Lower costs and major energy savings for waterworks

Hoyer IE4 motors with integrated frequency converters are a key element of a new solution that saves Danish waterworks money and energy. Hoyer Motors’ distributor, TPI El & Automation, has developed a method that has achieved energy savings of between 10% and 30% at several waterworks.


Energy optimisation and green transition is a focus area for Danish waterworks seeking to save energy, reduce water loss and minimise operational disruptions. For this to happen waterworks need reliable information on the operational status of their pumps. At the same time, pumps must be more energy efficient and easy to control, so that operations can be adapted to the actual conditions.

This is precisely what Danish company TPI El & Automation has made possible through a new control solution for electric motors. The solution was specifically developed to achieve energy savings at waterworks. Waterworks using the solution typically save more than 10% in power consumption and in some cases up to 30%.

“The energy optimisation projects Hoyer carried out at the waterworks with TPI are very interesting. They are an excellent example of how partners with a high level of technical knowledge and insight into an end user’s business can use Hoyer products to optimise operations and thus reduce energy consumption. This goes hand in hand with Hoyer’s sustainability ambitions and is a great fit in an area where we want to be strong,” says Brian Byskov, After Sales Segment Manager, Hoyer.

Easier to detect burst pipes

Hoyer IE4 motors with integrated frequency converters play a crucial role in the solution. In part because the energy-efficient IE4 motors help keep power consumption low, and because the frequency converter can utilise the built-in IO analogue and digital inputs in the motor. This eliminates any need for separate installations for temperature or pressure measurement near the pump.

TPI has designed a PLC controller that collects information about temperature and water pressure directly from the pump. The waterworks see this information via an operating interface. They use this information to optimise operations and respond quickly if problems arise.

“All the waterworks need to do is describe what they need, such as a certain pressure, and then we set the pump to deliver it. The control is very stable. You can monitor the increase when you change the pump, and if a burst pipe occurs you can determine this faster. It makes it easier for the waterworks to decide whether they should shut down or continue operating. They save both operational costs and on wear and tear,” says Henrik Nielsen, owner and manager, TPI.

The frequency converter enables precise control of the pump, and because the solution is very compact, the waterworks save space. And there is no need for laying long cables.

Collaboration developed over time

TPI has worked as a partner and distributor for Hoyer Motors for the past three years, and the distributor helped open the door to waterworks in Denmark. The collaboration is an excellent example of the strong synergy between Hoyer’s international set-up and distributors with extensive local knowledge and lots of potential to service local companies.

“Our distributors around the world are an excellent supplement to our own customer support. We believe there are great advantages in having a strong network of local distributors, acting as our extended arm in the market,” says Brian Byskov, After Sales Segment Manager, Hoyer.

Learn more about Hoyer’s energy-efficient motors

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