The path to Net Zero: Improving Energy Efficiency in the Water Industry with SAM4 Energy

Explore how water companies can reduce energy costs and carbon footprint drinking water systems and wastewater treatment plants by optimizing equipment performance with SAM4 Energy.

About Samotics

Samotics is a leading provider of real-time actionable insights to optimize performance and energy efficiency of AC motors and rotating equipment. An expert team of data scientists, software developers, and technical specialists has developed an AI-driven platform that supports global industrial companies in reducing energy waste and unplanned downtime. Our customer base includes sector-leading players such as Yorkshire Water, Anglian Water, Northumbrian Water, and Pidpa.

The challenge for water companies: reaching Net Zero

Water companies worldwide are under pressure to operate at net zero emissions. For example, the entire UK water industry is committed to reach this target by 2030. At the same time, companies are under pressure to treat larger amounts of wastewater and produce and distribute larger amounts of clean water as population and pollution grow. Up to two-thirds of emissions in the water industry are caused by electricity consumption in pumps, aerators, and other equipment, making this the largest controllable emission source. With up to 40% of the electricity used by electric motor-driven systems being wasted due to operational inefficiencies, process-machine mismatches, and developing damage, these emissions become even more significant. At the same time, OPEX budgets are under pressure with rising electricity prices and limited ways to pass these costs on to end customers. There is a clear need for a solution that drives down electricity consumption.

The solution: SAM4 Energy

In the water sector, equipment typically needs to service a large range of flow demands, so it is no simple task to optimize. As a global leader in analyzing electrical data, Samotics’ SAM4 Energy solution provides the world’s first automated tool to achieve continuous efficiency optimization. SAM4 Energy analyzes the efficiency of the entire drive train, from losses in the electric motor to driven equipment such as pumps. Furthermore, the platform distinguishes the losses inherent in the equipment—like rated motor efficiency—and those caused by the way the equipment is operated, such as pump efficiency losses from operating away from the best efficiency point.

Armed with this information, SAM4’s advanced algorithms go beyond individual asset performance, providing insight into the performance of entire pumping stations with multiple co-located pumps versus industry benchmarks. This generates cost-effective recommendations that can be put into operational practice, often in a very short timeframe and without the need for costly capital investments. It helps our many customers to reduce their energy consumption and achieve yearly recurring electricity savings of 10–15% across their equipment and up to almost 40% on specific assets. This has a very positive impact on sustainability goals and carbon footprint.

Energy Savings Potential in the Drinking Water Sector

Pumps are the lifeblood of the water supply industry, with pump systems on average accounting over 80% of the total energy consumption in drinking water treatment plants. Across water supply networks, around two-thirds of energy use is attributed to final water distribution. SAM4 Energy can achieve energy savings of 10–15% on average, with individual pumps showing savings of up to almost 40% in specific cases. Identifying where the performance and efficiency of critical pumps and other industrial equipment can be improved requires an in-depth understanding of energy use across the water sector and proven solutions to adress associated efficiency issues.

SAM4 Energy is employed by many water utilities to detect where and when energy is wasted within their water supply network, enhancing efficiency while reducing costs and emissions. Recommendations range from adjusting flow thresholds across co-located pumps (to function closer to optimal efficiency points) to suggesting component replacements and even entire pump replacements. SAM4 Energy’s process changes provide water utilities with a cost-effective and quick method to reduce costs and emissions without capital investment.

SAM4 Energy also detects electrical inefficiencies due to developing damage in industrial assets and their components, helping water industry customers optimize maintenance strategies and planning, further reducing costs.

Energy Use in Drinking Water Systems

Pump systems account for 87% of the total energy consumption in drinking water systems. SAM4 Energy can unlock savings ranging from 3% up to 37% for these systems. For a typical system serving 200,000 people, this means a reduction of up to 1.5 GWh—equivalent to over €325,000 per year—while avoiding approximately 660 tonnes of CO₂ emissions yearly*.

