Abstract:
Embodiments of the present invention include a computer-implemented method and system for estimating water consumption within a facility (e.g. residential, industrial, educational, medical, environmental, business, government facilities, etc.). More specifically, embodiments of the present invention estimate facility operation-specific water consumptions based on user-defined data. Another aspect of the present invention automatically generates a graphical water table for the facility. As an alternative to real-world or “current” data, users may specify hypothetical facility and operational data and characteristics as part of a “what-if” scenario to identify opportunities for improvement or optimization of facility water consumption. Notably, user-defined data and characteristics may be modified, updated or supplemented at any time. “What-if” and ROI analyses are also supported.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to estimating water consumption, and more specifically to a computer-implemented method and system for estimating facility water consumption.  
         [0003]     2. Background Art  
         [0004]     Conventional methodologies for estimating facility water consumption, and creating a complete facility water balance are difficult, costly and do not effectively assist facility water planners in identifying the best opportunities for reducing water consumption, thereby reducing the total cost of water to support the facility.  
         [0005]     More specifically, conventional methodologies for estimating facility water consumption include hiring expert consultants to evaluate a facility&#39;s water consumption habits at a particular point in time, in an effort to generate a water balance for the facility based on the evaluation. Although this brute-force methodology is certainly capable of producing an accurate water balance based on existing data, the water balance is fixed in time and does not allow planners to efficiently update/modify the underlying data to obtain an updated water table. To do so, facility water planners typically have to re-hire the expert consultant, or worse, start from scratch. In addition, these fixed-in-time water consumption analyses do not enable facility water planners to effectively conduct “what-if” scenarios with respect to facility architecture and operations to quickly (and cheaply) identify the best opportunities for reducing or otherwise optimizing facility water consumption.  
         [0006]     What is needed is a method and system that will overcome these and other drawbacks associated with prior art water planning and analysis methods.  
       SUMMARY OF THE INVENTION  
       [0007]     Embodiments of the present invention include a computer-implemented method and system for estimating water consumption within a facility (e.g. residential, industrial, educational, medical, environmental, business, government facilities, etc.). More specifically, embodiments of the present invention estimate facility operation-specific water consumptions based on user-defined data. Another aspect of the present invention automatically generates a graphical water table for the facility. As an alternative to real-world or “current” data, users may specify hypothetical facility and operational data and characteristics as part of a “what-if” scenario to identify opportunities for improvement or optimization of facility water consumption. Notably, user-defined data and characteristics may be modified, updated or supplemented at any time, resulting in an instantaneous update in corresponding operation or facility water consumptions.  
         [0008]     Another aspect of the present invention identifies the relative impact that different water consumption adjustments will have on the overall water balance can be considered. In this manner, a wide variety of return-on-investment (ROI) analyses may be implemented.  
         [0009]     Yet another aspect of the present invention enables a user to identify unusual water consumption rates within a facility. More specifically, this feature of the present invention enables a user to compare estimated or “typical” water consumption rates with actual consumption rates (where such data is available).  
         [0010]     According to a system and method embodiment of the present invention, a computer system for estimating water consumption for a facility is provided. The system comprises one or more computers operably programmed and configured to: (i) receive input defining a plurality of values or characteristics for one or more water-consuming operations within the facility, (ii) estimate and output an annual water consumption for each of the water-consuming operations based on the plurality of values or characteristics, and (iii) automatically create and display a water table for the facility based on the annual water consumption for each of the water-consuming operations. The system may additionally be configured to display a calculator for estimating and outputting the annual water consumption for one or more of the water-consuming operations.  
         [0011]     Water consuming operations may include but are not limited to domestic activities, lawn irrigation activities, fire protection systems, assembly operations, phosphate coating, e-coating, cooling tower systems and boiler systems. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a block flow diagram illustrating an example methodology for implementing one embodiment of the present invention;  
         [0013]      FIG. 2  illustrates an example graphical user interface (GUI) for selecting a facility type in accordance with one aspect of the present invention;  
         [0014]      FIG. 3  illustrates an example GUI for receiving a variety of known or estimated values or characteristics relating to a facility&#39;s water consumption;  
         [0015]      FIG. 4  illustrates an example GUI including a domestic water use calculator in accordance with one aspect of the present invention;  
         [0016]      FIG. 5  illustrates an example GUI including a lawn watering use calculator in accordance with one aspect of the present invention;  
         [0017]      FIG. 6  illustrates an example GUI including a fire water system use calculator in accordance with one aspect of the present invention;  
         [0018]      FIG. 7  illustrates an example GUI including a water consumption calculator for leak test and car wash operations in accordance with one aspect of the present invention;  
         [0019]      FIG. 8  illustrates an example GUI including a water consumption calculator for phosphate and electrocoat operations in accordance with one aspect of the present invention;  
         [0020]      FIG. 9  is an example GUI including a cooling tower use calculator in accordance with one aspect of the present invention;  
         [0021]      FIG. 10  is an example GUI including a boiler system/powerhouse water consumption calculator in accordance with one aspect of the present invention; and  
         [0022]      FIG. 11  illustrates a graphical facility water balance and water cost calculator in accordance with one aspect of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [heading-0023]     Methodology  
         [0024]      FIG. 1  is a block flow diagram illustrating an example methodology  10  for implementing or otherwise using the present invention. Notably, the content or arrangement of the block flow diagram illustrated in  FIG. 1  may be modified or adapted to best-fit a particular implementation of the present invention.  
