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Punjab Cities Governance Improvement Project
Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab
REPORT Disposal Division, Multan
November 2015
NEC Consultants (Pvt.) Ltd.
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Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab
November 2015
NEC Consultants Pvt. Ltd Perfect SITE, 22 KM Ferozepur Road, Near Gujju Matta Metro Bus Station, Lahore +92-42-35273741-46, www.nec.com.pk [email protected]
This study was assigned by The Urban Unit, Punjab
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DISCLAIMER
No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or information storage and retrieval system, without prior written permission of the USPMSU.
A publication of the Urban Sector Planning and Management Services Unit (Private) Limited, the opinion expressed in the document are solely those of the authors and publishing them does not in any way constitute an endorsement of the opinion by the USPMSU.
ACKNOWLEDGEMENTS
This report has been prepared by The Urban Unit (Urban Sector Policy & Management Unit), P&D Department, Government of Punjab. The Urban Unit, under the Punjab Cities Governance Improvement Project (PCGIP)-DLI-4 is supporting WASA Lahore for implementing Energy Audit Management Opportunities. Energy management opportunities have been extracted from the energy audits of WASA pumps.
The Team
Dr. Nasir Javed Engr. Abid Hussainy Engr. Ali Raza Shafqat Ullah Muhammad Rizwan Kashif Shaukat Adnan Khan
Editing & Layout By:
Ms. Madiha Qamar
Printed in Pakistan
Copyright: Urban Sector Planning and Management Services Unit (Private) Limited.
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CONTENTS Contents 4 List of Annexure 4 List of Figures 4 List of Tables 4 List of Acronyms and Abbreviations 5 Glossary 5 1.0 Introduction 7
1.1 Background 7 1.2 Methodology 7 1.3 Scope 8
2.0 Energy Audit Findings 9 2.1 Pumping system efficiency 10 2.2 Electricity consumption trend 12 2.3 Pumping system efficiency improvement potential 14 2.4 Interventions for the improvement of WASA stations 15
LIST OF ANNEXURE
I Energy Audit Reports 2 Selected Pictures
LIST OF FIGURES
I Pumping system efficiency category 12
LIST OF TABLES
1 Detail of WASAs pumps 8 2 Detail of Disposal Division Multan 9 3 Typical overall pumping system efficiency classification 10 4 Detail of motor loading and pumping system efficiency 11 5 Detail of water discharge and electricity consumption 12 6 System energy efficiency potential of waste water disposal pumps 14
7A Interventions & investment required in WASA stations-Disposal Division Multan 16
7B Interventions & investment required in WASA stations-Disposal Division Multan 18
7C Interventions & investment required in WASA stations-Disposal Division Multan 20
7D Interventions & investment required in WASA stations-Disposal Division Multan 22
7E Interventions & investment required in WASA stations-Disposal Division Multan 24
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LIST OF ACRONYMS AND ABBREVIATIONS
Bhp Brake Horsepower Cusec Cubic Feet per Second Ehp Electrical Horsepower Gpm Gallon Per Minute Hp Horsepower kVA Kilo Volt Ampere kW Kilo Watt kWh Kilo Watt Hour MEPCO Multan Electric Power Company m/s Meter Per Second m3/hr Cubic Meter Per Hour MCB Fuses or Miniature Circuit Breaker Mm Millimeter MS Mild Steel Psig Pound Per Square Inch (Gauge) RPM Revolution Per Minute TDH Total Dynamic Head VFD Variable Frequency Drive WASA Water and Sanitation Agency Whp Water Horsepower
GLOSSARY
Discharge Pressure
The pressure obtained at center line of pump discharge pipe using a calibrated gauge (psig). Discharge pressure is converted to feet and expressed as “Discharge Head”.
Brake Horsepower
The output horsepower of a motor to a pump; may also be used to refer to the required input horsepower to the pump itself.
Deep Well Turbine Pump
A turbine pump installed inside a well casing below the pumping water level in the well.
Discharge Head Head measured above center line of pump discharge pipe.
Drawdown The measured distance that a well’s water level changes from standing/static level to operating pumping level during observed test conditions.
Dynamic Head The sum of the pressure and the pumping head developed by a pump
Friction Head The head required to overcome the fluid friction in a pipe or water system
Friction Energy losses associated with moving water against rough
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Losses surfaces. In water pumping applications, it is the water pressure lost as a result of contact between moving water and a pipeline or open channel.
GPM per Foot Drawdown
The ratio of capacity (GPM) to drawdown feet is useful in determining the well’s performance.
Head Alternate term for pressure. One pound per square inch (psi) = 2.31 feet of water head
Overall Plant or Pumping System Efficiency
The ratio of the water horsepower (the overall output of the plant) to input horsepower (the power input). The overall output can also be defined as the amount of horsepower required to deliver the measured capacity (water gallons per minute) and the measured total head.
Pumping Water Level
The well’s operating water level below center line of discharge pipe as observed during test condition
Static Water Level The well’s water level obtained when pumping plant is at rest.
Suction Head Head measured above center line of pump suction intake. Most often obtained with calibrated bourdon tube pressure gauge (suction pressure) and converted to feet by conversion factor 2.31 ft. water/psi
Suction Lift The distance between pump discharge head and water level.
Total Head
The sum of the water head above and below the center line of the pump discharge pipe. For well applications, the Total Head is the sum of the Discharge Head and the Pumping Water Level. Total head is used in determination of water horsepower and pump performance.
Water Horsepower
The output horsepower of a water pump. It is the combination of flow rate and pressure.
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1.0 Introduction 1.1 Background Energy Audit & Energy Efficiency Improvement gram Government of the Punjab, Pakistan with financial assistance from the World Bank, is implementing “Punjab Cities Governance Improvement Project (PCGIP)” for strengthening systems for improved planning, resource management, and accountability in five large cities of Punjab i.e. Lahore, Faisalabad, Multan, Gujranwala and Rawalpindi. The project utilizes a result-based approach and, consistent with this focus, the disbursement decisions to the city and its entities are based on achievement of pre-specified results, referred to as Disbursement linked Indicators (DLIs) which reflect priority elements in furthering the Government’s urban agenda, critical at the provincial level, within the existing legislative, regulative and policy framework of the Government. DLIs includes intermediate outcomes, incremental steps and results contributing to improved efficiency, effectiveness, accountability and service delivery during and beyond the project life by building capacities , system and processes . Disbursement Linked Indicator 4 (DLI -4) aims for improvements in own source revenue collection system that encourages the City Local Government (CDGs), Development Authorities (DAs) and Service providers (WASAs) to bring improved systems for revenue enhancement. This DLI is linked with the initiative of WASAs to carry out the Energy Audit for resources conservation and efficiency to improved service delivery, accountability and own source revenue. One of the proposed actions & initiatives to enhance revenue was to conduct energy audit of WASAs to reduce the power cost by various systematic analysis of the energy use and finding out the energy management opportunities. WASAs each year incur significant cost. It was Rs. 4,697 million in 2014 year for energy/Electricity bills, with an installed capacity of approximately 131 MW for 5,663 Million Gallons per Day (water management), which can be reduced through detailed energy audit and implementing its findings. In the context of existing scenario energy audit of WASAs is a technical and efficient way to obtain energy analysis and savings through improvements that optimize pumping systems of tube well stations and disposal stations to operate efficiently with significant cost saving. The Urban Planning and Management Services Unit, Pvt. Ltd. has assigned NEC Consultants Pvt. Ltd to conduct energy audits of WASAs in Punjab in five major cities of Lahore, Rawalpindi, Faisalabad, Multan and Gujranwala. This is the energy audit report of Disposal Division, Multan 1.2 Methodology The primary and secondary sources were used to collect data for different WASAs and pumps installed there. The Urban Unit provided information and contact detail of all the WASAs. An energy audit report template was developed to collect field data from each WASA subdivision. Prior to start the on field measurements of each subdivision, meetings were conducted with the respective WASA management and briefed them about the activity. The technical team then collected data by on field measurements of each pump and recorded in their energy audit report template. On the basis of this energy audit report template, The Urban Unit also developed Android based software to record data of each pump online. This data was also recorded on line in this Android based application. On the basis of field measurements, efficiency of the pumping system was calculated and
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energy efficiency opportunities were identified. 1.3 Scope The scope of the this assignment is to conduct energy audits of about 1,600 fresh water supply and wastewater disposal pumps installed at different WASA stations in five major cities of Lahore, Rawalpindi, Multan, Faisalabad and Gujranwala. The detail of these pumps is given in Table-1.
Table-1: Detail of WASAs Pumps
WASA Population
Served (Million)
Total Water Connections
Total Sewerage
Connections
Total Supply
Stations
Total Disposal Stations
Total No. of Pump
Sets WASA Lahore 5.48 587,595 583,532 491 99 776
WASA Gujranwala 0.54 29,375 97,236 66 23 112
WASA Faisalabad 1.55 110,452 217,002 87 43 222
WASA Multan 1.2 43,996 175,615 102 21 161
WASA Rawalpindi 1.17 92,468 38,437 362 - 362
Total 9.94 863,886 1,111,822 1,108 186 1,633 The efficiency of each pumping system was evaluated and energy efficiency improvement opportunities were identified for those pumping systems whose efficiencies were not at required level. The detail of reports prepared is as under:
- The energy audit report of each pump was prepared. - On the basis of each pump report, summary report of findings of each WASA
subdivision was prepared. - On the basis of each subdivision summary report, one consolidated report of each city
for energy efficiency improvement opportunities of the WASAs was prepared.