*Cost of 1 kWh is €0.21, and 1 MWh of CO₂ emissions equals 0.429 tonnes.

Calculating Energy Savings Potential

The energy savings potential in the drinking water sector differs depending on total energy consumption, specific operations, and control settings. Factors such as diurnal and seasonal water demand patterns, as well as equipment setups (age, presence of variable speed drives, etc.), will also impact the potential for energy savings.

In this infographic significant (medium) and high savings potential have been listed for commonly used types of equipment, based on industry expertise.

SAM4 Energy in Action: Clean Water Pumping a Case Study

Solving Inefficient Pump Operations to Reduce Energy Consumption

Three pumps that form the core of a clean water pumping station were analyzed by the SAM4 Energy platform. These pumps are crucial for supplying water to customers during peak and non-peak periods. The station includes two larger 55 kW pumps and one smaller 11 kW pump.

SAM4 Energy identified that the larger pumps were often used inefficiently, handling flow rates that the smaller pump could manage more efficiently. SAM4 Energy found that operational inefficiencies in the pump and motor led to approximately 10% of total efficiency losses.

By implementing SAM4 Energy’s recommendations, the customer adjusted two simple settings to achieve more efficient pumping during low-flow periods. First, the flow threshold for the 11 kW pump was increased, as it could handle the low flow more efficiently than the two larger pumps. Second, the speed of the 11 kW pump was increased by adjusting the VFD supply frequency, extending its operating range to deliver increased flow at the required pressure. The larger pumps were activated only when necessary. These changes were implemented within hours, without any capital expenditure.

After implementing these process changes, SAM4 Energy showed that all three pumps were operating closer to their optimal efficiency points. The total pump station efficiency improved by 7.1%, taking into account the distribution of running time, pressure, and flow differences between the old and new set ups. This resulted in yearly electricity savings of €2,500 and a reduction of 9.2 tonnes of CO₂. Scaling these savings across an entire water supply network offers significant benefits.

Energy Savings Potential in the Wastewater Sector

In the wastewater sector, SAM4 Energy can achieve significant savings across the whole network. Pumps and blowers consume up to 65% of energy consumption in wastewater treatment plants. SAM4 Energy can unlock 10–15% savings on average for these systems and up to almost 40%* for specific assets. By analyzing performance and energy waste across the variable wastewater network, SAM4 Energy enhances efficiency and reduces costs and emissions. Similar to the water water supply sector, SAM4 Energy gave a variety of advises, from process changes (i.e., changing the operational setup of co-located pumps to function closer to their best efficiency points) to component replacement or even asset replacement (i.e., replace a worn impeller or add a variable speed drive).

SAM4 Energy’s recommended process changes provide water companies a cost-effective and quick way to reduce costs and emissions without the need for capital investment. Furthermore, SAM4 Energy’s insights identify an indication of inefficient operations that may be causing damage to equipment or its components, allowing further savings by addressing maintenance needs proactively.

*Global Water Research Coalition: Energy Efficiency in the Water Industry: A Compendium of Best Practices and Case Studies Global Report.

Energy Use in Wastewater Treatment Plants

Pumps and blowers consume up to 65% of the total energy in wastewater treatment plants. SAM4 Energy can unlock savings from 3% up to 40% for these systems. For a typical system serving 200,000 people, this means a reduction of up to 1.7 GWh of energy saved, translating to over €360,000 annually, avoiding approximately 740 tonnes of CO₂ per year.*

*Cost of 1 kWh is €0.21, and 1 MWh of CO₂ emissions equals 0.429 tonnes.

Calculating Energy Savings Potential

Calculating the energy savings potential for different equipment in the wastewater sector is a combination of the total energy consumption of the equipment and the degree of variation in operating modes for the equipment. Factors such as varying levels of biological oxygen demand, which affect sludge thickness, also impact equipment load variations.

