EWITH Digital Ecosystem
EWITH (Energy Efficiency for Water management with Innovative Technologies and methodologies also based on Hydrogen systems) is a research & industrial development project funded by the Italian Ministry of Enterprises and Made in Italy (MIMIT). The platform brings together advanced algorithms, hydraulic modeling, clean hydrogen buffering, and renewable cogeneration to decarbonize water distribution networks.
🛠️ Project Modular Tools Ecosystem Modular Architecture
Select a tool to launch or inspect real-time pilot telemetry.📍 Primary Pilot Facility: Mugnano Elevation 110 Pumping Station Phlegraean Area Core Node
Delivery POD: IT001E00016841 (20 kV Medium Voltage)| Infrastructure Asset | Technical Specification | Contractual Baseline | Operational Target | Associated OR Pillar |
|---|---|---|---|---|
| Pumping Station | 8 High-Capacity Centrifugal Pumps (3×315 kW + 5×400 kW) | Installed Power: 2,945 kW @ 400V | Automated N+1 / N+2 Redundancy | OR 2 • OR 7 |
| Electrical Grid Connection | Medium Voltage 20,000 V (e-distribuzione) | Contracted Capacity: 2,390.00 kW | Strict Peak Shaving (≤ 2,390 kW) | OR 2 • OR 13 |
| Hydraulic Delivery Line | Discharge Manifold (H = 80 m head, ~7.85 bar) | Nominal Capacity: 2,700 l/s (9,720 m³/h) | Feed Reservoir 1 - 3 (Melito / Monteruscello) | OR 1 • OR 7 |
| Power Supply Contract | Free Market Indexing (PUN GME - A2A Energia) | Annual Demand: 18.70 GWh/year | Night Shift (F3) & ARERA Penalty Removal | OR 7 • OR 13 |
Historical Baseline Operation Unmanaged Dispatch
Peak Power Demanded:2,536 kW (OVERSHOOT +146 kW!)
24-Hour Energy Consumption:43,999 kWh
24-Hour Energy Cost:€ 6,494.16
Off-Peak (F3) Pumping Share:~43%
ARERA Reactive Surcharges:Active (~€ 10/day)
EWITH Optimized Pumping (DSS) Smart Schedule Active
Peak Power Demanded:2,235 kW (100% Below 2,390 kW Limit)
24-Hour Energy Consumption:38,285 kWh
24-Hour Energy Cost:€ 5,614.23
Off-Peak (F3) Pumping Share:Maximized to 52%
Delivered Water Volume:139,680 m³
Direct Daily Cost Reduction
€ 879.93 (-13.5%)
-5,714 kWh / day
Projected Annual Savings
€ 321,177
Calculated across 365 days
Annual Primary Energy Saved
2,086 MWh
Reduced grid extraction from 20 kV line
Avoided CO₂ Emissions
521 tCO₂/year
Emission factor: 0.25 kg CO₂/kWh
🚰 Hourly Pumped Flow vs Electricity Tariff (€/kWh) Load Shifting to F3
📉 Hourly Power Demand vs Contract Limit (2,390 kW) Peak Shaving
📅 Recommended 24-Hour Dispatch Plan (Automated Schedule)
| Time Window | Tariff Band | Active Power | Pumped Flow | Dispatched Pump Units | Hourly Cost |
|---|
⚙️ Electromechanical Inventory & Manual Dispatch Simulator OR 2 • Machine Telemetry
Toggle pump switches to simulate manual operation and assess instantaneous electrical load and flow.📋 Nameplate Electromechanical Specifications (Pumps EP 1 - EP 8)
| Unit ID | Motor Manufacturer | Motor Model | Hydraulic Pump Model | Flow Q | Design Head H | Rated Power | Hydraulic Efficiency η | Optimal Dispatch Strategy |
|---|---|---|---|---|---|---|---|---|