         [0025]     In accordance with the example implementation  10 , one or more computers are operably programmed and configured to receive input selecting a type of facility (e.g., assembly plant, engine/transmission plant, stamping plant, casting plant, office building, etc.), as represented in block  12 . See below for an example GUI illustrating this aspect of the present invention. In an alternate embodiment, the present invention may be customized or otherwise specialized for estimating water consumption for a single facility type. Those of ordinary skill in the art will recognize, however, that the functionality and usefulness of the present invention transcends all types of facilities that consume or otherwise utilize water—including but not limited to residential, industrial, educational, medical, environmental, business and governmental facilities.  
         [0026]     As represented in block  14 , the computer receives input defining certain general water consumption values/estimations and/or attributes for the facility. See below for an example GUI illustrating this aspect of the present invention. Notably, input may be provided in a variety of manners and formats including but not limited to user-input, data import and/or electronic data transfer with legacy systems or other external applications. Based on the input reflected in block  14 , the computer calculates an initial water consumption estimation for the facility and/or one or more facility operations (e.g. domestic water use, etc.), as represented in block  16 .  
         [0027]     As represented in block  18 , water consumption estimations/values and related attributes (e.g., units, etc.) are input for one or more facility operations. Facility operations include any water consumption activity within or otherwise associated with the facility. For example, an automotive manufacturing or assembly facility might include operations such as domestic lawn care, fire system, plant operations, cooling towers, boiler system, etc. See below for example GUIs illustrating this aspect of the present invention.  
         [0028]     Upon inputting water consumption estimations/values and related attributes for each facility operation, the computer preferably calculates a total estimated water consumption for that facility, as represented in block  20 . As represented by decision point  22  and arrow  24 , steps  18  and  20  may be repeated for each facility operation that consumes water.  
         [0029]     When water consumption estimations/values and related attributes for each facility operation have been input (blocks  18 ,  20  and  22 ), the computer creates a water table for the facility as represented in block  26 . See below for an example GUI illustrating this aspect of the present invention.  
         [0030]     As represented by dashed line  28 , water consumption estimations/values and related attributes may be modified or updated at any time. This feature of the present invention enables the accuracy of estimations and the water table to increase as more accurate data is collected and input or otherwise revised. In addition, this feature of the present invention supports “what if” analyses to see what impact certain modifications in facility or operation water consumption estimations/values and related attributes have on overall facility water consumption and/or the water table (see  FIG. 11 ).  
         [heading-0031]     System Implementation  
         [0032]     A system embodiment of the present invention may be implemented in software with application utilities including but not limited to Microsoft Visual Basic, and executed on stand-alone computers (e.g., personal computers, notebooks, handheld devices, etc.) or in a networked computing environment (e.g., local area network, intranet, Internet, etc.).  
         [0033]     In the following detailed description of a system implementation of the present invention, a variety of example graphical user interfaces (GUIs) are provided to enable those of ordinary skill in the art to make and use features of the present invention. Notably, those of ordinary skill in the art recognize that functionality associated with the example GUIs disclosed or otherwise discussed herein may be provided or otherwise supported in adapted or modified embodiments within the scope of the present invention. For illustrative purposes only, certain aspects and/or embodiments of the present invention are described in association with the automotive industry. Those of ordinary skill in the art will recognize, however, that the functionality and usefulness of the present invention transcends all types of facilities that consume or otherwise utilize water—including but not limited to residential, industrial, educational, medical, environmental, business and governmental facilities.  
