Every year, the world wastes enough energy pumping water to power entire cities, while 2.2 billion people face daily water shortages. Having one the world's lowest water resources, Jordan loses substantial energy through inefficient systems, oversized pumps, and hydraulic imbalances. Nowhere was this more evident than in As-Salt, Jordan. The water network forced pumps to labor against unnecessary head, burning electricity while the throttling valves dissipated excess pressure as waste heat. Designed as a single pressure zone despite vast elevation differences, the system ran pumps at full capacity regardless of actual demand: costs spiraled and water service faltered. But by tackling hydraulic inefficiencies head-on, As-Salt is proving that even the most energy-intensive water systems can be transformed.
The Water Authority of Jordan (WAJ), backed by KfW Development Bank, partnered with Engicon and ILF Consulting Engineers to implement a comprehensive energy efficiency program targeting both pumping infrastructure and network hydraulics.
Technical Approach: Systematic Network Restructuring
Engicon's team applied systems-level thinking to the As-Salt network, combining detailed hydraulic analysis with energy optimization principles. The engineering team developed a comprehensive WaterGEMS model calibrated against 40 monitoring points, revealing that a three-zone configuration—Upper, Middle, and Lower—would optimize pumping efficiency by aligning system pressures with topographic requirements.
Each zone was subdivided into Distribution Metered Areas (DMAs), creating 12 hydraulically isolated districts with dedicated flow metering and pressure monitoring. This configuration enables precise water balance calculations and rapid leak detection through minimum night flow analysis.
Five critical pumping stations underwent complete rehabilitation: Share'a, Yazidieh, Naqab Al Daboor, Al-Bhaira, and Zai. The rehabilitation focused on duty-point optimization rather than simply increasing capacity. New pumps, variable frequency drives, and control logic were specified to match actual system requirements, not theoretical maximums.
Implementation: From Design to Operation
Engicon managed the complete project lifecycle from conceptual design through construction supervision and commissioning. The hydraulic redesign necessitated 186 kilometers of new pipeline installation, ranging from 63mm distribution mains to 800mm trunk lines. Pipeline sizing was optimized to minimize friction losses while maintaining adequate flow velocities for self-cleaning.
Pressure reducing valves, flow control valves, and automated isolation valves were strategically placed to maintain optimal pressures within each zone and DMA, reducing stress on aging infrastructure while improving service consistency.
FIDIC Red Book contracts were prepared for network construction, while pumping station work followed FIDIC Yellow Book provisions. Technical evaluation weighted energy efficiency commitments alongside traditional cost and schedule factors, ensuring contractors understood performance expectations from project award.
On-site supervision focused on critical installation details: pipeline bedding procedures, valve chamber waterproofing, control panel protection ratings, and pump foundation alignment. Commissioning protocols included comprehensive performance testing at design flow rates and energy consumption measurements under various operating scenarios.
Knowledge Transfer and Capacity Building
Parallel to construction, Engicon implemented a structured training program targeting WAJ and Miyahuna staff through three phases: classroom instruction covering hydraulic modeling and SCADA operation (175 training hours), hands-on field training during construction (14 weeks), and six-month coaching programs with Train-the-Trainer elements. Training venues included Engicon offices, operational sites, equipment supplier facilities, and SCADA training centers.
Technical Results and Performance Metrics
The systematic approach delivered measurable improvements across multiple performance indicators. Specific energy consumption (kWh/m³) decreased at all rehabilitated pumping stations through optimized duty point operation. Variable speed drives enabled pumps to track demand precisely, eliminating energy waste from throttling and bypass operations.
DMA configurations enabled rapid leak detection through continuous minimum night-flow monitoring. Pressure management reduced background leakage rates and pipe burst frequency. SCADA integration provided real-time monitoring of flow rates, pressures, and energy consumption across the network, giving operators data-driven decision-making capability. Predictive maintenance protocols based on vibration analysis and performance trending replaced reactive repair strategies.
Scaling and Replication Potential
The As-Salt project demonstrates scalable engineering principles applicable throughout the Middle East and similar climatic regions. The three-zone configuration with DMA subdivisions can be adapted to other topographically varied service areas. Pump specifications and control logic developed for As-Salt provide templates for similar applications, while the phased capacity building approach addresses common challenges in technology transfer and institutional sustainability. The project's emphasis on knowledge transfer distinguishes it from conventional infrastructure upgrades.
