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Kenworth Trucks saving water case study
- 1. James Rees Maintenance Supervisor
- 7. KW is ISO 14001:2004 Accredited
- 19. Ample existing concrete slab. Easy connection to down pipes. 1 2 3 4 5 5 new 30 000L Nylex Poly Tanks Capital Funding from Government Location: South east wall of Paccar Parts
- 29. Pic of trench and pipes and water meters
- 34. Saving Water
- 39. KENWORTH Australia Plant Improvement Activities 18 March, 2010
- 40. Cost and Environment Improvement Paint Booth Wash Water Filtration Onsite filtering of the paint booth wash water has saved nearly 80 000L of paint contaminated water to liquid disposal. A mobile filter press and temporary holding tanks enabled 52 000L of water to be treated and filtered on site, creating a dry waste paint cake. This saved around $50 000Aus in waste water disposal costs. Dry Filter Cake Return of Cleaned Water Temporary Storage 52 000L
Editor's Notes
- Good morning My names is James Rees My previous role was under the facilities manager as facilities engineer. Where I developed this water harvesting system
- Just so you know what we do, In Bayswater we design and manufacture heavy duty trucks Here’s a pic of our current model If you have enough money we’ll even custom build a truck for you.
- Here’s a C540, one of the larger mining companies contracted us to make, its my favourite truck, cos it’s the biggest heaviest and ugliest.. In Bayswater we manufacture Kenworths for Australia, New Zealand and PNG
- Here’s a brief summary of what I’ll talk about, Essentially it’ll be the story of our experience from conception to implementation. Project development Data collection Analysis of data Project realisation Funding Implementation Saving water
- In early 2007 my boss (Bill Baldwin) and I were charged with a water saving project. We were not given much scope they just wanted to save water. Me being new to a role in facilities was all excited about doing something good for the community. Bill and I discussed what were going to do. We had a number of brain storming sessions. Some ideas included a very large tank, stormwater harvesting, water less urinals Pretty soon we realised we did not have any tangible data on which to base our decisions.
- Water MAP government requirement we obligated to develop water reduction projects.
- Resource conservation
- Our previous facilities manager was quite proactive there were a number of water meters around the facility and there were some records. Initially we implemented a monthly maintenance PM to read the meters and I developed a database in which to track water usage. We quickly discovered we have a large portion unaccounted for. Naturally we implemented more end use water meters to reduce that unknown factor, we currently have 30 meters
- You can now see the un-metered portion is down to 13% At this point we were able to determine avenues for an alternate supply Paint shop Wash water Humidifiers - we have not noticed any issues yet Demineraliser – cab wash process to prepare for painting, water tested advice from veolia water said not only was it fine it would probably would make the de-mineralising resin last longer due the reduced amount of minerals in rain water. Wash down hoses 2. Toilet flushers and cistern header tanks where the plumbing was convenient. Through this study we were able to develop a daily demand. Around 15kL / Day
- With the talk of 2 meg tank and stormwater harvesting and using a sump pump that could pump 2000L/min; Bill and I were increasingly concerned about cost and hence the likely hood if this would ever get off the ground. We need a way of estimating potential water saved versus cost. Water being very cheap it’s very hard to develop an attractive business case. We thought the ideal scenario was where the water tanks would empty quickly and fill quickly, hence getting the best use from your asset, but what's the ideal capacity? I contacted the BOM and had emailed daily rainfall data from the closest station Scoresby. With this information I began developing a spreadsheet and hence a model where I could vary size of the tanks, roof area, demand. Incidentally I discovered that the data prior to 1996 was unusable, because gee, it used to rain a lot more back then. So I based my model on the last 10 yrs. The spreadsheet could estimate Water saved Payback period Water lost due to the tanks being full (Overflow) Mains make up required when the tanks were empty A graph of level in tank.
- The graph of the level in the tank proved most valuable. Knowing 15000L per day could be used as an alternate supply this figure formed our target. With the usage fixed we were able to vary volume of storage in the spreadsheet If the storage was too large the tanks would never empty If the storage was too small the tanks would empty long before the next rain event. What I was looking for was this saw tooth patterns indicating a large number of fills and hence the best value for money. We settled on a capacity of 360 000L
- Existing infrastructure We had 7 existing tanks, 5 tanks were only for irrigation purposes 2 of them were used for the separation tank An un-used irrigation pipe on the perimeter fence was looking useful. Slab Pump station
- At his point in time realised that this project may actually get off the ground, Because, adding some more irrigation pipe would be reasonable cheap, adding a larger pump at the existing pumping station would be cheap we just need to find the funds for the extra tanks.
- Given there were a number of distinct parts to the larger project it was decided to deal with a number of smaller purchases. But we still had to purchase some tanks. I raised and AFE only to be told I need to raise a Capital Budget Expenditure After waiting a few months management decided corporate wouldn't provide money for a water saving measure. However they did say I could expense one tank per month, about 5mins a PR was ready for signing. My initiation into creative accounting….
- As leverage to management approving these tanks I applied to the AI group for a government grant. I was successful, we received a $10 000 grant.
- Initial Works Phase 1 comprised of 5 off 30 000L Nylex poly tanks. Connect to down pipes Pipeline and transfer pump From here on I’ve got a bunch of slides showing the works performed.
- Note easy connection to down pipes And existing slab
- This completed the ability to have on hand 360 000L, that even in a small rain event would fill fairly quickly.
- Pumping station with larger pump.
- Follow up works over next 12 months Phase 2 Humidifiers Factory toilet block flushers Demineraliser Booth wash hoses Again these projects had 1 off purchase requisitions raised against them.
- 2009 we off set mains water by nearly 3 million litres Mains make up was only 5% Note: the reduced overall consumption is related to a reduced build rate, due to the GFC
- Here we can see seasonal variations as well as other factors like Christmas shut The important thing to note is as I have implemented more and more tank water to equipment, the green line has diverged from red. This shows more and more tank water is off setting mains water.
- This year we’re looking to improve mains water off set again, currently were tracking 1.2 Mega Litres which is about double for this time last year. And we’re saving over half the used water from rain water harvesting.
- Developing the project Data collection BOM data developed a spreadsheet End use data (where we used water and how much) Analysis of data Alternate supply to processes and appliances What's the smallest size capacity to meet our needs Project realisation We already had the beginnings
- Funding Smaller amounts fly under the radar Implementation Pipeline and tanks Saving water Nearly 3ML in 09 Currently tracking double this year
- Closing slide.