SAM4 Energy in Action: Wastewater Sector Case Study

Optimizing Screw Pump Operations to Reduce Energy Consumption

At a wastewater treatment inlet station, two 185kW screw pumps operate frequently in parallel to meet flow requirements. SAM4 Energy monitors the pumps which are crucial for maintaining a steady wastewater supply.

Moreover, any failure may result in wastewater backup into the collection network, potentially causing sewage overflows. The SAM4 platform determined that the two screw pumps were used inefficiently (operating at low loads). Both operated simultaneously at low loads for approximately 75% of the time. This behavior is beneficial under wet weather flow conditions (common during storms). However, during dry weather periods, a single pump could adequately meet required demand/flow rates. Operating a single pump in these conditions allowed it to function closer to its peak efficiency point, optimizing energy efficiency for both pumps during dry weather. With the recommendations provided by SAM4 Energy, the customer applied a simple setting change, improving pumping efficiency during low and regular flow periods. The adjustment involved changing the flow threshold, determining when one pump should operate independently and when both pumps should run in tandem.

After implementing this simple process change, the SAM4 Energy platform immediately showed a significant improvement in the system’s efficiency. The new mode of operation significantly increased efficiency, leading to a 25% energy reduction across the two pumps. This equated to savings of up to €41K p.a. in electricity costs and an associated reduction of ~75 metric tonnes of CO2eq p.a. based on energy reduction alone. This offers very significant savings when translating these savings across a whole wastewater network which can incorporate hundreds of lift stations. In addition to the immediate generated savings, having industrial equipment operating closer to its best efficiency point prolongs the life of the equipment. This has additional financial and sustainability benefits with respect to capital expenditure, depreciation and industrial and environmental costs of capital production.

How SAM4 Energy Platform Works in the Water Industry

1. Monitor Energy Efficiency of Equipment 24/7
   SAM4 Energy performs continuous monitoring of your pumping systems and other industrial assets by integrating it with your existing data sources or gathering data from IoT sensors within your motor control cabinet. This provides an in-depth picture of each asset’s energy use and efficiency over time to enable effective energy reporting.
2. Identify Energy Waste and Prioritize Opportunities
   Using advanced analytics, SAM4 Energy processes your data continuously. It pinpoints energy waste in your industrial systems, quantifying where energy consumption, costs, and efficiency losses are highest. This helps you understand exactly where improvements are needed to cut costs and reduce your carbon footprint.
   
   SAM4 Energy offers concrete advice you can follow to reduce energy waste, costs and carbon footprint for your water company. It is accomplished with the step-by-step approach outlined on these pages.
   
3. Receive Actionable Recommendations
   SAM4 Energy diagnoses the cause of your energy waste and generates recommendations you can implement. Whether it’s adjusting operational processes like flow thresholds or replacing components, SAM4 Energy ranks these suggestions by their potential savings, so you know where to focus for the most impact. Implementing these changes can lead to a 10–15% reduction in your annual electricity costs and lower carbon emissions.
   
4. Validate Results and See the Savings
   After you implement SAM4 Energy’s recommendations, the platform continues to measure, track, and validate the results, giving you clear visibility into the energy and cost savings achieved. This helps you monitor your system’s performance and ensure that you’re maximizing efficiency across your industrial assets.

Technical Deep-Dive: Real-Time Machine Energy Efficiency Audit

SAM4 Energy audits your machines’ energy efficiency in real-time using electrical signature analysis (ESA). Unlike many energy monitoring services that only take into account your equipment’s rated efficiency, SAM4 Energy’s algorithms determine the efficiency of your machines, and the way you operate them, in three ways:

• Electrical Grid Efficiency: Poor power quality, such as voltage imbalances or harmonic distortions from your utility provider, can reduce electric motor performance.
• Electric Motor Efficiency: An electric motor performs best at its rated load and speed. SAM4 Energy analyzes how various settings affect efficiency, power factor, and output power.
• Driven Load Efficiency: Like motors, driven loads (e.g., pumps, blowers, compressors) perform optimally at their designed work point. SAM4 Energy calculates how much of the input power translates into hydraulic power (e.g., pump flow) automatically.