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2.0 Energy Audit Findings There are 19 WASA wastewater disposal stations and 92 wastewater disposal pumps (33 waste water pumps were not in operation) in disposal division Multan. The detail of these stations along with pumps installed capacity and actual discharge is given in Table-2:
Table-2: Detail of Disposal Division Multan
# WASA wastewater Pumps
No. of Wastewater
Pumps Installed
Installed Capacity (Cusec)
Actual Discharge (Cusec)
1 Advag Vera 01 01 3.0 1.8 2 Chungi No. 9-01 01 20.0 8.6 3 Chungi No. 9-04 01 20.0 10.9 4 Chungi No. 9-05 01 12.0 7.7 5 Chungi No. 9-07 01 12.0 9.6 6 Chungi No. 9-08 01 10.0 4.0 7 Chungi No. 9-09 01 5.0 4.2 8 Chungi No. 9-10 01 5.0 3.5 9 Chungi No. 9-11 01 10.0 8.0 10 Chungi No. 9-12 01 10.0 8.0 11 Fareedabad 01 01 2.0 2.0 12 Farooqpura 01 01 2.0 1.8 13 Farooqpura 02 01 8.0 4.8 14 Farooqpura 04 01 8.0 5.0 15 Garden Town 01 01 10.0 8.8 16 Garden Town 02 01 5.0 3.9 17 Khan Village, Bosan Road 01 01 15.0 9.3 18 Khan Vllage, Bosan Road 02 01 15.0 12.4 19 Khan Village, Bosan Road 03 01 15.0 14.1 20 Khan Village, Bosan Road 05 01 20.0 15.4 21 Khan Village, Bosan Road 09 01 20.0 14.4 22 Kirri Jamndan (New) 01 01 15.0 9.3 23 Kirri Jamndan (New) 02 01 10.0 7.2 24 Kirri Jamndan (New) 05 01 10.0 6.4 25 Kirri Jamndan (New) 06 01 15.0 8.7 26 Kotala Waris Shah 01 01 1.50 1.4 27 Madina Colony 02 01 4.0 3.2 28 Muzafrabad 01 01 4.0 2.0 29 Muzafrabad 02 01 1.50 0.8 30 Old Shujaabad Road 01 01 15.0 8.2 31 Old Shujaabad Road 03 01 15.0 8.2 32 Old Shujaabad Road 04 01 15.0 8.7 33 Old Shujaabad Road 05 01 15.0 9.8 34 Old Shujaabad Road 06 01 15.0 10.0 35 Purana Burf Khana 01 01 1.0 0.6 36 Qadeer Abad 01 01 2.0 1.0 37 Qasimbella 01 01 10.0 8.5 38 Qasimbella 02 01 5.0 3.9 39 Qasimbella 03 01 10.0 8.3 40 Qasimbella 04 01 5.0 3.8
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41 Sameejabad (New) 02 01 10.0 7.0 42 Sameejabad (New) 04 01 20.0 11.2 43 Sameejabad (New) 05 01 20.0 11.1 44 Sameejabad (New) 06 01 15.0 10.3 45 Suraj Miani 02 01 15.0 8.1 46 Suraj Miani 03 01 15.0 7.1 47 Suraj Miani 04 01 15.0 8.0 48 Suraj Miani 06 01 15.0 8.7 49 Suraj Miani 08 01 15.0 9.2 50 Suraj Miani 09 01 15.0 9.2 51 Toya Taqqi Shah 01 01 1.50 1.4 52 Vehari Road 02 01 15.0 8.6 53 Vehari Road 03 01 15.0 9.4 54 Vehari Road 04 01 15.0 9.6 55 Vehari Road 06 01 15.0 10.0 56 Vehari Road 07 01 15.0 9.6 57 Vehari Road 09 01 15.0 10.0 58 Wahidabad 01 01 1.50 1.3 59 Wahidabad 02 01 2.0 1.4 Total 59 646 419
The installed capacity of WASA disposal pumps of Disposal Division Multan is 385 million m3 per annum whereas actual discharge is 249 million m3 per annum, for average 16 hours per day operation and 365 days per year. This actual discharge is about 35% lesser than the installed capacity. 2.1 Pumping System Efficiency Pumping plant performance can be classified as “Low”, “Fair”, “Good”, or “Excellent” by referring to the following table, which is based upon the results of thousands of pump tests conducted by Pacific Gas & Electric Company, USA. This classification is used to categorize WASA pumps.
Table-3: Typical Overall Pumping System Efficiency Classification
Motor HP Low Fair Good Excellent 3-7.5 <44.0 44-49.9 50-54.9 >54.9
10 <46.0 46-52.9 53-57.9 >57.9 15 <47.1 48-53.9 54-59.9 >59.9
20-25 <48.0 50-56.9 57-60.9 >60.9 30-50 <52.1 52.1-58.9 59-61.9 >61.9 60-75 <56.0 56-60.9 61-65.9 >65.9 100 <57.3 57.3-62.9 63-66.9 >66.9 150 <58.1 58.1-63.4 63.5-68.9 >68.9 200 <59.1 59.1-63.8 63.9-69.4 >69.4 250 <59.1 59.1-63.8 63.9-69.4 >69.4 300 <60 60-64.0 64.1-69.9 >69.9
Source: Pacific Gas & Electric Company, USA The detail of pumping system efficiency and motor loading of each WASA disposal station is given in Table-4. The calculations for the efficiency determination are given in the energy audit report of each pump in Annexure-1.
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Table-4: Detail of Motor Loading and Pumping System Efficiency WASA Disposal Station Motor Load
(%) Pumping System
Efficiency (%)
Pumping System
Efficiency Rating
1 Chungi No. 9-05 32 80 EXCELLENT 2 Chungi No. 9-10 62 69 EXCELLENT 3 Chungi No. 9-11 52 74 EXCELLENT 4 Chungi No. 9-12 51 75 EXCELLENT 5 Khan village, Bosan Road 03 72 84 EXCELLENT 6 Khan village, Bosan Road 05 78 86 EXCELLENT 7 Khan village, Bosan Road 09 72 80 EXCELLENT 8 Kirri Jamndan (New) 05 56 79 EXCELLENT 9 Qasimbella 02 38 67 EXCELLENT 10 Suraj Miani 03 34 76 EXCELLENT 11 Chungi No. 9-04 56 66 GOOD 12 Chungi No. 9-09 54 59 GOOD 13 Old Shujaabad Road 03 53 69 GOOD 14 Qadeer Abad 01 25 57 GOOD 15 Suraj Miani 04 57 67 GOOD 16 Suraj Miani 09 72 66 GOOD 17 Farooqpura 02 54 57 FAIR 18 Farooqpura 04 67 60 FAIR 19 Khan village, Bosan Road 02 74 63 FAIR 20 Kirri Jamndan (New) 02 95 60 FAIR 21 Kotala Waris Shah 01 62 51 FAIR 22 Old Shujaabad Road 01 48 61 FAIR 23 Sameejabad (New) 04 64 59 FAIR 24 Suraj Miani 02 60 58 FAIR 25 Fareedabad 01 88 34 LOW 26 Farooqpura 01 97 52 LOW 27 Gardentown 01 94 51 LOW 28 Gardentown 02 111 26 LOW 29 Khan village, Bosan Road 01 54 50 LOW 30 Old Shujaabad Road 04 106 37 LOW 31 Old Shujaabad Road 05 94 51 LOW 32 Old Shujaabad Road 06 97 52 LOW 33 Purana Burf Khana 01 68 43 LOW 34 Qasimbella 03 71 52 LOW 35 Qasimbella 04 129 19 LOW 36 Sameejabad (New) 02 71 47 LOW 37 Sameejabad (New) 05 65 57 LOW 38 Sameejabad (New) 06 84 51 LOW 39 Madina Colony 02 55 35 LOW 40 Muzafrabad 01 53 44 LOW 41 Muzafrabad 02 47 43 LOW 42 Kirri Jamndan (New) 01 76 41 LOW 43 Kirri Jamndan (New) 06 78 35 LOW 44 Qasimbella 01 76 42 LOW 45 Advag Vera 01 45 39 LOW 46 Chungi No. 9-01 51 42 LOW 47 Chungi No. 9-07 80 52 LOW 48 Chungi No. 9-08 40 38 LOW 49 Toya Taqqi Shah 01 89 27 LOW
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50 Vehari Road 02 45 52 LOW 51 Vehari Road 03 51 50 LOW 52 Vehari Road 04 56 48 LOW 53 Vehari Road 06 63 38 LOW 54 Vehari Road 07 56 48 LOW 55 Vehari Road 09 65 37 LOW 56 Wahidabad 01 46 27 LOW 57 Wahidabad 02 78 41 LOW 58 Suraj Miani 06 85 51 LOW 59 Suraj Miani 08 121 39 LOW About 27% of the operational disposal pumps are under excellent and good category of pumping system efficiency whereas 73% are under fair and low category as illustrated in Fig-1.
Figure-1: Pumping System Efficiency Category
2.2 Electricity Consumption Trend The detail of annual water discharge and correspondingly electricity consumption and unit electricity consumption of each WASA disposal station is given in Table-5.
Table-5: Detail of Water Discharge and Electricity Consumption
# WASA Station Annual Water
Discharge (m3)
Annual Electricity Consumption
(kWh)
Unit Electricity Consumption
(kWh/m3) 1 Advag Vera 01 788,400 44,035 0.06 2 Chungi No. 9-01 7,082,460 557,041 0.08 3 Chungi No. 9-04 6,077,250 412,827 0.07 4 Chungi No. 9-05 4,297,875 165,131 0.04 5 Chungi No. 9-07 5,349,075 412,827 0.08 6 Chungi No. 9-08 2,244,750 165,131 0.07
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7 Chungi No. 9-09 2,326,875 110,087 0.05 8 Chungi No. 9-10 1,943,625 126,600 0.07 9 Chungi No. 9-11 4,440,225 214,670 0.05
10 Chungi No. 9-12 4,440,225 209,166 0.05 11 Fareedabad 01 876,000 58,126 0.07 12 Farooqpura 01 472,675 46,237 0.10 13 Farooqpura 02 1,239,175 77,061 0.06 14 Farooqpura 04 1,303,050 96,069 0.07 15 Gardentown 01 6,570,000 410,992 0.06 16 Gardentown 02 2,920,000 242,192 0.08 17 Khan village, Bosan Road 01 3,814,250 290,630 0.08 18 Khan village, Bosan Road 02 4,165,380 330,261 0.08 19 Khan village, Bosan Road 03 4,710,690 320,354 0.07 20 Khan village, Bosan Road 05 5,147,595 383,103 0.07 21 Khan village, Bosan Road 09 4,828,950 356,682 0.07 22 Kirri Jamndan (New) 01 4,507,750 405,488 0.09 23 Kirri Jamndan (New) 02 2,398,050 234,486 0.10 24 Kirri Jamndan (New) 05 1,660,750 106,601 0.06 25 Kirri Jamndan (New) 06 2,923,650 287,063 0.10 26 Kotala Waris Shah 01 919,800 45,576 0.05 27 Madina Colony 02 2,135,250 81,244 0.04 28 Muzafrabad 01 1,460,000 115,225 0.08 29 Muzafrabad 02 584,000 51,374 0.09 30 Old Shujaabad Road 01 6,095,500 330,261 0.05 31 Old Shujaabad Road 03 6,095,500 359,618 0.06 32 Old Shujaabad Road 04 6,482,400 726,575 0.11 33 Old Shujaabad Road 05 7,263,500 645,845 0.09 34 Old Shujaabad Road 06 7,482,500 660,523 0.09 35 Purana Burf Khana 01 344,925 28,072 0.08 36 Qadeer Abad 01 464,280 20,696 0.04 37 Qasimbella 01 3,801,840 303,840 0.08 38 Qasimbella 02 1,795,800 62,529 0.04 39 Qasimbella 03 3,723,000 233,385 0.06 40 Qasimbella 04 1,708,200 212,688 0.12 41 Sameejabad (New) 02 4,146,400 311,180 0.08 42 Sameejabad (New) 04 6,657,600 557,775 0.08 43 Sameejabad (New) 05 6,622,560 569,517 0.09 44 Sameejabad (New) 06 6,132,000 551,903 0.09 45 Suraj Miani 02 7,227,000 493,190 0.07 46 Suraj Miani 03 5,475,000 281,823 0.05 47 Suraj Miani 04 7,104,360 466,769 0.07 48 Suraj Miani 06 7,752,600 695,751 0.09 49 Suraj Miani 08 8,225,640 995,188 0.12 50 Suraj Miani 09 8,190,600 590,067 0.07 51 Toya Taqqi Shah 01 777,450 55,044 0.07 52 Vehari Road 02 4,507,020 215,771 0.05 53 Vehari Road 03 4,905,600 246,595 0.05 54 Vehari Road 04 5,365,500 286,227 0.05 55 Vehari Road 06 5,584,500 324,757 0.06 56 Vehari Road 07 6,438,600 343,472 0.05 57 Vehari Road 09 7,818,300 470,072 0.06
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58 Wahidabad 01 886,950 91,152 0.10 59 Wahidabad 02 919,800 76,819 0.08 Total 241,622,700 17,563,382 0.07 Total annual energy cost of Disposal Division Multan is about Rs. 228.3 million.
2.3 Pumping System Efficiency Improvement Potential The 43 disposal pumps having system efficiency in the category of FAIR to LOW, as given in Table-4, have the potential of efficiency improvement into the GOOD category. Table-6 gives detail of this efficiency improvement potential.