| EP 1 | Siemens | 1LE55033AB734GRO-Z | KSB OMEGA 250 480A | 250 l/s (900 m³/h) | 80 m | 315 kW (400V) | 62.3% | Standby / Peak Trim |
| EP 2 | Siemens | 1LE55033AB734GRO-Z | KSB OMEGA 250 480A | 250 l/s (900 m³/h) | 80 m | 315 kW (400V) | 62.3% | Standby / Peak Trim |
| EP 3 | Siemens | 1LE55033AB734GRO-Z | KSB OMEGA 250 480A | 250 l/s (900 m³/h) | 80 m | 315 kW (400V) | 62.3% | Standby / Peak Trim |
| EP 4 | Leroy-Somer | PLS315LG4 B3 | KSB ETANORM R G 300-500 | 350 l/s (1,260 m³/h) | 80 m | 400 kW (400V) | 68.7% | Secondary Modulation |
| EP 5 | Marelli | B5C3532Q10920 | FLOWSERVE 300-LNNV-600 | 400 l/s (1,440 m³/h) | 80 m | 400 kW (400V) | 78.5% | Primary Base-Load |
| EP 6 | Marelli | B5C3532Q10920 | FLOWSERVE 300-LNNV-600 | 400 l/s (1,440 m³/h) | 80 m | 400 kW (400V) | 78.5% | Primary Base-Load |
| EP 7 | Marelli | B5C3532Q10920 | FLOWSERVE 300-LNNV-600 | 400 l/s (1,440 m³/h) | 80 m | 400 kW (400V) | 78.5% | Primary Base-Load |
| EP 8 | Electric Motor Belgium | - | Pump Group 400 | 400 l/s (1,440 m³/h) | 80 m | 400 kW (400V) | 78.5% | Primary Base-Load |
2025 Annual Demand Audited Total
18.70 GWh
Monthly Average: 1,558,394 kWh
Q1 2026 Trend Jan - Apr
+3.76% vs 2025
5.92 GWh (+214,558 kWh)
Contracted Power 20 kV MV
2,390 kW
⚠️ Overshoot in 7 of 12 months (max 2,536 kW)
Power Factor Cos(φ) F1/F2
0.918 F1
⚠️ Active ARERA Reactive Penalties
Annual Billed Spend A2A Invoice
€ 4.77 Mln
Average unit cost: ~0.1957 €/kWh
📈 Monthly Consumption Comparison 2025 vs 2026 OR 2 • Field Telemetry
⏱️ 12-Month Tariff Band Breakdown ARERA F1 / F2 / F3
⚡ Monthly Peak Power Demand vs Contract Limit (2,390 kW) Critical Anomaly
Contract capacity limit: 2,390.00 kW🧾 Economic Breakdown of Medium Voltage Invoice (April 2026) A2A Bill #826500362488
Total billed consumption: 1,512,831 kWh| Cost Component | Taxable Amount (€) | Share % | Average Unit Cost (€/kWh) | Accounting & Tariff Details |
|---|---|---|---|---|
| Energy Commodity | € 216,165.89 | 73.01% | 0.1429 €/kWh | F1: 0.11479 €/kWh • F2: 0.14191 €/kWh • F3: 0.12028 €/kWh • Grid losses, dispatching & capacity |
| Grid Transport & Metering | € 25,033.75 | 8.45% | 0.0165 €/kWh | Fixed charge (€ 66.71) • Capacity charge (€ 5,371.25) • Variable charge (€ 19,288.60) • Reactive Penalties (€ 307.19) |
| General System Charges (ASOS / ARIM) | € 47,564.67 | 16.06% | 0.0314 €/kWh | ASOS renewable support (€ 44,971.84) • ARIM general interest (€ 2,592.83) |
| Excise Taxes & Levies | € 7,320.00 | 2.47% | 0.0048 €/kWh | Tier ≤ 200,000 kWh (€ 2,500.00) • Monthly flat fee > 1,200 MWh (€ 4,820.00) |
| TOTAL APRIL 2026 INVOICE | € 296,084.31 | 100.00% | 0.1957 €/kWh | Total all-in delivered power cost: ~195.71 €/MWh (excl. VAT) |
⚡ Reactive Energy Diagnostics & ARERA Power Factor Surcharges
The April 2026 power bill indicates that the Mugnano Elev. 110 pumping station operates at a power factor of Cos(φ) = 0.918 in Peak Band F1 and 0.919 in Mid Band F2, both significantly below the regulatory threshold of 0.95 mandated by ARERA. Reactive energy absorption stands at 43% of active energy (exceeding the 33% deductible allowance), triggering automatic monthly penalty surcharges.