         [0034]      FIG. 2  is an example GUI  30  for initiating a facility water analysis in accordance with one embodiment of the present invention. In addition to providing a general overview and instruction  32  for using a software implementation of the present invention, GUI  30  includes a drop-down menu  34  enabling a user to specify a particular facility type to analyze (e.g., assembly plant, engine/transmission plant, stamping plant, casting plant, office building, etc.). Of course, the types of facilities that may be analyzed with the present invention are not limited to those shown in drop-down menu  14 . Other types of facilities may include (but are not limited to) residential, industrial, educational, medical, environmental, business and governmental facilities.  
         [0035]     According to one embodiment of the present invention, the nature of selection  34  will dictate the combination of user interfaces presented for defining known or estimated water consumption and related attributes (e.g. units, etc.) for different operations within or otherwise associated with the facility. Table 1 identifies an example combination of interfaces provided to a user depending on facility type selection  34 . For example, a user selecting “Office Building” from drop-down menu  34  would be presented with one or more interfaces for domestic, lawn care, fire system, and boiler system water consumption sources. A user selecting “Engine Plant” from drop-down menu  34 , however, would be presented with one or more interfaces for domestic, lawn care, fire system, plant operations, cooling towers and boiler system water consumption sources.  
                                                 TABLE 1                           Enterprise   Sources of Water Consumption       Type   (User Interfaces)            (User       Lawn   Fire   Plant   Cooling   Boiler       Selection)   Domestic   Care   System   Operations   Towers   System               Assembly   X   X   X   X   —   X       Plant       Engine   X   X   X   X   X   X       Plant       Stamping   X   X   X   X   —   X       Plant       Casting   X   X   X   X   X   X       Plant       Office   X   X   X   —   —   X       Building                  
 
         [0036]      FIG. 3  is an example GUI  36  for receiving a variety of known or estimated values or characteristics  38  relating to a facility&#39;s water consumption. Unit selection drop-down menus  40 ,  42  and  44  enable unit flexibility in data entry. As will be discussed in greater detail below, input  38  may be included in computations for calculating or estimating water consumption rates for facility operations and/or creating a water balance for the enterprise.  
         [0037]     Selection of buttons  46  initiate a plurality of water consumption calculators for operations within or otherwise associated with the facility. Of course, selections  46  are not limited to those shown and may include calculators for determining or estimating water consumption for any operation within or otherwise associated with the facility. This feature of the present invention is described in greater detail below.  
         [0038]      FIG. 4  is an example GUI including a domestic water use calculator  50  in accordance with one aspect of the present invention. This feature of the present invention may be utilized to receive data  52  associated with facility domestic water consumption (e.g., employee use, cafeteria use, janitorial use, etc.) and estimate a total annual domestic water consumption value  52  for the facility. Preferably, one or more initial consumption estimates are automatically provided in calculator  50  based on the data  38  referred to with respect to  FIG. 3 . Notably, a user may modify or update any initial consumption estimates, yielding an updated total annual domestic water consumption value  52 .  
         [0039]     Table 2 includes example calculations executed by the domestic water use calculator  50 . Of course, the calculations provided in Table 2 may be modified or supplemented to best-fit a particular implementation of the present invention.  
                   TABLE 2                       Value   Calculation                   Cafeteria   = number meals * 1.6 (gallons/meal) * conversion to       Water Use   preferred units * production days per year       Sanitary   = X (gal/day) * number employees * conversion to       Water Use   preferred units * prod days per year           (X = 15 for assembly, 20 for engine/trans, 30 for           casting and stamping)       Janitorial   = plant area * conversion to sq ft * (17/3500)       Water Use   (gal/sq ft/day) * prod days per year                  
 
         [0040]      FIG. 5  is an example GUI including a lawn watering use calculator  54  in accordance with one aspect of the present invention. This feature of the present invention may be utilized to receive data  56  associated with lawn watering (e.g. irrigation months per year, irrigations per week, watering event length, etc.), and estimate a total annual lawn watering consumption value  58  for the facility. Notably, a user may modify or update any initial consumption estimates, yielding an updated total annual lawn watering consumption value  58 .  
         [0041]     Table 3 includes example calculations executed by the lawn watering use calculator  54 . Of course, the calculations provided in Table 3 may be modified or supplemented to best-fit a particular implementation of the present invention.  
                           TABLE 3                                   Value   Calculation                           Total   = area watered * conv. to sq ft * 0.0042           Irrigation   (gal/sq ft/min) * min/event * events/week * 1/7           Use   (weeks/days) * 30.4 (ave days/month) * months/               year                      
 
         [0042]      FIG. 6  is an example GUI including a fire water system use calculator  60  in accordance with one aspect of the present invention. This feature of the present invention may be utilized to receive data  62  associated with the facility fire water system, and estimate a total annual fire water system consumption value  64  for the facility. Notably, a user may modify or update any initial consumption estimates, yielding an updated total annual fire water system consumption value  64 .  