Table-6: System Energy Efficiency Potential of waste water disposal pumps
WASA Station
Existing Pumping Efficienc
y (%)
Improved Pumping Efficiency
(%)
Annual
(kWh)
Saving
(Rs)
Impeller Adjustment
(IA)
IA &
Repair Mainten
ance
Intervention
Motor Replace
Pump Replace
Advag Vera 01 39 65 17,609 228,912 × Chungi No. 9-01 42 63 183,778 2,389,115 × Chungi No. 9-07 52 63 70,797 920,359 × Chungi No. 9-08 38 65 69,392 902,096 × Fareedabad 01 34 57 23,260 302,378 × Farooqpura 01 52 60 5,942 77,249 × Farooqpura 02 57 62 5,757 74,843 × Farooqpura 04 60 62 3,071 39,926 × Gardentown 01 51 65 86,112 1,119,461 × Gardentown 02 26 65 144,460 1,877,980 × Khan village 01 50 64 61,427 798,549 × Khan village 02 63 64 7,524 97,807 × Kirri Jamndan (New) 01 41 65 151,896 1,974,654 × Kirri Jamndan (New) 02 60 65 19,625 255,126 × Kirri Jamndan (New) 06 35 65 131,162 1,705,106 × Kotala Waris Shah 01 51 54 2,399 31,183 × Madina Colony 02 35 60 33,186 431,422 × Muzafrabad 01 44 59 30,248 393,230 × Muzafrabad 02 43 57 13,057 169,738 × Old Shujaabad Road 01 61 64 10,993 142,905 × Old Shujaabad Road 04 37 65 308,678 4,012,811 × Old Shujaabad Road 05 51 64 133,563 1,736,320 × Old Shujaabad Road 06 52 64 121,426 1,578,542 × Purana Burf Khana 01 43 46 1,681 21,859 × Qasimbella 01 42 65 109,739 1,426,606 × Qasimbella 03 52 65 46,194 600,528 × Qasimbella 04 19 65 151,299 1,966,884 × Sameejabad (New) 02 47 65 84,107 1,093,385 × Sameejabad (New) 04 59 65 51,337 667,379 ×
Sameejabad (New) 05 57 65 68,156 886,031 ×
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Sameejabad (New) 06 51 65 117,722 1,530,384 × Suraj Miani 02 58 63 38,144 495,868 × Suraj Miani 06 51 63 131,028 1,703,358 × Suraj Miani 08 39 64 385,182 5,007,372 × Toya Taqqi Shah 01 27 54 27,579 358,529 × Vehari Road 02 52 65 44,250 575,245 × Vehari Road 03 50 65 55,670 723,708 × Vehari Road 04 48 65 76,151 989,969 × Vehari Road 06 38 65 133,248 1,732,227 × Vehari Road 07 48 65 91,382 1,187,963 × Vehari Road 09 37 65 201,960 2,625,477 × Wahidabad 01 27 59 49,654 645,503 × Wahidabad 02 41 57 21,795 283,335 × Total 3,521,640 45,781,322
2.4 Interventions for the Improvement of WASA Stations Energy audit activity of Disposal Division Multan revealed that there are certain areas of electrical, mechanical and housekeeping which needs improvement. Table-7 presents detail of interventions and investment requirement in each WASA disposal station for better, efficient and safe operation of WASA station. About Rs. 8.28 million are required to improve WASA stations of Disposal Division Multan
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Table-7A: Interventions & Investment Required in WASA Stations- Disposal Division Multan
Intervention WASA Disposal Stations Advag
Vera 01 Chungi No. 9-01
Chungi No. 9-04
Chungi No. 9-05
Chungi No. 9-07
Chungi No. 9-08
Chungi No. 9-
09
Chungi No. 9-10
Chungi No. 9-11
Chungi No. 9-12
Fareedabad 01
Farooqpura 01
Farooqpura 02
Electrical Install VFD Install hour meter × × × × × × × × × × × × × Replace ampere meter × × × × × × × × × × × Replace volt meter × × × × × × × × × Replace over current relays × Replace over voltage relay × Install/maintain PFI plant × × × × Install/connect capacitors at PFI plant
Install PFI control/relay Install/replace motor terminal box /Improve open and loose motor connection
Improve panel condition × Improve wiring condition × Replace de-rated capacitors Relocate panel away from bore hole Replace electrical motor Install fan in the panel × × × × × × × × × × × × × Replace PFI HRC fuses Replace PFI display meter Correct date & time of electrical meter
× × × × × × × × × ×
Replace/correct electrical meter × × × × × × × × × × Replace change over Replace main circuit breaker Mechanical Replace damaged/install new flow × × × × × × × × × × × × ×
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Intervention WASA Disposal Stations Advag
Vera 01 Chungi No. 9-01
Chungi No. 9-04
Chungi No. 9-05
Chungi No. 9-07
Chungi No. 9-08
Chungi No. 9-
09
Chungi No. 9-10
Chungi No. 9-11
Chungi No. 9-12
Fareedabad 01
Farooqpura 01
Farooqpura 02
meter Replace damaged/install new digital pressure gauge × × × × × × × × × × × × × Control gland leakage Make operational/install new chlorinator
Maintain ratchet plate Adjust impeller × × × × × × Repair & maintenance of pump × × × × Replace existing pumping system × Maintain/install new non return valve
Housekeeping Improve general housekeeping × × × × × × × × × × × × × Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption
× × × × × × × × × × × × ×
Station Wise Investment (M. Rs) 0.21 0.10 0.04 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.17 0.29 0.09
Annual Saving (M. Rs) 0.23 2.39 - - 0.92 0.90 - - - - 0.30 0.08 0.07 Payback (Year) 0.92 0.04 0.11 0.11 0.57 3.70 1.15
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Table-7B: Interventions & Investment Required in WASA Stations- Disposal Division Multan Intervention WASA Stations
Farooqpura 04
Gardentown 01
Gardentown 02
Khan village, Bosan
Road 01
Khan village, Bosan
Road 02
Khan village, Bosan
Road 03
Khan village, Bosan
Road 05
Khan village, Bosan
Road 09
Kirri Jamndan (New)
01
Kirri Jamndan (New)
02
Kirri Jamndan (New)
05
Kirri Jamndan (New)
06
Kotala Waris
Shah 01
Electrical Install VFD Install hour meter × × × × × × × × × × × × × Replace ampere meter × × × × × × × Replace volt meter × × × × Replace over current relays Replace over voltage relay Install/maintain PFI plant × × × × × × × × Install/connect capacitors at PFI plant
Install PFI control/relay Install/replace motor terminal box /Improve open and loose motor connection
Improve panel condition × × × × × × × × Improve wiring condition × × × × × × × × × Replace de-rated capacitors Relocate panel away from bore hole Replace electrical motor Install fan in the panel × × × × × × × × × × × × × Replace PFI HRC fuses Replace PFI display meter Correct date & time of electrical meter
× × × × ×
Replace/correct electrical meter × × × × × Replace change over
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Intervention WASA Stations
Farooqpura 04
Gardentown 01
Gardentown 02
Khan village, Bosan
Road 01
Khan village, Bosan
Road 02
Khan village, Bosan
Road 03
Khan village, Bosan
Road 05
Khan village, Bosan
Road 09
Kirri Jamndan (New)
01
Kirri Jamndan (New)
02
Kirri Jamndan (New)
05
Kirri Jamndan (New)
06
Kotala Waris
Shah 01
Replace main circuit breaker Mechanical Replace damaged/install new flow meter
× × × × × × × × × × × × ×
Replace damaged/install new digital pressure gauge
× × × × × × × × × × × × ×
Control gland leakage Make operational/install new chlorinator
Maintain ratchet plate Adjust impeller × × × × × × × × Repair & maintenance of pump × × × Replace existing pumping system Maintain/install new non return valve
Housekeeping Improve general housekeeping × × × × × × × × × × × × × Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption × × × × × × × × × × × × × Station Wise Investment (M. Rs) 0.09 0.10 0.29 0.20 0.10 0.10 0.10 0.10 0.14 0.14 0.09 0.14 0.10 Annual Saving (M. Rs) 0.04 1.12 1.88 0.80 0.10 - - - 1.97 0.26 - 1.71 0.03 Payback (Year) 2.14 0.09 0.15 0.25 1.03 0.07 0.53 0.08 3.24
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Table-7C: Interventions & Investment Required in WASA Stations- Disposal Division Multan Intervention WASA Stations
Muzafrabad 01
Muzafrabad 02
Old Shujaa
bad Road
01
Old Shujaabad Road
03
Old Shujaabad
Road 04
Old Shujaabad Road
05
Old Shujaabad Road
06
Purana Burf
Khana 01
Qadeer Abad 01
Qasimbella 01
Qasimbella 02
Qasimbella 03
Qasimbella 04
Electrical Install VFD Install hour meter × × × × × × × × × × × × × Replace ampere meter × × × × × Replace volt meter × × × × × × Replace over current relays Replace over voltage relay Install/maintain PFI plant × × × × × × × × × Install/connect capacitors at PFI plant
Install PFI control/relay Install/replace motor terminal box /Improve open and loose motor connection
Improve panel condition × × × × × × × × Improve wiring condition × × × × × × × × Replace de-rated capacitors Relocate panel away from bore hole Replace electrical motor Install fan in the panel × × × × × × × × × × × × × Replace PFI HRC fuses Replace PFI display meter Correct date & time of electrical meter
Replace/correct electrical meter Replace change over Replace main circuit breaker Mechanical Replace damaged/install new flow × × × × × × × × × × × × ×
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Intervention WASA Stations
Muzafrabad 01
Muzafrabad 02
Old Shujaa
bad Road
01
Old Shujaabad Road
03
Old Shujaabad
Road 04
Old Shujaabad Road
05
Old Shujaabad Road
06
Purana Burf
Khana 01
Qadeer Abad 01
Qasimbella 01
Qasimbella 02
Qasimbella 03
Qasimbella 04
meter Replace damaged/install new digital pressure gauge × × × × × × × × × × × × × Control gland leakage Make operational/install new chlorinator
Maintain ratchet plate Adjust impeller × × × × × × × × × Repair & maintenance of pump × × × × × × × Replace existing pumping system Maintain/install new non return valve
Housekeeping Improve general housekeeping × × × × × × × × × × × × × Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption × × × × × × × × × × × × × Station Wise Investment (M. Rs)
0.21 0.11 0.40 0.09 0.10 0.10 0.10 0.11 0.09 0.08 0.10 0.10 0.30
Annual Saving (M. Rs) 0.39 0.17 0.14 - 4.01 1.74 1.58 0.02 - 1.43 0.024 0.60 1.97 Payback (Year) 0.54 0.65 2.80 - 0.03 0.06 0.06 4.85 - 0.05 42.42 0.17 0.15
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Table-7D: Interventions & Investment Required in WASA Stations- Disposal Division Multan Intervention WASA Stations Sameejab
ad (New) 02
Sameejabad (New)
04
Sameejabad (New)
05
Sameejabad
(New) 06 Suraj Miani
02 Suraj
Miani 03 Suraj
Miani 04 Suraj
Miani 06 Suraj
Miani 08 Suraj
Miani 09
Toya Taqqi
Shah 01 Vehari
Road 02 Vehari
Road 03
Electrical Install VFD Install hour meter × × × × × × × × × × × × × Replace ampere meter × Replace volt meter × Replace over current relays Replace over voltage relay Install/maintain PFI plant × × Install/connect capacitors at PFI plant
Install PFI control/relay Install/replace motor terminal box /Improve open and loose motor connection
Improve panel condition × × × Improve wiring condition × × × Replace de-rated capacitors Relocate panel away from bore hole Replace electrical motor Install fan in the panel × × × × × × × × × × × × × Replace PFI HRC fuses Replace PFI display meter Correct date & time of electrical meter
Replace/correct electrical meter Replace change over Replace main circuit breaker Mechanical Replace damaged/install new flow meter
× × × × × × × × × × × × ×
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Intervention WASA Stations Sameejab
ad (New) 02
Sameejabad (New)
04
Sameejabad (New)
05
Sameejabad
(New) 06 Suraj Miani
02 Suraj
Miani 03 Suraj
Miani 04 Suraj
Miani 06 Suraj
Miani 08 Suraj
Miani 09
Toya Taqqi
Shah 01 Vehari
Road 02 Vehari
Road 03
Replace damaged/install new digital pressure gauge
× × × × × × × × × × × × ×
Control gland leakage Make operational/install new chlorinator
Maintain ratchet plate Adjust impeller × × × × × × × × × Repair & maintenance of pump × × × Replace existing pumping system × Maintain/install new non return valve
Housekeeping Improve general housekeeping × × × × × × × × × × × × × Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption
× × × × × × × × × × × × ×
Station Wise Investment (M. Rs) 0.10 0.10 0.10 0.10 0.09 0.10 0.10 0.09 0.30 0.10 0.10 0.80 0.10 Annual Saving (M. Rs) 1.09 0.67 0.89 1.53 0.50 - - 1.70 5.01 - 0.36 0.58 0.72 Payback (Year) 0.09 0.15 0.11 0.07 0.17 - - 0.05 0.06 - 0.28 1.39 0.14
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Table-7E: Interventions & Investment Required in WASA Stations- Disposal Division Multan Intervention WASA Stations Vehari
Road 06 Vehari
Road 07
Vehari Road
09 Wahidab
ad 01 Wahidabad
02
Electrical Install VFD Install hour meter × × × × × Replace ampere meter × × × × Replace volt meter × × × × × Replace over current relays Replace over voltage relay Install/maintain PFI plant × × Install/connect capacitors at PFI plant
Install PFI control/relay Install/replace motor terminal box /Improve open and loose motor connection
Improve panel condition × × × × × Improve wiring condition × × × × × Replace de-rated capacitors Relocate panel away from bore hole Replace electrical motor Install fan in the panel × × × × × Replace PFI HRC fuses Replace PFI display meter Correct date & time of electrical meter
Replace/correct electrical meter Replace change over Replace main circuit breaker Mechanical Replace damaged/install new flow meter
× × × × ×
Replace damaged/install new digital × × × × ×
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Intervention WASA Stations Vehari
Road 06 Vehari
Road 07
Vehari Road
09
Wahidabad 01
Wahidabad 02
pressure gauge Control gland leakage Make operational/install new chlorinator
Maintain ratchet plate Adjust impeller × × × × Repair & maintenance of pump × × × × Replace existing pumping system × Maintain/install new non return valve
Housekeeping Improve general housekeeping × × × × × Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption
× × × × ×
Station Wise Investment (M. Rs)
0.10 0.10 0.10 0.20 0.16
Annual Saving (M. Rs) 1.73 1.19 2.63 0.65 0.28 Payback (Year) 0.06 0.08 0.04 0.31 0.57 Total Investment of disposal division (M.Rs) = 8.28
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ANNEXURE-1
Energy Audit Reports
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station ADWAQ WERA P#1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact NAZIR AHMAD 0301 5745070
iv) Total Number of Pumps Installed 1
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 1
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 1
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 12 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 50
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 1
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 3 Cusec 306 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 8
ii) Enter Length of Suction Pipe (ft) 24.4
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 6
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 18.2 ft
Suction Side Elevation 16.2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 30 hp 22 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 11547.05
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N / A
Panel Condition/Issues POOR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring POOR
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 6 inches
v) Pipe Perimeter 479 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 180 m3/hr 3 m3/min
Velocity in Pipe 2.74 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 53 meter
Electric Measurements Volt 387
Ampere 15
kW 10 Power Factor 0.75
vi) Motor Working on Loading Basis 45 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 83.5
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 16.2 ft
v) Static Discahrge Head 18.2 ft
vi) Frictional Head (Suction and Discahrge) 24.13 ft
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viii) Total Dynamic Head of Pump (TDH) 26.13 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 5.23 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 13.40 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 39.01 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 12 hrs
xxi) Daily Pump flow 2,160 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 788,400 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 44,035 kWh/yr
xxv) Annual Energy Expenditure on Pumping 572,453 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 300 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.03 kWh/m3
xxix) Potential of Energy Reduction 39.99 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 17,609 kWh/yr
xxxi) Annual Financial Saving on Pumping 228,912 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 39%. For pump attached with 300 HP motor, efficiency below 52.1% is considered to be LOW, (Above 61.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 228,912 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 210,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
No PFI plant is installed PFI of 50 KVAR is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 22 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 1150
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 20 Cusec 2,040 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 30 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 180 hp 134 kW
iii) Voltage Range 400 Volts
iv) Current 245.5 Amperes
v) Power Factor (Cos ɸ) 0.83
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 424
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr/operational
Panel Condition/Issues Good, V&A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Good,
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 882 m3/hr 14.7 m3/min
Velocity in Pipe 2.47 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 15 meter
Electric Measurements Volt 414 416 417
Ampere 94 100 100
kW 69 Power Factor 0.97 0.98 0.98
vi) Motor Working on Loading Basis 51 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 30 ft
vi) Frictional Head (Suction and Discahrge) 14.82 ft
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viii) Total Dynamic Head of Pump (TDH) 39.82 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 39.05 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 92.49 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 42.22 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 22 hrs
xxi) Daily Pump flow 19,404 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,082,460 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 557,041 kWh/yr
xxv) Annual Energy Expenditure on Pumping 7,241,532 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 63 %
xxvii) Water Flow after Efficiency Improvement 1,316 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 32.99 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 183,778 kWh/yr
xxxi) Annual Financial Saving on Pumping 2,389,115 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 42.22%. For pump attached with 180 HP motor, efficiency below 59% is considered to be LOW. This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 63% (GOOD Efficiency range), with annual savings of 2,389,115PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
No water flow meter Water flowmeter is recommended
Install the New A &VmeterA&V meter defective
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#4
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 04