Monitor Pump Operations in Real-Time Without Flow Sensors

SAM4 Energy monitors electrical signals, but its insights are not limited to electrical motors. Using advanced algorithms, our analytics platform also provides insights into pump flow and head, by taking into account:

• Pump Curve: Every pump manufacturer designs their pumps for a certain flow and head, at a specific input power. SAM4 Energy combines this data with real-time electrical signals to provide reliable pump operation estimates at any point in time. If pump curves aren’t available, SAM4 can integrate existing flow or pressure data as an alternative.
• Pump RPM: SAM4 Energy determines a pump’s speed through an analysis of supply frequency of the electric motor and adjusts the pump’s head and flow accordingly

Key Benefits of SAM4 Energy for the Water Industry

Learn how you can benefit from SAM4 Energy’s advanced analytics platform in achieving your sustainability and carbon reduction goals.

Access Our World-Leading Analytics Platform: Maximize the Value of Your Data

Your energy data is processed on our advanced analytics platform. Using proprietary algorithms backed by years of industry expertise, we transform your data into actionable insights. These insights empower you to reduce energy waste across your water network, giving you control over your industrial energy usage. Samotics combines AI-driven monitoring with expert knowledge in the water sector to support your energy efficiency journey.

Quick and Easy to Implement: No Major Disruptions or Infrastructure Changes

Setting up of the SAM4 Energy system is fast and easy. It integrates with your existing data sources or through our energy sensors installed in your motor control cabinet, all with minimal disruption. The system can be implemented in stages, allowing it to fit smoothly with your operations, without major costs or infrastructure changes. This rapid setup means you can start seeing results quickly.

Easy to Use, All the Time: Monitor Your Pumps’ Efficiency in Real Time

SAM4 Energy provides you with a visually interactive reporting tool to continually monitor the status of your pumps and other equipment. You can perform ongoing energy audits without needing to install additional (flow) sensors in the field. This feature lets you continuously track energy usage and identify areas of waste, helping you prioritize the most impactful opportunities for energy savings. You can also export data for further analysis.

Supporting You Through the Process: Making Your Journey to Efficiency Simple

Samotics supports you in all steps of your energy efficiency journey with SAM4 Energy. We provide you with help to identify the most appropriate pumps, blowers and other industrial equipment to focus on and offer clear guidance during implementation. We provide you with familiarization of the system and the metrics you can generate to optimize your customer experience. We further help in reviewing your results after an initial data build-up and analysis phase.

Input for Pump Replacements: Use Historical Data to Make Informed Decisions

When a pump needs replacement due to failure, SAM4 Energy provides a comprehensive historical overview of flow rates, duty points, and power usage. This helps you select the most efficient replacement pump based on actual performance data.

Adapting with Your Water Company: Scalability and Flexibility with SAM4 Energy

The SAM4 Energy system is designed to scale effortlessly, whether at a single treatment plant or across an entire water network. The system’s flexibility means you can implement it without disruption, and it continues to function seamlessly as you expand or update your assets. SAM4 adapts as your infrastructure evolves, ensuring ongoing energy efficiency without inconvenience.

Enjoy High Return on Investment: Experience Real Value and Quick Payback

Samotics’ water industry customers achieve a high ROI with SAM4 Energy, typically seeing payback within just 3–6 months. The platform provides cost-effective recommendations, allowing customers to prioritize and target the areas with the highest potential for energy savings first. By focusing on inefficient processes, companies can often cut energy waste and costs with minimal or no additional investment, offering the fastest and most affordable path to achieving energy and CO2 reductions. This approach ensures a rapid time-to-value. Compared to other solutions, SAM4 Energy is a highly economical choice that helps water companies exceed their financial and sustainability targets.