         [0043]     Table 4 includes example calculations executed by the fire water system use calculator  60 . Of course, the calculations and values provided in Table 4 may be modified or supplemented to best-fit a particular implementation of the present invention.  
                   TABLE 4                       Value   Calculation                   Daily Jockey   = minutes running/day * pump rate       Pump       Annual   = jockey pump daily * 365       Jockey Pump       Riser   If number of risers are known:       Tests/Two   = number of risers * 175 GPM * 7.5 minutes/       Inch Drain   (conversion to preferred units) * 4 tests/year       Tests   If number of risers are unknown:           = plant area * conversion to sqft/40,000 * 175 GPM * 7.5           minutes/(conversion to preferred           units) * 4 tests/year       Flow Switch   If number of flow switches are known:       Tests/One   = number of flow switches * 120 * 1.5/       Inch Drain   (conversion to preferred units) * 8 tests/year       Tests   If number of flow switches are unknown:           = plant area * conversion to sqft/40,000 * 2           (flow switches/area) * 120 GPM * 1.5/           (conversion to preferred units) * 8 tests/year       Hydrant   = number of hydrants * 2600 gallons/test/       Tests   (conversion to preferred units)                  
 
         [0044]      FIGS. 7 and 8  are example GUIs for calculating assembly operation water consumption in the automotive industry. Notably, the industry-specific illustrated and described with respect to  FIGS. 7 and 8  are for illustrative purposes only. Water consumption for an unlimited number of industrial operations may be calculated or estimated within the scope of the present invention.  
         [0045]      FIG. 7  includes an example water consumption calculator  66  for leak test and car wash operations. Calculator  66  may be utilized to receive information  68  associated with the leak test and car wash operations, and estimate a total annual leak test and car wash consumption value  70  for the facility. Notably, a user may modify or update any consumption estimates, yielding an updated total annual domestic water consumption value  70 .  
         [0046]     Table 5 includes example calculations executed by the leak test and car wash operations water use calculator  60 . Of course, the calculations and values provided in Table 5 may be modified or supplemented to best-fit a particular implementation of the present invention.  
                       TABLE 5                           Value   Calculation                   Once Through   Soak   = production vehicles per year * 1/40       Operations   Test/   (vehicles tested/vehicles produced) * 1998           Static   gal/vehicle * (conversion to           Leak Test   preferred units)           Hurricane   = production vehicles per year * 617.96           Tunnel/   gal/vehicle * (conversion to           Dynamic   preferred units)           Leak Test           Car Wash   = production vehicles per year * 695               gal/vehicle * conversion to preferred               units       Recirculating   Soak   = tank volume * dumps/month * 12       Systems   Test/   months/yr           Static           Leak Test           Hurricane   = tank volume * dumps/month * 12           Tunnel/   months/yr           Dynamic           Leak Test           Car Wash   = tank volume * dumps/month * 12               months/yr                  
 
         [0047]      FIG. 8  includes an example water consumption calculator  72  for phosphate and electrocoat operations. Calculator  72  may be utilized to receive information  74  and  76  associated with the phosphate and e-coat operations, respectively, and estimate total annual/daily phosphate and electrocoat operation consumptions  78  and  80 , respectively. Notably, a user may modify or update any consumption estimates, yielding updated total consumption values  78  and/or  80 .  
         [0048]     Table 6 includes example calculations executed by the phosphate conversion coating and electrocoating consumption calculator  72 . Of course, the calculations and values provided in Table 6 may be modified or supplemented to best-fit a particular implementation of the present invention.  
                                           TABLE 6                       Value   Calculation                                Phosphate   Make-Up Water   = hours of operation * make-up flow       Conversion   Calculation   (vol/min) * 60 (min/hr) * production       Operations       days per year           Annual Water-   = tank vol * dumps/month * 12           Use By Dumping   (months/yr)            Electrocoat Operations   = sum of all flows (vol/min) * 60           (min/hr) * hours of operation/day                  
 
         [0049]      FIG. 9  is an example GUI including a cooling tower use calculator  82  in accordance with one aspect of the present invention. This feature of the present invention may be utilized to receive data  84  associated with facility cooling towers, and estimate a total annual cooling tower consumption value  86  for the facility. Consumptions per day and per year for each individual cooling tower may also be provided. Notably, a user may modify or update any initial consumption estimates, yielding an updated total annual cooling tower water consumption value  86 .  