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 20 Cusec 2,040 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 180 hp 134 kW
iii) Voltage Range 400 Volts
iv) Current 245.5 Amperes
v) Power Factor (Cos ɸ) 0.83
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 424
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr opertational
Panel Condition/Issues Good, V&A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Good,
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,110 m3/hr 18.5 m3/min
Velocity in Pipe 3.10 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 17 meter
Electric Measurements Volt 417 414 420
Ampere 101 104 100
kW 75 Power Factor 0.96 0.97 0.98
vi) Motor Working on Loading Basis 56 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 23.52 ft
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viii) Total Dynamic Head of Pump (TDH) 53.52 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 66.06 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 100.54 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 65.70 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 16,650 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,077,250 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 412,827 kWh/yr
xxv) Annual Energy Expenditure on Pumping 5,366,748 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,098 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
11 Summary of Findings
Pumping system efficiency is 66%. For pump attached with 180 HP motor, efficiency above 63% is considered to be good. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 41,000 PKR
Install the New A &VmeterA&V meter defective
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#5
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 05
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 12 Cusec 1,224 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr/operational
Panel Condition/Issues Fair, A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal NO TERMILAN BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 785 m3/hr 13.083 m3/min
Velocity in Pipe 2.20 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 17 meter
Electric Measurements Volt 408 409 410
Ampere 80 81 86
kW 30 Power Factor 0.68 0.7 0.69
vi) Motor Working on Loading Basis 32 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 11.79 ft
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viii) Total Dynamic Head of Pump (TDH) 36.79 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 32.11 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 40.21 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 79.85 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 11,775 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,297,875 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 165,131 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,146,699 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 68 %
xxvii) Water Flow after Efficiency Improvement 669 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
11 Summary of Findings
Pumping system efficiency is 79.85%. For pump attached with 125 HP motor, efficiency above 69% is considered to be excellent, . This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,500 PKR
Install the New A meterA meter defective
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#7
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 1150
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 07
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 12 Cusec 1,224 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 35
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr/operational
Panel Condition/Issues Fair, A & V meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 977 m3/hr 16.283 m3/min
Velocity in Pipe 2.73 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 408 410 415
Ampere 132 136 135
kW 75 Power Factor 0.78 0.79 0.81
vi) Motor Working on Loading Basis 80 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 18.31 ft
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viii) Total Dynamic Head of Pump (TDH) 48.31 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 52.48 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 100.54 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 52.20 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 14,655 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 5,349,075 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 412,827 kWh/yr
xxv) Annual Energy Expenditure on Pumping 5,366,748 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 63 %
xxvii) Water Flow after Efficiency Improvement 1,179 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 17.15 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 70,797 kWh/yr
xxxi) Annual Financial Saving on Pumping 920,359 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 52.20%. For pump attached with 125 HP motor, efficiency below 57% is considered to be LOW. This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 63% (GOOD Efficiency range), with annual savings of 920,359PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
No water flow meter Water flowmeter is recommended
Install the New A & VmeterA & Vmeter defective
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#8
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 08
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 35
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr/operational
Panel Condition/Issues Fair, A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 410 m3/hr 6.8333 m3/min
Velocity in Pipe 1.15 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 406 408 411
Ampere 41 42 49
kW 30 Power Factor 0.85 0.86 0.86
vi) Motor Working on Loading Basis 40 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 3.24 ft
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viii) Total Dynamic Head of Pump (TDH) 33.24 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 15.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 40.21 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 37.69 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 6,150 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,244,750 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 165,131 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,146,699 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 707 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 42.02 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 69,392 kWh/yr
xxxi) Annual Financial Saving on Pumping 902,096 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 37%. For pump attached with 100 HP motor, efficiency below 57% is considere to be LOW. This pumping system requires impeller adjustments, repair and maintenance to increase it efficiency to 66% which is considered to be excellent. This intervention will save 902,096 Rs annually.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,500 PKR
No water flow meter Water flowmeter is recommended
Install the New A meterA meter defective
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#9
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 1150
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 09
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 5 Cusec 510 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 8
ii) Length of Discharge Pipe (ft) 35
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 50 hp 37 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr/operational
Panel Condition/Issues Fair, A & V meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 425 m3/hr 7.0833 m3/min
Velocity in Pipe 1.19 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 407 409 410
Ampere 74 76 78
kW 20 Power Factor 0.78 0.79 0.78
vi) Motor Working on Loading Basis 54 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 3.49 ft
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viii) Total Dynamic Head of Pump (TDH) 33.49 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 15.82 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 26.81 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 59.02 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 6,375 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,326,875 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 110,087 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,431,133 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 59 %
xxvii) Water Flow after Efficiency Improvement 425 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
11 Summary of Findings
Pumping system efficiency is 59.02%. For pump attached with 50 HP motor, efficiency above 59% is considered to be good. This pumping system requires np interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
Install the New A & V meterA & V meter defective
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#10
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 1150
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 10
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 5 Cusec 510 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 8
ii) Length of Discharge Pipe (ft) 35
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 50 hp 37 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr
Panel Condition/Issues Fair, A & V meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches
v) Pipe Perimeter 638 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 355 m3/hr 5.9167 m3/min
Velocity in Pipe 3.04 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 406 407 409
Ampere 77 71 76
kW 23 Power Factor 0.79 0.8 0.76
vi) Motor Working on Loading Basis 62 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 23.59 ft
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viii) Total Dynamic Head of Pump (TDH) 53.59 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 21.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 30.83 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 68.61 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 5,325 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,943,625 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 126,600 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,645,803 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 59 %
xxvii) Water Flow after Efficiency Improvement 305 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.08 kWh/m3
11 Summary of Findings
Pumping system efficiency is 68.61%. For pump attached with 50 HP motor, efficiency above 61% is considered to be excellent, . This pumping system requires no interventation
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
No water flow meter Water flowmeter is recommended
Install the New A & V meterA & V meter defective
No pressure guage Digital pressure guage is recommended
![Page 91: Energy Audit & Energy Efficiency Improvement Program …pcgip.urbanunit.gov.pk/docs/energy/Disposal Division Multan.pdf · Energy Audit & Energy Efficiency Improvement Program for](https://reader031.vdocument.in/reader031/viewer/2022012914/5ab992367f8b9ab62f8e0a9e/html5/thumbnails/91.jpg)
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#11
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 11
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 12
ii) Length of Discharge Pipe (ft) 35
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr-operational
Panel Condition/Issues Fair, A & V meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 811 m3/hr 13.517 m3/min
Velocity in Pipe 2.27 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 407 408 406
Ampere 91 87 93
kW 39 Power Factor 0.74 0.74 0.73
vi) Motor Working on Loading Basis 52 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 12.63 ft
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viii) Total Dynamic Head of Pump (TDH) 42.63 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 38.44 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 52.28 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 73.53 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 12,165 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,440,225 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 214,670 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,790,709 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 63 %
xxvii) Water Flow after Efficiency Improvement 695 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
11 Summary of Findings
Pumping system efficiency is 73.53%. For pump attached with 100 HP motor, efficiency above 66% is considered to be excellent. . This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
Install the New A & V meterA & V meter defective
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station CHUNGI NO 9 P#12
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact SHAFQAT RAZA 0306 6509792
iv) Total Number of Pumps Installed 12
v) Total Number of Pumps in Operation 9
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 12
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 12
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 1150
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 12
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 12
ii) Length of Discharge Pipe (ft) 35
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 35 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER DEFECTIVE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 600 KVAr-non operational
Panel Condition/Issues Fair
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 811 m3/hr 13.517 m3/min
Velocity in Pipe 2.27 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 410 407 409
Ampere 94 96 91
kW 38 Power Factor 0.75 0.76 0.77
vi) Motor Working on Loading Basis 51 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 35 ft
vi) Frictional Head (Suction and Discahrge) 12.63 ft
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viii) Total Dynamic Head of Pump (TDH) 42.63 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 38.44 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 50.94 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 75.47 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 12,165 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,440,225 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 209,166 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,719,152 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 63 %
xxvii) Water Flow after Efficiency Improvement 677 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
11 Summary of Findings
Pumping system efficiency is 75.47%. For pump attached with 100 HP motor, efficiency above 66% is considered to be excellent. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station FARIDABAD
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact Masood
iv) Total Number of Pumps Installed 1
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 1
vi) Operational Scheme of Pumps Qty
Independent 1
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 12 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 8
ii) Enter Length of Suction Pipe (ft) 10
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 8
ii) Length of Discharge Pipe (ft) 20
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 30 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 20 hp 15 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 15394.9
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 50 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not Available
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring good
Housekeeping good
Motor Terminal not Installed
Foundation/Civil work poor
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches
v) Pipe Perimeter 638 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 200 m3/hr 3.3333 m3/min Estimated
Velocity in Pipe 1.71 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 9 meter
Electric Measurements Volt 419 418 419
Ampere 19.6 19.3 19.6
kW 13.2 Power Factor 0.57 0.59 0.56
vi) Motor Working on Loading Basis 88 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 30 ft
vi) Frictional Head (Suction and Discahrge) 7.21 ft
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viii) Total Dynamic Head of Pump (TDH) 27.21 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 6.05 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 17.69 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 34.19 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 12 hrs
xxi) Daily Pump flow 2,400 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 876,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 58,126 kWh/yr
xxv) Annual Energy Expenditure on Pumping 755,638 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 57 %
xxvii) Water Flow after Efficiency Improvement 333 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 40.02 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 23,260 kWh/yr
xxxi) Annual Financial Saving on Pumping 302,378 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 34.19%. For pump attached with 20 HP motor, efficiency below 48% is considered to be LOW. This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 57% (GOOD Efficiency range), with annual savings of 302,378 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 171,000 PKR
No PFI plant is installed
Install VoltmeterVoltmeter not working
No pressure guage Digital pressure guage is recommended
PFI plant of 25 KVAR is recommended
Ampere meter not working install Ampere meter
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station FAROOQ PURA P#1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact UMAIR ALI 0300 6387426
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 4
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 7 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 300
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 12
ii) Enter Length of Suction Pipe (ft) 55
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 12
ii) Length of Discharge Pipe (ft) 75
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 65 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 25 hp 19 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 3197.33
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N/A
Panel Condition/Issues FAIR/Defective A and V meter
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches
v) Pipe Perimeter 957 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 185 m3/hr 3.0833 m3/min
Velocity in Pipe 0.70 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 40 meter
