduction in repairs to pay for the upgrades.
The average energy saving is 15-30 percent at most conventional facilities and about 10-15 percent at very large wastewater plants. In one recent case at a U.K. pumping station, the Xylem audit team estimated a four-year payback, but once the improvements were put in place, the actual energy savings were higher than forecast and the payback period has been reduced to less than three years.
One member of the Xylem energy audit team, Gavin Westworth, developed a tool called the Westworth-Flygt Pumping System Efficiency Index, which compares how much a pumping system currently costs with how much it would cost if the system had been designed, installed and was being operated in the most energy-efficient way.
The index uses achievable values to calculate the costs and puts the results on a scale between 0 and 100. If the result is 36, it means that for every $100 spent running the pump system, the user should only be spending $36 if the system was running optimally.
This easy-to-understand index from Xylem has been accepted by Europump and may become part of the new ISO14414 standard for Energy-Efficient Testing of Pumping Systems.
Energy savings … and more
“On top of reducing energy use, these audits also take care of many reliability problems which lower maintenance and repair costs,” says Abhijit Menon, Market Development Manager, Aftermarket and Service, for Water Solutions.
There’s also a sustainability benefit. Energy savings go hand-in-hand with reduced emissions of carbon dioxide (CO2), a greenhouse gas that contributes to climate change. With the energy audits, Xylem helps customers reduce their carbon footprint and advance their sustainable development.
As an example, if Xylem audits a European wastewater pump station with four fairly old 55-kilowatt pumps – each of them running about 4,000 hours a year – the audit team is likely to find a solution that would save about 150,000 to 200,000 kilowatt hours per year.
“This savings corresponds to a reduction of 88-117 tons of CO2, or CO2 equivalents, each year, which is equal to the emissions from heating nine to 12 houses for one full year in a Nordic climate,” says Cathrin Stock, Sustainability Manager for Xylem’s Water Solutions business.
Click here for more information about the Xylem TotalCare offerings, including the customer energy audits.