         [0050]     Table 7 includes example calculations executed by the cooling tower use calculator  82 . Of course, the calculations and values provided in Table 7 may be modified or supplemented to best-fit a particular implementation of the present invention.  
                   TABLE 7                       Value   Calculation                   Annual   = 0.00085 * Qc * dT * CC/(CC − 1) * 1440       Cooling   (min/day) * months of operation/yr * 30.4       Tower   (days/month)       Consumption   Where:           Qc = recirculation rate           CC = Cycles of Concentration           dT = change in temperature (from inlet to outlet)           85% of total cooling is assumed to be evaporative,           and 15% from sensible cooling                  
 
         [0051]      FIG. 10  is an example GUI including a boiler system/powerhouse water consumption calculator  88  in accordance with one aspect of the present invention. This feature of the present invention may be utilized to receive data  90  associated with facility boiler systems/powerhouses, and estimate a total annual boiler system/powerhouse consumption value  92  for the facility. Notably, a user may modify or update any initial consumption estimates, yielding an updated total annual boiler system/powerhouse water consumption value  92 .  
         [0052]     Table 8 includes example calculations executed by the boiler system/powerhouse water consumption calculator  88 . Of course, the calculations and values provided in Table 8 may be modified or supplemented to best-fit a particular implementation of the present invention.  
                   TABLE 8                       Value   Calculation                   Boiler Water   = total output rating * conversion to hp.hr. * 4       Consumption   (gal water/hp.hr) * (1 − percent condensate return/           100) * 24 hours/day * production days/year * filtration           factor * conversion to preferred units           The filtration factor accounts for water           consumption due to a reject stream if membrane           filtration is used for pre-treatment.                  
 
         [0053]      FIG. 11  illustrates a graphical facility water table  94  and water cost calculator  96  in accordance with one aspect of the present invention. In accordance with a preferred embodiment of the present invention, facility water table  94  is automatically created based on data and information collected and computed via GUIs such as those illustrated in  FIGS. 2-10 . Those of skill in the art will recognize that graphical water table  94  may be generated in a variety of computer-assisted or computer-implemented fashions. For example, water table  94  may be generated utilizing one or more Microsoft Visual Basic macro programs in conjunction with a Microsoft Excel spreadsheet for data collection, processing and display. More specifically, Microsoft Office 2000 integrates Visual Basic 5.0 as “Visual Basic for Applications” (VBA) functionality for creating macros interfacing with Microsoft office applications including Microsoft Excel.  
         [0054]     Facility water table  94  may include a one or more tiers  98   a  and  98   b  of water consumption sources, each tier having one or more instances  100  of water consumption. Preferably, additional data-entry fields (e.g.  102 ) are provided for user-defined or miscellaneous sources of water consumption not covered or otherwise considered with respect to the various water consumption calculators provided (some examples  46  are collectively shown in  FIG. 3 ). A total annual facility water consumption  104  is also provided. Water cost calculator  96  calculates the total cost  106  of purchased water  108  at a user-defined water cost  110 .  
         [0055]     Notably, values and attributed input into GUIs and calculators such as those illustrated in  FIGS. 2-11  may be modified or updated at any time. This feature of the present invention enables the accuracy of the various water consumption estimations and the water table  94  to increase as more accurate or additional data is collected and input or otherwise revised. In addition, this feature of the present invention supports “what if” analyses to see what impact (e.g. cost and water savings) certain modifications in facility or operation water consumption estimations/values and related attributes have on overall facility water consumption.  
         [0056]     For example, the relative impact that different water consumption adjustments will have on the overall water balance can be considered. In this manner, a wide variety of return-on-investment (ROI) analyses may be implemented.  
         [0057]     Yet another aspect of the present invention enables a user to identify unusual water consumption rates within a facility. More specifically, this feature of the present invention enables a user to compare estimated or “typical” water consumption rates with actual consumption rates (where such data is available). Large discrepancies might suggest a water consumption problem within the facility (e.g., over-consumption, under-consumption, etc.), requiring further investigation.  
         [0058]     For example, if the cooling tower calculator  82  illustrated in  FIG. 9  estimates that cooling tower  1  should have a water consumption rate of 2,938 gallons/day, yet a field test indicates that the actual water consumption of cooling tower  1  is over 4,000 gallons/day, water consumption at cooling tower  1  should be investigated.  
         [0059]     While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.