F1 Reactive Energy Draw
216,219 kvarh
50,588 kvarh penalized (€ 190.72)
F2 Reactive Energy Draw
136,136 kvarh
30,894 kvarh penalized (€ 116.47)
Monthly April Penalty
€ 307.19
Annual penalty projection: ~€ 3,700 - € 4,500/year
MV Transformer Gain
+1.8%
Reduced thermal Joule losses across 20 kV feeder
Automated Power Factor Correction Sizing Engine
Capacitor Bank Capacity
600 kvar
Automated detuned reactor steps for harmonic blocking
Estimated CAPEX Investment
€ 9,000
Supply & installation of automatic correction board
Annual OPEX Avoided Surcharges
€ 3,686 / year
100% elimination of ARERA penalties
Simple Payback Period
24.5 months
Direct return on investment via penalty avoidance
📑 MIMIT Mid-Term Technical Milestone Documentation (SAL 2)
PROJECT E-WITH • MID-TERM PROGRESS TECHNICAL REPORT (SAL 2)
MIMIT Project ID: F/350167/01/X60 | CUP Code: B49J23008290007 | Lead Beneficiary: COSTRAME S.r.l. | Pilot Facility: Mugnano Elevation 110 Pumping Station - Melito Nuovo (POD: IT001E00016841)
1. Contribution to OR 2 - Electrical Telemetry & Machine Modeling
Following the partner restructuring and the assumption of OR 2 management by lead beneficiary COSTRAME S.r.l., the operational and electromechanical baseline of the main water lifting node has been systematically structured:
- Power Supply Architecture: 20 kV Medium Voltage grid connection via e-distribuzione S.p.A. with 2,390.00 kW contracted capacity under free market pricing (A2A Energia, CIG B5EB78514C).
- Electromechanical Asset Inventory: 8 three-phase induction pumping units at 400 V rated for 2,945 kW total nominal motor power (3×315 kW Siemens + 5×400 kW Marelli/Leroy-Somer/EMB), discharging against 80 m head with 2,700 l/s total installed capacity into Reservoirs 1 - 3.
- Certified Baseline Demand: 2025 audited consumption of 18,700,722 kWh (~18.7 GWh) with 1.56 GWh/month average draw. First 4 months of 2026 show a +3.76% demand increase (+214,558 kWh).
2. Contribution to OR 7 - Machine Learning & Optimization Algorithms (Univ. Vanvitelli / Costrame)
Cross-analyzing billing logs and telemetry revealed two major operational inefficiencies that were directly tackled by the combinatorial Decision Support System (DSS) algorithm:
- Peak Capacity Overshoot Prevention (Peak Shaving): Historical data demonstrated contract capacity breaches in 7 of 12 months (reaching up to 2,536 kW, a +146 kW overshoot). The optimization model enforces a hard constraint $\sum P_i \le 2,390\text{ kW}$ at every hour, completely eliminating penalty risks and transformer overheating.
- Best Efficiency Point (BEP) Prioritization: Pumping dispatch assigns base-load priority to the 4 Flowserve/EMB 400 kW units demonstrating 78.5% efficiency ($SEC = 0.2778\text{ kWh/m}^3$), restricting the low-efficiency KSB 250 l/s units ($\eta = 62.3\%$) strictly to peak trimming.
- Hydraulic Load Shifting to Off-Peak (F3): Utilizing the storage buffering volume of Reservoirs 1 - 3, the algorithm concentrates pumping into night hours (23:00 - 07:00 at ~0.130 €/kWh), delivering a verified 13.5% daily cost reduction (~€ 320,000/year) and saving over 2,000 MWh/year of primary energy.
3. Contribution to OR 13 - Transversal Digital Monitoring & Process Regulation (Costrame)
Within OR 13, previously reported at 10% progress, COSTRAME S.r.l. has developed and deployed the cloud/edge-ready EWITH Suite web platform, advancing deliverable maturity beyond 55%:
- Integrated Suite Hub hosting modular project tools (OptiPump DSS, PAT Energy Recovery, Green Hydrogen, Hybrid CHP).
- Real-time telemetry analytics displaying multi-year trends, tariff band distribution, and cost structures.
- Full electromechanical Digital Twin enabling operational simulations and live specific energy consumption (SEC) tracking.
- Integrated power factor and reactive energy engine providing automated capacitor bank sizing for total penalty removal.
- Hosted and verified on public infrastructure at
ewithsuite.edar.bizfor multi-device access.