Kenworth Trucks saving water case study

James ReesJames ReesMaintenance SupervisorMaintenance Supervisor

KENWORTH WATER KENWORTH WATER

KENWORTH WATER KENWORTH WATER

• Project DevelopmentProject Development

• Data CollectionData Collection

• Analysis of DataAnalysis of Data

• Project RealisationProject Realisation

• FundingFunding

• ImplementationImplementation

• Saving WaterSaving Water

KENWORTH WATER KENWORTH WATER

• Project DevelopmentProject Development

KENWORTH WATER KENWORTH WATER

Source: www.southcross.com.au/__data/page/9517/Liner_Tank_Leaflet.pdf (23/5/10)

Water Reduction RequirementsWater Reduction Requirements

• A government requirement (waterMAP) A government requirement (waterMAP) requires us to submit an annual report of requires us to submit an annual report of our water use and develop water reduction our water use and develop water reduction projects, targets and efficient practices.projects, targets and efficient practices.

KW is ISO 14001:2004 AccreditedKW is ISO 14001:2004 Accredited

• Data CollectionData Collection

• Where is our water is going?Where is our water is going?

KENWORTH WATER KENWORTH WATER

Water Usage February 2007

• Reduced Un-metered Use to 13%Reduced Un-metered Use to 13%

KENWORTH WATER KENWORTH WATER

Water Usage April 2010

Water Savings ModelWater Savings Model

• Estimate CapacityEstimate Capacity

• Estimated Water Savings Estimated Water Savings

Estimated Water SavingsEstimated Water Savings

• 360 000 L Capacity360 000 L Capacity

• Estimated to save 4 000 000 L annually Estimated to save 4 000 000 L annually

Realisation of a ProjectRealisation of a Project• Some existing infrastructureSome existing infrastructure

– 7 existing tanks7 existing tanks

– Irrigation pipe on perimeter fenceIrrigation pipe on perimeter fence

– A pumping stationA pumping station

– Separation tank was already connected to tank Separation tank was already connected to tank water but often ran drywater but often ran dry

Realisation of a ProjectRealisation of a Project

• Enhance ExistingEnhance Existing– 5 more tanks (enough concrete already existed)5 more tanks (enough concrete already existed)

– UtiliseUtilise irrigation pipe and continue to main plant irrigation pipe and continue to main plant

– UtiliseUtilise existing pump station and add a pump existing pump station and add a pump

FundingFunding

• Project to be chipped away at.Project to be chipped away at.

• 5 Nylex 30000L Tanks $262915 Nylex 30000L Tanks $26291

• AFEAFE

• Capital Budget ExpenditureCapital Budget Expenditure

• Removed from Cap ExRemoved from Cap Ex– Expense one tank per month for 5 monthsExpense one tank per month for 5 months

FundingFunding

• Received a $10000 grant from the Received a $10000 grant from the government sought through the Australian government sought through the Australian Industry Group.Industry Group.

• Initial WorksInitial Works

• Phase 1Phase 1– 5 off 30 000L Nylex poly tanks.5 off 30 000L Nylex poly tanks.

– Connect to down pipesConnect to down pipes

– Pipeline and transfer pumpPipeline and transfer pump

ImplementationImplementation

Previous Infrastructure

Completed Infrastructure

Ample existing concrete slab.

Easy connection to down pipes.

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45

5 new 30 000L Nylex Poly Tanks5 new 30 000L Nylex Poly Tanks Capital Funding from GovernmentCapital Funding from Government

Location: South east wall of Paccar Parts

Pic of trench and pipes and water meters

• Follow up works over next 12 monthsFollow up works over next 12 months

• Phase 2Phase 2– HumidifiersHumidifiers

– Factory toilet block flushersFactory toilet block flushers

– DemineraliserDemineraliser

– Booth wash hosesBooth wash hoses

ImplementationImplementation

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10,000

15,000

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25,000

2001 2002 2003 2004 2005 2006 2007 2008 2009 YearEnd

Kilo

Lit

res

of

Wat

er

Used Mains Water Used Rain Water

• The year 2009 saved 2 956 100L (8 fills)The year 2009 saved 2 956 100L (8 fills)

• Tanks only ran dry less than 5%Tanks only ran dry less than 5%

Saving WaterSaving Water

Water Consumption Daily Rate Bayswater Facility

0

5

10

15

20

25

30

35

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55

60

Jan-07 Apr-07 Jul-07 Oct-07 Jan-08 Apr-08 Jul-08 Oct-08 Jan-09 Apr-09 Jul-09 Oct-09 Jan-10 Apr-10

Kilo

litre

s

Total Mains Water Used

Total Water Used (Includes Captured Rain Water)

Saving WaterSaving Water

Current Use• YTD 1 234 200LYTD 1 234 200L

Saving WaterSaving Water

KW WaterKW Water

Summary

• Developing the project• Data collection

– BOM data– End use data

• 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

Summary

• Funding– Smaller amounts fly under the radar

• Implementation– Pipeline and tanks

• Saving water– Nearly 3ML in 09– Currently tracking double this year

KW WaterKW Water

KENWORTH AustraliaKENWORTH AustraliaPlant Improvement Activities18 March, 2010

Cost and Environment Improvement Cost and Environment Improvement Paint Paint Booth Wash Water FiltrationBooth 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

Captured Water Improvements

Completed Infrastructure

• 1 off old Dyno tank 25 000 Litres•Now connected to Eastern Toilet Block Header tank•Has already saved 65 000L water.