Water, Wastewater & Pump Systems Manufacturing worked example

Flow Test Energy Cost at 98% test-stand utilization share: a worked example

Push test-stand utilization share up to 98% and the picture changes. This example computes every intermediate figure at that operating point. a pump test lab needs to cost the electricity consumed during performance and witness testing of a pump batch

The inputs for this scenario

  • Pump flow-test running hours: 900 kWh-hr (unchanged)
  • Electricity rate at the test stand: 0.14 $ / kWh (unchanged)
  • Test-stand utilization share: 98 % (raised for this scenario; the documented default is 85)
  • Fixed water and instrumentation cost: 300 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total flow test energy cost = test running hours x electricity cost per unit x stand utilization share + fixed water and instrumentation cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 423 $ for total flow test energy cost, the number this scenario is built around.
  • At this operating point the engine returns 0.47 $ / piece for flow test energy cost per unit.
  • At this operating point the engine returns 123 $ for variable flow test energy cost.
  • At this operating point the engine returns 300 $ for fixed flow test energy cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where test-stand utilization share sits at 85% and the headline result is 407 $, this scenario comes in 4.02% above the baseline at 423 $.
  • It totals the variable electricity cost of a test run, scaled by stand utilization, plus a fixed water and instrumentation adder, and derives cost per test hour. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total flow test energy cost: 423 $ (headline result)
  • Flow test energy cost per unit: 0.47 $ / piece
  • Variable flow test energy cost: 123 $
  • Fixed flow test energy cost adder: 300 $

Run it with your numbers

  • Every input above is editable in the live Flow Test Energy Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.