The Challenge
The facility operated high-horsepower pumps under sustained load, resulting in elevated harmonic distortion and excess current flowing through the electrical system. These conditions increased thermal stress on motors, breakers, and upstream electrical components.
Prior to the project, the site experienced frequent replacement of large 1600-amp breakers due to electrical stress, creating maintenance burden and operational risk. In addition, elevated current draw and harmonics reduced overall system efficiency and increased energy consumption.
The Solution
XCT deployed XECO power filtering technology designed to mitigate harmonic distortion and stabilize power supplied to the injection pumps. The solution was delivered in a containerized, weather-resistant configuration suitable for remote and industrial environments.
The system was engineered to integrate seamlessly with existing electrical infrastructure and was installed without disrupting pumping operations.
The Results
Post-installation performance data demonstrated measurable improvements in both electrical efficiency and equipment reliability:
- Approximately 6.35% reduction in total energy consumption
- 5–6% reduction in amperage draw on pump motors
- Approximately 30% reduction in total harmonic distortion
- Improved pump reliability and operational stability
Notably, the frequency of replacing 1600-amp breakers, which had previously occurred multiple times per year, was significantly reduced following installation.
The Impact
By addressing harmonic distortion and excess current at the source, the facility reduced electrical stress across critical assets while improving efficiency and reliability. The project delivered long-term energy savings while extending the useful life of pumps, breakers, and associated electrical infrastructure.
The solution demonstrated a scalable approach for midstream water operations seeking to reduce risk, lower maintenance burden, and improve system performance across injection and pumping applications.