Electric Measurements Volt 407 409 410
Ampere 26 27 30
kW 18 Power Factor 0.44 0.4 0.49
vi) Motor Working on Loading Basis 97 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 85.6
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 65 ft
vi) Frictional Head (Suction and Discahrge) 1.34 ft
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viii) Total Dynamic Head of Pump (TDH) 61.34 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 12.62 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 24.13 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 52.29 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.10 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 7 hrs
xxi) Daily Pump flow 1,295 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 472,675 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 46,237 kWh/yr
xxv) Annual Energy Expenditure on Pumping 601,076 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 60 %
xxvii) Water Flow after Efficiency Improvement 212 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.09 kWh/m3
xxix) Potential of Energy Reduction 12.85 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 5,942 kWh/yr
xxxi) Annual Financial Saving on Pumping 77,249 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 52.29%. For pump attached with 25 HP motor, efficiency between 50-56.9% is considered to be FAIR, (Above 60.9% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 60% (GOOD Efficiency range), with annual savings of 77,249 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 286,000 PKR
No water flow meter Water flowmeter is recommended
A and V meter is recommendedDfective V & A meter
No pressure guage Digital pressure guage is recommended
PFI plant is not installed in disposal station PFI plant of 100 KVAR for disposal station is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station FAROOQ PURA P#2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact UMAIR ALI 0300 6387426
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 4
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 7 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 300
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 8 Cusec 816 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 55
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 75
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 75 hp 56 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 3197.33
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N/A
Panel Condition/Issues Good, V &A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Good
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 485 m3/hr 8.0833 m3/min
Velocity in Pipe 1.04 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 40 meter
Electric Measurements Volt 409 410 408
Ampere 70 50 57
kW 30 Power Factor 0.72 0.74 0.74
vi) Motor Working on Loading Basis 54 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 85.4
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 2.78 ft
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viii) Total Dynamic Head of Pump (TDH) 42.78 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 23.07 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 40.21 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 57.37 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 7 hrs
xxi) Daily Pump flow 3,395 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,239,175 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 77,061 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,001,793 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 62 %
xxvii) Water Flow after Efficiency Improvement 524 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 7.47 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 5,757 kWh/yr
xxxi) Annual Financial Saving on Pumping 74,843 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 57.37%. For pump attached with 75 HP motor, efficiency between 56-60.9% is considered to be FAIR, (Above 65.9% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 62% (GOOD Efficiency range), with annual savings of 74,843 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 86,000 PKR
No water flow meter Water flowmeter is recommended
Install the New V&A meterV&A meter defective
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station FAROOQ PURA P#4
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact UMAIR ALI 0300 6387426
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 4
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 7 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 300
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 04
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 8 Cusec 816 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 60
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 65
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 55 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 75 hp 56 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 3197.33
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N/A
Panel Condition/Issues Fair, A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring fair,
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,280 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 510 m3/hr 8.5 m3/min
Velocity in Pipe 1.09 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 38 meter
Electric Measurements Volt 410 402 403
Ampere 78 49 70
kW 37.4 Power Factor 0.82 0.81 0.8
vi) Motor Working on Loading Basis 67 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 85.6
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 55 ft
vi) Frictional Head (Suction and Discahrge) 3.06 ft
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viii) Total Dynamic Head of Pump (TDH) 53.06 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 30.09 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 50.13 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 60.02 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 7 hrs
xxi) Daily Pump flow 3,570 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,303,050 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 96,069 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,248,902 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 62 %
xxvii) Water Flow after Efficiency Improvement 527 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
xxix) Potential of Energy Reduction 3.20 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 3,071 kWh/yr
xxxi) Annual Financial Saving on Pumping 39,926 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 60.02%. For pump attached with 75 HP motor, efficiency between 56-60.9% is considered to be FAIR, (Above 65.9% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 62% (GOOD Efficiency range), with annual savings of 39,926 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 85,500 PKR
No water flow meter Water flowmeter is recommended
Install the New A meterA meter defective
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station GARDEN TOWN P#1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M SHEHZAD 0300 2046496
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 4
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 365
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 15
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 12
ii) Length of Discharge Pipe (ft) 45
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 25 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 397.78
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 175 KVAr
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 900 m3/hr 15 m3/min
Velocity in Pipe 2.52 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 428 427 423
Ampere 83 99 108
kW 56 Power Factor 0.83 0.77 0.79
vi) Motor Working on Loading Basis 94 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 25 ft
vi) Frictional Head (Suction and Discahrge) 15.54 ft
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viii) Total Dynamic Head of Pump (TDH) 38.54 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 38.57 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 75.07 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.38 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 18,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,570,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 410,992 kWh/yr
xxv) Annual Energy Expenditure on Pumping 5,342,895 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,139 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 20.95 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 86,112 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,119,461 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 51%. For pump attached with 80 HP motor, efficiency below 54% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,119,461 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station GARDEN TOWN P#2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M SHEHZAD 0300 2046496
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty 2
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 365
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 5 Cusec 510 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 15
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 12
ii) Length of Discharge Pipe (ft) 45
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 25 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 40 hp 30 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 397.78
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 175 KVAr
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 400 m3/hr 6.6667 m3/min
Velocity in Pipe 1.12 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 424 419 425
Ampere 66 72 67
kW 33 Power Factor 0.64 0.67 0.71
vi) Motor Working on Loading Basis 111 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 25 ft
vi) Frictional Head (Suction and Discahrge) 3.09 ft
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viii) Total Dynamic Head of Pump (TDH) 26.09 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 11.60 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 44.24 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 26.23 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 8,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,920,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 242,192 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,148,492 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 991 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.03 kWh/m3
xxix) Potential of Energy Reduction 59.65 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 144,460 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,877,980 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 26%. For pump attached with 40 HP motor, efficiency below 51% is considered to be LOW, (Above 65.9% is EXCELLENT). This pumping system requires motor replace . After this adjustment its efficiency will be improved to 61% (GOOD Efficiency range), with annual savings of 1,877,980PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 285,000 PKR
No pressure guage Digital pressure guage is recommended
Motor is in efficient Replacement of motor is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kerri Jamandan DISP P1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Mazhar Hussain 0301-7426276
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 13 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 635,630,300 KVA
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KVP 350-500 D2 Serial 17-6647
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 55 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 121 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 27 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 400 Volts
iv) Current 203 Amperes
v) Power Factor (Cos ɸ) 0.84
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 215726/1001
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630,630 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 225 KVAR NOT OPERATIONAL
Panel Condition/Issues FAIR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring FAIR
Housekeeping FAIR
Motor Terminal OPEN AND LOSE MOTOR CONNECTIONS
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 950 m3/hr 15.833 m3/min
Velocity in Pipe 2.66 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 54 meter
Electric Measurements Volt 402 401 401
Ampere 139 140 141
kW 85 Power Factor 0.81 0.82 0.82
vi) Motor Working on Loading Basis 76 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 87
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 27 ft
vi) Frictional Head (Suction and Discahrge) 18.85 ft
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viii) Total Dynamic Head of Pump (TDH) 43.85 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 46.32 hp
xiv) Brake Horsepower (bhp) (OEM Data) 121.30 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 113.94 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 38.18 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 40.65 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.09 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 13 hrs
xxi) Daily Pump flow 12,350 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,507,750 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 405,488 kWh/yr
xxv) Annual Energy Expenditure on Pumping 5,271,339 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,519 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 37.46 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 151,896 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,974,654 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 40.5%. For pump attached with 150 HP motor, efficiency below 54% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,974,654 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv) PFI plant is demaged Repair of PFI plant is recommended
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 135,500 PKR
No pressure guage Digital pressure guage is recommended
V meter is not available V meter is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kerri Jamandan DISP P2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Mazhar Hussain 0301-7426276
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 9 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 635,630,300 KVA
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KVP 350-500 D2 Serial 17-6644
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 55 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 82 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 10
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 10
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 27 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range 400 Volts
iv) Current 138 Amperes
v) Power Factor (Cos ɸ) 0.84
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 310-6AA84
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 215726/1001
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630,630 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 225 KVAR NOT OPERATIONAL
Panel Condition/Issues FAIR/Defective A and V meter
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches
v) Pipe Perimeter 798 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 730 m3/hr 12.167 m3/min
Velocity in Pipe 4.00 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 54 meter
Electric Measurements Volt 402 401 402
Ampere 138 141 140
kW 71 Power Factor 0.81 0.82 0.82
vi) Motor Working on Loading Basis 95 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 84.5
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 27 ft
vi) Frictional Head (Suction and Discahrge) 44.84 ft
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viii) Total Dynamic Head of Pump (TDH) 69.84 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 56.69 hp
xiv) Brake Horsepower (bhp) (OEM Data) 81.88 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 95.17 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 69.23 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 59.56 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.10 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 9 hrs
xxi) Daily Pump flow 6,570 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,398,050 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 234,486 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,048,313 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 797 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.09 kWh/m3
xxix) Potential of Energy Reduction 8.37 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 19,625 kWh/yr
xxxi) Annual Financial Saving on Pumping 255,126 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 59 which is FAIR, For pump attached with 100 HP motor, efficiency below 57.3% is considered to be LOW, (Above 66.9% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 255,126 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 136,000 PKR
No pressure guage Digital pressure guage is recommended
A and V meter is not working A and V meter is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kerri Jamandan DISP P5
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Mazhar Hussain 0301-7426276
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 7 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 635,630,300 KVA
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 05
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KVP 350-500 D2 Serial 17-6648
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 55 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 121 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 10
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 10
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 27 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range 400 Volts
iv) Current 138 Amperes
v) Power Factor (Cos ɸ) 0.84
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 310-6AA86
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 215726/1001
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630,630 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 225 KVAR NON OPERATIONAL
Panel Condition/Issues POOR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring POOR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches
v) Pipe Perimeter 798 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 650 m3/hr 10.833 m3/min
Velocity in Pipe 3.56 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 54 meter
