Controlling costs is critical to long-term success for clients managing operations and maintenance (O&M) projects. Labor, chemicals, utilities, and equipment replacements or repairs typically account for the majority of expenses, often representing up to 80% of a project’s operating budget. Implementing strategic cost-saving measures in these areas can maintain efficiency and reliability while minimizing expenses.
At U.S. Water, we understand the challenges of balancing operational demands with cost control. Drawing on our expertise, we’ve developed approaches to optimize these key cost drivers without compromising quality.
Optimizing Labor Costs Through Efficiency
Labor is often the largest expense in O&M projects, encompassing operators, maintenance personnel, administrative staff, and specialists. One of the most effective ways to manage this cost is by optimizing staffing schedules and responsibilities.
Reducing labor costs starts with evaluating work schedules and task distribution. Depending on operational needs, staff hours can often be adjusted. Common labor structures and their associated total labor hours include:
- 24-hour coverage (7 days per week) – 168 hours
- 12-hour shifts (7 days per week) – 84 hours
- 12-hour shifts (5 days per week) – 60 hours
- 8-hour shifts (7 days per week) – 56 hours
- 8-hour shifts (5 days per week) – 40 hours
By reviewing tasks and staffing requirements annually, U.S. Water helps clients identify opportunities to reduce labor hours. Implementing automation, remote monitoring, and process modifications can significantly decrease the need for on-site personnel.
For example, we partnered with a client to reconfigure a metals removal pretreatment system, enabling the facility to reduce staffing from 24/7 coverage to 12-hour shifts, 7 days a week—cutting labor costs by 50%.
Facilities equipped with SCADA systems allow operators to monitor performance remotely, reducing the need for continuous on-site supervision. Maintenance staff and specialists can also be scheduled as needed, focusing on high-value tasks such as training, preventive maintenance, and process optimization.
Managing Chemical Costs Through Precision
Chemicals are another significant expense in O&M projects, particularly specialty chemicals like polymers, defoamers, and antiscalants. While generic chemicals (e.g., sulfuric acid, phosphoric acid, hydrochloric acid, sodium hydroxide, etc.) often have stable costs, specialty chemicals are more expensive and can be overused without careful monitoring.
Optimizing chemical use starts with understanding their purpose. The table below presents specialty chemicals and methods for optimization.
| Specialty Chemicals | Purpose | Optimization Method | Analysis Frequency |
|---|---|---|---|
| Polymer | Enhances floc formation for dewatering or settling. | Conduct jar testing to select the optimal product and determine the proper dosage. | Annually |
| Defoamer | Minimizes or prevents foam formation. | Perform benchtop foam testing with current and alternative products. Systematically reduce dosage while conducting visual inspections. | Quarterly |
| Reverse Osmosis (RO) Antiscalant | Prevents scale formation that can lead to system shutdowns for Clean-in-Place (CIP) procedures. | Conduct metals analysis to determine the appropriate dosage, ensuring scale-forming metals remain below saturation levels to prevent fouling of RO units. | Quarterly |
| RO Biocide | Inhibits bacterial growth on RO membrane surfaces, preventing premature CIP shutdowns. | Perform ATP analysis of reject to assess bacterial viability. Gradually reduce dosage until some bacteria remain alive but are insufficient to enable growth. If 5 mg/L is effective, higher dosages (e.g., 8 mg/L) do not provide additional benefit. | Quarterly |
| RO Cleaner | Supports CIP procedures to remove metal scale and bacterial fouling. | Monitor CIP cycles and track starting pressures using a normalization program. Compare CIP results over time to adjust chemical formulations and dosages. | Quarterly |
Through comprehensive testing and analysis, U.S. Water ensures the precise selection and dosing of treatment chemicals. For example, by optimizing the dosage of an RO antiscalant for one client, we reduced chemical consumption by 15% while maintaining system performance. In another case, a defoamer study led to a strategic change in the application point, enhancing efficiency and cutting defoamer costs by $60,000 annually. Regular testing and data-driven adjustments help identify cost-saving opportunities without compromising performance.
Our approach also includes training operators to monitor chemical usage closely, avoiding unnecessary overdosing. Tracking chemical consumption and comparing it to process outcomes helps ensure cost efficiency over time.
Utility Reduction
Reducing electricity and water consumption can lead to significant cost savings—often in thousands or even tens of thousands of dollars annually. U.S. Water has successfully implemented the following strategies to optimize utility usage:
- Optimized Aeration Control – Installing dissolved oxygen (DO) sensors to regulate aeration blower speeds, reducing energy consumption while also minimizing foam formation and the need for defoamer chemicals.
- Equipment Shutdown Protocols – Powering down laboratory equipment such as ovens and furnaces when not in use to eliminate unnecessary energy waste.
- Water Reuse Strategies – Utilizing effluent or ultrafiltration (UF) permeate for make-up water, wash water, or general plant use instead of relying on municipal water supplies.
Preventing High-Cost Equipment Failures
Unexpected equipment failures can be among the most significant costs in O&M projects. Replacing or repairing critical components, such as a 100 HP aeration blower, can exceed $100,000, with additional expenses for rental equipment and process adjustments during downtime.
To mitigate these risks, U.S. Water prioritizes preventative maintenance and predictive monitoring. By tracking key parameters—such as motor temperatures, vibrations, and bearing conditions—we can detect early warning signs and address potential failures before they become costly disruptions.
U.S. Water leverages the Artesis monitoring system, which analyzes motor voltage and current fluctuations to predict necessary maintenance or part replacements, such as motor alignments or bearing changes, before a critical failure occurs. The system requires no external sensors, as it is installed directly on motor power leads, allowing for remote access and data analysis.
Additionally, thermal imaging is used to identify hot spots in transformers, VFDs, and MCCs, helping to correct issues that could lead to equipment failures proactively.
Beyond monitoring, we assist clients in evaluating redundancy and spare parts availability for high-cost equipment. Maintaining a well-stocked inventory of spare parts or backup units for critical systems minimizes downtime and ensures operational continuity.
Partnering for Cost Efficiency
At U.S. Water, we collaborate with clients to develop tailored strategies that address their unique operational needs. Whether it’s optimizing staffing, reducing chemical usage, or implementing preventative maintenance plans, our goal is to help you operate efficiently while controlling costs.
By leveraging our expertise, advanced technologies, and commitment to client success, we can identify opportunities to improve your operations and reduce expenses. Contact U.S. Water today to explore how we can support your cost-saving initiatives.