Electric Measurements Volt 399
Ampere 94.1
kW 41.5 Power Factor 0.71
vi) Motor Working on Loading Basis 56 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 84.1
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 27 ft
vi) Frictional Head (Suction and Discahrge) 35.65 ft
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viii) Total Dynamic Head of Pump (TDH) 60.65 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 43.83 hp
xiv) Brake Horsepower (bhp) (OEM Data) 121.30 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 55.63 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 36.14 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 78.80 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 7 hrs
xxi) Daily Pump flow 4,550 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,660,750 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 106,601 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,385,814 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 536 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.08 kWh/m3
11 Summary of Findings
Pumping system efficiency is 78.8%. For pump attached with 100 HP motor, efficiency above 56.9% is considered to be EXCELLENT. This pumping system does not require any intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 85,500 PKR
Repair of PFI plant is recommended PFI plant is demaged
No pressure guage Digital pressure guage is recommended
V meter is not available V meter is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kerri Jamandan DISP P6
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Mazhar Hussain 0301-7426276
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 9 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 635,630,300 KVA
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 06
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KVP 350-500 D2 Serial 17-6645
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) 55 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 82 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 27 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 400 Volts
iv) Current 203 Amperes
v) Power Factor (Cos ɸ) 0.84
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 215726/1001
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630,630 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 225 KVAR NON OPERATIONAL
Panel Condition/Issues FAIR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 890 m3/hr 14.833 m3/min
Velocity in Pipe 2.49 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 54 meter
Electric Measurements Volt 397 396 397
Ampere 142 144 143
kW 86.92 Power Factor 0.8 0.81 0.81
vi) Motor Working on Loading Basis 78 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 86.8
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 27 ft
vi) Frictional Head (Suction and Discahrge) 16.56 ft
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viii) Total Dynamic Head of Pump (TDH) 41.56 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 41.13 hp
xiv) Brake Horsepower (bhp) (OEM Data) 81.88 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 116.51 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 50.23 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 35.30 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.10 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 9 hrs
xxi) Daily Pump flow 8,010 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,923,650 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 287,063 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,731,822 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,639 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 45.69 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 131,162 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,705,106 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 35.3%. For pump attached with 150 HP motor, efficiency below 58.1% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,705,106 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 135,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
PFI plant is demaged Repair of PFI plant is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station KHAN VILLAGE P#1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact KHURSHED AHMAD 0300 4872544
iv) Total Number of Pumps Installed 10
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 5
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 10
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 11 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KW-PK 350/500 D-2 Serial 17-7304
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 106 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 10
ii) Enter Length of Suction Pipe (ft) 15
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 12
ii) Length of Discharge Pipe (ft) 75
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 18 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 180 hp 134 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NOT VISIBLE
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N/A
Panel Condition/Issues Fair, A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring fair,
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches
v) Pipe Perimeter 957 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 950 m3/hr 15.833 m3/min
Velocity in Pipe 3.62 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 27 meter
Electric Measurements Volt 422 423 423
Ampere 91 99 96
kW 72 Power Factor 0.98 0.98 0.98
vi) Motor Working on Loading Basis 54 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 18 ft
vi) Frictional Head (Suction and Discahrge) 33.12 ft
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viii) Total Dynamic Head of Pump (TDH) 46.12 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 48.71 hp
xiv) Brake Horsepower (bhp) (OEM Data) 106.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 96.51 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 45.96 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 50.47 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 11 hrs
xxi) Daily Pump flow 10,450 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,814,250 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 290,630 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,778,190 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 1,205 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 21.14 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 61,427 kWh/yr
xxxi) Annual Financial Saving on Pumping 798,549 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 50.47%. For pump attached with 180 HP motor, efficiency below 59% is considered to be LOW. This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 64% (GOOD Efficiency range), with annual savings of 798,549 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 201,000 PKR
Install the New A meterA meter defective
No pressure guage Digital pressure guage is recommended
PFI Plant not installed PFI of 50 KVAr is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station KHAN VILLAGE P#2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact AHMAD RAZA 0331 2700234
iv) Total Number of Pumps Installed 10
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 5
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 10
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 9 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KW PK 350/500 Serial 17-7299
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 106 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 50
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 85
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 180 hp 134 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 5909.9/1026.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 337.5 KVAr
Panel Condition/Issues Good, A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Good,
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,268 m3/hr 21.133 m3/min
Velocity in Pipe 3.55 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 41 meter
Electric Measurements Volt 376 377 375
Ampere 186 180 182
kW 100 Power Factor 0.83 0.84 0.82
vi) Motor Working on Loading Basis 74 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 32.46 ft
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viii) Total Dynamic Head of Pump (TDH) 59.46 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 83.84 hp
xiv) Brake Horsepower (bhp) (OEM Data) 106.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 134.05 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 79.09 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 62.54 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 9 hrs
xxi) Daily Pump flow 11,412 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,165,380 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 330,261 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,293,398 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 1,298 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.08 kWh/m3
xxix) Potential of Energy Reduction 2.28 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 7,524 kWh/yr
xxxi) Annual Financial Saving on Pumping 97,807 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 62.54%. For pump attached with 180 HP motor, efficiency between 59-63% is considered to be fair, . This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 64% (GOOD Efficiency range), with annual savings of 97,807PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,500 PKR
Install the New A meterA meter defective
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station KHAN VILLAGE P#3
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact AHMAD RAZA 0331 2700234
iv) Total Number of Pumps Installed 10
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 5
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 10
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 9 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 03
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KW PK 350-500 D2 Serial 17-7300
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 106 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 50
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 85
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 180 hp 134 kW
iii) Voltage Range 400 Volts
iv) Current 195.6 Amperes
v) Power Factor (Cos ɸ) 0.89
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 989 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 315 6B3
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 5909.9/1026.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 337.5 KVAr
Panel Condition/Issues Good, V&A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Good,
Housekeeping Fair
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,434 m3/hr 23.9 m3/min
Velocity in Pipe 4.01 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 41 meter
Electric Measurements Volt 360 359 360
Ampere 186 167 76
kW 97 Power Factor 0.82 0.83 0.82
vi) Motor Working on Loading Basis 72 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 989 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 41.45 ft
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viii) Total Dynamic Head of Pump (TDH) 68.45 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 109.14 hp
xiv) Brake Horsepower (bhp) (OEM Data) 106.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 130.03 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 102.96 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 83.94 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 9 hrs
xxi) Daily Pump flow 12,906 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,710,690 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 320,354 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,164,596 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 1,093 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.09 kWh/m3
11 Summary of Findings
Pumping system efficiency is 83.94%. For pump attached with 180 HP motor, efficiency above 69% is considered to be excellent. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
Install new A &VmeterA &V meter defective
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station KHAN VILLAGE P#5
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact AHMAD RAZA 0331 2700234
iv) Total Number of Pumps Installed 10
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 5
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 10
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 9 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 500
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 05
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KW PK 350-500 D2 Serial 17-7279
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 20 Cusec 2,040 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 132 BHP
ix) Speed (n) 985 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 50
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 85
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 200 hp 149 kW
iii) Voltage Range 400 Volts
iv) Current 231.5 Amperes
v) Power Factor (Cos ɸ) 0.87
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 991 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 315 6B3
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 5909.9/1026.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 337.5 KVAr
Panel Condition/Issues Good, V&A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Good,
Housekeeping Fair
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,567 m3/hr 26.117 m3/min
Velocity in Pipe 4.38 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 41 meter
Electric Measurements Volt 361 362 360
Ampere 222 208 227
kW 116 Power Factor 0.71 0.86 0.83
vi) Motor Working on Loading Basis 78 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 991 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 49.44 ft
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viii) Total Dynamic Head of Pump (TDH) 76.44 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 133.17 hp
xiv) Brake Horsepower (bhp) (OEM Data) 132.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 155.50 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 100.89 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 85.65 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 9 hrs
xxi) Daily Pump flow 14,103 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 5,147,595 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 383,103 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,980,342 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,189 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.10 kWh/m3
11 Summary of Findings
Pumping system efficiency is 85.65%. For pump attached with 200 HP motor, efficiency above 64% is considered to be excellent. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
Install the New A &VmeterA&V meter defective
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station KHAN VILLAGE P#9
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact AHMAD RAZA 0331 2700234
iv) Total Number of Pumps Installed 10
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 5
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 10
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 9 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 500
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 09
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KW PK 350-500 D2 Serial 17-7281
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 20 Cusec 2,040 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 132 BHP
ix) Speed (n) 985 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 50
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 85
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 200 hp 149 kW
iii) Voltage Range 400 Volts
iv) Current 231.5 Amperes
v) Power Factor (Cos ɸ) 0.87
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 991 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 315 6B3
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 5909.9/1026.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 337.5 KVAr
Panel Condition/Issues Good, V&A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Good,
Housekeeping Fair
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,470 m3/hr 24.5 m3/min
Velocity in Pipe 4.11 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 41 meter
Electric Measurements Volt 361 360 375
Ampere 203 210 213
kW 108 Power Factor 0.82 0.83 0.86
vi) Motor Working on Loading Basis 72 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 991 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 43.54 ft
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viii) Total Dynamic Head of Pump (TDH) 70.54 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 115.30 hp
xiv) Brake Horsepower (bhp) (OEM Data) 132.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 144.77 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 87.35 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 79.64 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 9 hrs
xxi) Daily Pump flow 13,230 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,828,950 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 356,682 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,636,870 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,200 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.09 kWh/m3
11 Summary of Findings
Pumping system efficiency is 79.64%. For pump attached with 200 HP motor, efficiency above 69% is considered to be excellent. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
No water flow meter Water flowmeter is recommended
Install the New A &VmeterA&V meter defective
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kot La Waris Shah
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact M ARIF 0300 7891759
iv) Total Number of Pumps Installed 1
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 1
vi) Operational Scheme of Pumps Qty
Independent 1
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 18 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 1.5 Cusec 153 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 6
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 6
ii) Length of Discharge Pipe (ft) 200
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 25 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 15 hp 11 kW not know about this value??
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 79733.7
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not Installed
Panel Condition/Issues Poor/Faulty A and V meter
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring poor
Housekeeping poor
Motor Terminal
Foundation/Civil work not Good
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 6 inches
v) Pipe Perimeter 479 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 140 m3/hr 2.3333 m3/min Estimated
Velocity in Pipe 2.13 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 62 meter
Electric Measurements Volt 403 383 395
Ampere 13.3 13.2 12.5
kW 6.9 Power Factor 0.76 0.7 0.72
vi) Motor Working on Loading Basis 62 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 25 ft
vi) Frictional Head (Suction and Discahrge) 15.40 ft
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viii) Total Dynamic Head of Pump (TDH) 30.40 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 4.73 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 9.25 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.16 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 2,520 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 919,800 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 45,576 kWh/yr
xxv) Annual Energy Expenditure on Pumping 592,489 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 54 %
xxvii) Water Flow after Efficiency Improvement 148 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 5.26 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 2,399 kWh/yr
xxxi) Annual Financial Saving on Pumping 31,183 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 51.16%. For pump attached with 15 HP motor, efficiency in between 48-54% is considered to be fair, . This pumping system requires impeller adjustment . After this adjustment its efficiency will be improved to 54% (GOOD Efficiency range), with annual savings of 31,183 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
Install ampere meterAmpere meter not working
No pressure guage Digital pressure guage is recommended
Voltmeter not working Install Voltmeter
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Madina Colony disp P-2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Mamoon Haider 0306-6269878
iv) Total Number of Pumps Installed 2
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 2
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 18 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 45 KVA
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 14
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 20 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 30 hp 22 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 2792.13
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 150 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N/A
Panel Condition/Issues FAIR, V & A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 325 m3/hr 5.4167 m3/min
Velocity in Pipe 0.70 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 20 meter
Electric Measurements Volt 417 430 415
Ampere 24 25 25
kW 12.3 Power Factor 0.67 0.7 0.66
vi) Motor Working on Loading Basis 55 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 20 ft
vi) Frictional Head (Suction and Discahrge) 1.19 ft
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viii) Total Dynamic Head of Pump (TDH) 16.19 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 5.85 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 16.49 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 35.49 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 5,850 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,135,250 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 81,244 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,056,176 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 60 %
xxvii) Water Flow after Efficiency Improvement 549 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.02 kWh/m3
xxix) Potential of Energy Reduction 40.85 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 33,186 kWh/yr
xxxi) Annual Financial Saving on Pumping 431,422 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 35.49%. For pump attached with 30 HP motor, efficiency below 52.1% is considered to be LOW, (Above 61.9% is EXCELLENT). This pumping system requires impeller adjustment,repair and maintenance. After this adjustment its efficiency will be improved to 60% (GOOD Efficiency range), with annual savings of 431,422 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 196,000 PKR
Install the New V&A meterDefective V & A meter
No pressure guage Digital pressure guage is recommended
PFI Plant not installed Install the 25 KVAr PFI plant
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Muzafarabad DISP P1
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact M AKBAR 0306 7301303
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model kw pk 150/135 D-2 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 40 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 31 BHP
ix) Speed (n) 1,450 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 6
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
18-4038
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 6
ii) Length of Discharge Pipe (ft) 100
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 24 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 40 hp 30 kW
iii) Voltage Range 400 Volts
iv) Current 56 Amperes
v) Power Factor (Cos ɸ) 0.85
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,485 RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1313.45
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not Available
Panel Condition/Issues Poor/Faulty A and V meter
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring Poor
Housekeeping Poor
Motor Terminal OK
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 6 inches
v) Pipe Perimeter 479 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 200 m3/hr 3.3333 m3/min Estimated
Velocity in Pipe 3.05 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 37 meter
Electric Measurements Volt 397
Ampere 35.4
kW 15.7 Power Factor 0.65
vi) Motor Working on Loading Basis 53 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 24 ft
vi) Frictional Head (Suction and Discahrge) 27.18 ft
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viii) Total Dynamic Head of Pump (TDH) 41.18 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 9.16 hp
xiv) Brake Horsepower (bhp) (OEM Data) 30.70 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 21.05 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 29.83 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 43.51 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 4,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,460,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 115,225 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,497,919 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 59 %
xxvii) Water Flow after Efficiency Improvement 271 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 26.25 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 30,248 kWh/yr
xxxi) Annual Financial Saving on Pumping 393,230 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 43.51%. For pump attached with 40 HP motor, efficiency below 52% is considered to be LOW, (Above 61% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 59% (GOOD Efficiency range), with annual savings of 393,230 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 211,000 PKR
No water flow meter Water flowmeter is recommended
PFI of 50 KVAR is recommended for the disposal stationNo PFI plant is installed
No pressure guage Digital pressure guage is recommended
Defective A and v meter Replacement of A and V meter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Muzafarabad DISP P2
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact M AKBAR 0306 7301303
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model kw pk 100/250 D-2 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 1.5 Cusec 153 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 50 BHP
ix) Speed (n) 1,450 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 4
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
17-6948
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 4
ii) Length of Discharge Pipe (ft) 200
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 24 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 20 hp 15 kW
iii) Voltage Range 400 Volts
iv) Current 28.3 Amperes
v) Power Factor (Cos ɸ) 0.85
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,462 RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 7121.002
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not Installed
Panel Condition/Issues Poor/Defective A and V meter
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring Poor
Housekeeping Poor
Motor Terminal Installed
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 4 inches
v) Pipe Perimeter 319 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 80 m3/hr 1.3333 m3/min Estimated
Velocity in Pipe 2.74 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 67 meter
Electric Measurements Volt 378 376 379
Ampere 20 19 17
kW 7 Power Factor 0.53 0.6 0.61
vi) Motor Working on Loading Basis 47 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 24 ft
vi) Frictional Head (Suction and Discahrge) 30.85 ft
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viii) Total Dynamic Head of Pump (TDH) 44.85 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 3.99 hp
xiv) Brake Horsepower (bhp) (OEM Data) 50.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 9.38 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 7.98 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 42.51 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.09 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 1,600 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 584,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 51,374 kWh/yr
xxv) Annual Energy Expenditure on Pumping 667,862 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 57 %
xxvii) Water Flow after Efficiency Improvement 107 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
xxix) Potential of Energy Reduction 25.42 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 13,057 kWh/yr
xxxi) Annual Financial Saving on Pumping 169,738 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 42.51%. For pump attached with 20 HP motor, efficiency below 48% is considered to be LOW, (Above 60% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 57% (GOOD Efficiency range), with annual savings of 169,738 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 111,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
Defective A and V meter Replacement of A and V meter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station OLD SHUJABAD P#1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M SALEEM 0307 7473356
iv) Total Number of Pumps Installed 6
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 6
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 630
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 1
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 18
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 315 S
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 292348/12058.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 750 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N / A
Panel Condition/Issues FAIR, V meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 18 inches
v) Pipe Perimeter 1,436 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 835 m3/hr 13.917 m3/min
Velocity in Pipe 1.41 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 21 meter
Electric Measurements Volt 410 399 396
Ampere 117 106 122
kW 45 Power Factor 0.47 0.57 0.58
vi) Motor Working on Loading Basis 48 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 4.88 ft
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viii) Total Dynamic Head of Pump (TDH) 39.88 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 37.03 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 60.32 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 61.39 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 16,700 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,095,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 330,261 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,293,398 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 864 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 3.33 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 10,993 kWh/yr
xxxi) Annual Financial Saving on Pumping 142,905 PKR/Yr
11 Summary of Findings
Pumping system efficiency is61.39 %. For pump attached with 125 HP motor, efficiency between 58-63% is considered to be fair. This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 63% (GOOD Efficiency range), with annual savings of 142,905 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 400,500 PKR
No water flow meter Water flowmeter is recommended
PFI of 150 KVAR is recommendedPFI plant not installed
No pressure guage Digital pressure guage is recommended
V meter defective install new V meter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station OLD SHUJABAD P#3
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M SALEEM 0307 7473356
iv) Total Number of Pumps Installed 6
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 6
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 630
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 3
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 18
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 54 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 315 S
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 292348/12058.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 750 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N / A
Panel Condition/Issues POOR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring POOR
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 18 inches
v) Pipe Perimeter 1,436 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 835 m3/hr 13.917 m3/min
Velocity in Pipe 1.41 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 21 meter
Electric Measurements Volt 398 394 393
Ampere 110 113 118
kW 49 Power Factor 0.67 0.59 0.66
vi) Motor Working on Loading Basis 53 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 54 ft
vi) Frictional Head (Suction and Discahrge) 4.88 ft
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viii) Total Dynamic Head of Pump (TDH) 48.88 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 45.39 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 65.68 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 69.10 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 16,700 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,095,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 359,618 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,675,034 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 773 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
11 Summary of Findings
Pumping system efficiency is 69%. For pump attached with 125 HP motor, efficiency above 64% is considered to be good. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 85,000 PKR
No pressure guage Digital pressure guage is recommended
No PIF plant is installed PFI of 150 KVAR is recommended for thr disposal station
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station OLD SHUJABAD P#4
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M SALEEM 0307 7473356
iv) Total Number of Pumps Installed 6
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 6
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 630
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 4
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 18
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 168 Amperes
v) Power Factor (Cos ɸ) 0.85
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 313 -6AA61
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 292348/12058.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 750 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N / A
Panel Condition/Issues FAIR, A meter faulty
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 888 m3/hr 14.8 m3/min
Velocity in Pipe 2.48 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 21 meter
Electric Measurements Volt 387 390 392
Ampere 188 177 164
kW 99 Power Factor 0.81 0.82 0.87
vi) Motor Working on Loading Basis 106 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 15.25 ft
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viii) Total Dynamic Head of Pump (TDH) 50.25 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 49.61 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 132.71 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 37.39 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.11 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 17,760 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,482,400 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 726,575 kWh/yr
xxv) Annual Energy Expenditure on Pumping 9,445,476 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,544 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 42.48 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 308,678 kWh/yr
xxxi) Annual Financial Saving on Pumping 4,012,811 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 37.39%. For pump attached with 125 HP motor, efficiency below 58% is considered to be LOW. This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 4,012,811 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,500 PKR
PFI of 150 KVAR is recommended for the disposal stationNo PFI plant is installed
No pressure guage Digital pressure guage is recommended
A meter faulty Install new A meter
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station OLD SHUJABAD P#5
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M SALEEM 0307 7473356
iv) Total Number of Pumps Installed 6
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 6
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 630
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 5
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 18
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 168 Amperes
v) Power Factor (Cos ɸ) 0.85
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 313 6AA61
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 292348/12058.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 750 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N / A
Panel Condition/Issues FAIR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring Fair
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 995 m3/hr 16.583 m3/min
Velocity in Pipe 2.78 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 21 meter
Electric Measurements Volt 391 393 394
Ampere 155 159 156
kW 88 Power Factor 0.81 0.82 0.84
vi) Motor Working on Loading Basis 94 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 19.13 ft
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viii) Total Dynamic Head of Pump (TDH) 54.13 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 59.88 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 117.96 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 50.76 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.09 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 19,900 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,263,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 645,845 kWh/yr
xxv) Annual Energy Expenditure on Pumping 8,395,979 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 1,254 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
xxix) Potential of Energy Reduction 20.68 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 133,563 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,736,320 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 50.76%. For pump attached with 125 HP motor, efficiency below 58% is considered to be low. This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 64% (GOOD Efficiency range), with annual savings of 1,736,320 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
No PFI plant is installed PFI of 150 KVAR is recommended for the disposal station
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station OLD SHUJABAD P#6
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M SALEEM 0307 7473356
iv) Total Number of Pumps Installed 6
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 6
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 630
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 6
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 20
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 18
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 168 Amperes
v) Power Factor (Cos ɸ) 0.85
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 313 6AA61
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 292348/12058.8
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 750 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N / A
Panel Condition/Issues GOOD,A meter defective
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,025 m3/hr 17.083 m3/min
Velocity in Pipe 2.87 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 21 meter
Electric Measurements Volt 394 397 392
Ampere 151 157 164
kW 90 Power Factor 0.9 0.85 0.84
vi) Motor Working on Loading Basis 97 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 20.29 ft
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viii) Total Dynamic Head of Pump (TDH) 55.29 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 63.02 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 120.64 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 52.23 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.09 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 20,500 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,482,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 660,523 kWh/yr
xxv) Annual Energy Expenditure on Pumping 8,586,796 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 1,256 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
xxix) Potential of Energy Reduction 18.38 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 121,426 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,578,542 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 52.23%. For pump attached with 125 HP motor, efficiency below 58% is considered to be LOW. This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 64% (GOOD Efficiency range), with annual savings of 1,578,542 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,500 PKR
No water flow meter Water flowmeter is recommended
PFI of 150 KVAR is recommended for the disposal stationNo PFI plant is installed
No pressure guage Digital pressure guage is recommended
A meter defective Install new A meter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Purana Baraf khana DISP P1
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact Shabir Hussain 0306 6692850
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 1
Submersible Disposal Pump Qty 2
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 1 Cusec 102 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 4
ii) Enter Length of Suction Pipe (ft) 40
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 4
ii) Length of Discharge Pipe (ft) 200
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 42 ft
Suction Side Elevation 20 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 10 hp 7 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 311.07
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 50 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not Available
Panel Condition/Issues Fair/Defective A & V meter
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring Fair
Housekeeping ok
Motor Terminal not Installed
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 4 inches
v) Pipe Perimeter 319 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 63 m3/hr 1.05 m3/min Estimated
Velocity in Pipe 2.16 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 73 meter
Electric Measurements Volt 386.4
Ampere 11.3
kW 5.1 Power Factor 0.64
vi) Motor Working on Loading Basis 68 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 20 ft
v) Static Discahrge Head 42 ft
vi) Frictional Head (Suction and Discahrge) 20.21 ft
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viii) Total Dynamic Head of Pump (TDH) 42.21 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 2.96 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 6.84 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 43.24 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 945 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 344,925 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 28,072 kWh/yr
xxv) Annual Energy Expenditure on Pumping 364,939 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 46 %
xxvii) Water Flow after Efficiency Improvement 67 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.08 kWh/m3
xxix) Potential of Energy Reduction 5.99 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 1,681 kWh/yr
xxxi) Annual Financial Saving on Pumping 21,859 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 43.24%. For pump attached with 10 HP motor, efficiency below 46% is considered to be LOW, (Above 57.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 53% (GOOD Efficiency range), with annual savings of 21,859 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 106,000 PKR
No water flow meter Water flowmeter is recommended
Install VoltmeterVoltmeter not Installed
No pressure guage Digital pressure guage is recommended
Ampere meter not installed install Ampere meter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Qadeerabad DISP P1
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact M Khalid 0300 6326675
iv) Total Number of Pumps Installed 2
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 2
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 12 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 8
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 6
ii) Length of Discharge Pipe (ft) 1000
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 20 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 25 hp 19 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 27613.5
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 25 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not Available
Panel Condition/Issues Poor/No A and V meter
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring poor
Housekeeping ok
Motor Terminal Not Installed
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 6 inches
v) Pipe Perimeter 479 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 106 m3/hr 1.7667 m3/min Estimated
Velocity in Pipe 1.61 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 314 meter
Electric Measurements Volt 395 394 397
Ampere 30 32 33
kW 4.7 Power Factor 0.21 0.31 0.33
vi) Motor Working on Loading Basis 25 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
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ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 20 ft
vi) Frictional Head (Suction and Discahrge) 20.61 ft
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viii) Total Dynamic Head of Pump (TDH) 30.61 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 3.61 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 6.30 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 57.25 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 12 hrs
xxi) Daily Pump flow 1,272 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 464,280 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 20,696 kWh/yr
xxv) Annual Energy Expenditure on Pumping 269,053 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 57 %
xxvii) Water Flow after Efficiency Improvement 106 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
11 Summary of Findings
Pumping system efficiency is 57.25%. For pump attached with 25 HP motor, efficiency above 57% is considered to be Good. This pumping system need no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 86,000 PKR
No water flow meter Water flowmeter is recommended
Install VoltmeterVoltmeter not Installed
No pressure guage Digital pressure guage is recommended
Ampere meter not installed Install Ampere meter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station QASIM BELA P#1
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact GHULAM RASOOL 0306 7373066
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 4
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 12 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 365
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 1
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 20
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 20
ii) Length of Discharge Pipe (ft) 60
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 30 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 183.62/731.51
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 150 KVAr
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 868 m3/hr 14.467 m3/min
Velocity in Pipe 2.43 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 27 meter
Electric Measurements Volt 406 407 408
Ampere 121 123 120
kW 69 Power Factor 0.78 0.76 0.75
vi) Motor Working on Loading Basis 76 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 30 ft
vi) Frictional Head (Suction and Discahrge) 14.80 ft
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viii) Total Dynamic Head of Pump (TDH) 39.80 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 38.41 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 92.49 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 41.52 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 12 hrs
xxi) Daily Pump flow 10,416 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,801,840 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 303,840 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,949,926 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,359 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 36.12 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 109,739 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,426,606 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 41%. For pump attached with 100 HP motor, efficiency below 54% is considered to be LOW, (Above 65.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,426,606 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 75,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station QASIM BELA P#2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact GHULAM RASOOL 0306 7373066
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 4
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 12 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 365
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 2
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 5 Cusec 510 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 20
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 20
ii) Length of Discharge Pipe (ft) 60
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 30 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 50 hp 37 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 183.62/731.51
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 150 KVAr
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 395 m3/hr 6.5833 m3/min
Velocity in Pipe 1.10 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 27 meter
Electric Measurements Volt 420
Ampere 51
kW 14.2 Power Factor 0.41
vi) Motor Working on Loading Basis 38 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 30 ft
vi) Frictional Head (Suction and Discahrge) 3.09 ft
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viii) Total Dynamic Head of Pump (TDH) 28.09 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 12.34 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 19.03 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 64.81 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 12 hrs
xxi) Daily Pump flow 4,740 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,730,100 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 62,529 kWh/yr
xxv) Annual Energy Expenditure on Pumping 812,883 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 396 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 0.29 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 181 kWh/yr
xxxi) Annual Financial Saving on Pumping 2,357 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 64%. For pump attached with 40 HP motor, Which is EXECELLENT
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 100,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station QASIM BELA P#3
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact GHULAM RASOOL 0306 7373066
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 4
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 12 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 365
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 3
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 20
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 20
ii) Length of Discharge Pipe (ft) 60
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 30 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 183.62/731.51
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 150 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 850 m3/hr 14.167 m3/min
Velocity in Pipe 2.38 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 27 meter
Electric Measurements Volt 404 405 406
Ampere 62 80 80
kW 53 Power Factor 0.79 0.99 0.9
vi) Motor Working on Loading Basis 71 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 30 ft
vi) Frictional Head (Suction and Discahrge) 14.19 ft
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viii) Total Dynamic Head of Pump (TDH) 39.19 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 37.04 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 71.05 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 52.13 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 12 hrs
xxi) Daily Pump flow 10,200 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,723,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 233,385 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,034,001 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,060 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 19.79 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 46,194 kWh/yr
xxxi) Annual Financial Saving on Pumping 600,528 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 52%. For pump attached with 100 HP motor, efficiency below 54% is considered to be LOW, (Above 65.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 600,528 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 100,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station QASIM BELA P#4
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact GHULAM RASOOL 0306 7373066
iv) Total Number of Pumps Installed 4
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 4
vi) Operational Scheme of Pumps Qty
Independent 4
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 12 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 365
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 4
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 5 Cusec 510 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 20
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 20
ii) Length of Discharge Pipe (ft) 60
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 30 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 50 hp 37 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 183.62/731.51
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 150 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 390 m3/hr 6.5 m3/min
Velocity in Pipe 1.09 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 27 meter
Electric Measurements Volt 398 397 396
Ampere 73 74 73
kW 48.3 Power Factor 0.77 0.78 0.76
vi) Motor Working on Loading Basis 129 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 30 ft
vi) Frictional Head (Suction and Discahrge) 3.01 ft
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viii) Total Dynamic Head of Pump (TDH) 28.01 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 12.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 64.75 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 18.76 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.12 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 12 hrs
xxi) Daily Pump flow 4,680 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,708,200 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 212,688 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,764,948 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,351 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 71.14 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 151,299 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,966,884 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 19% which is LOW. For 50 HP motor efficiency <52% is LOW and efficiency >63% is GOOD. This pumping system require motor replacement to increase its efficiency to 65% which is GOOD. This intervention will save Rs.1,966,884 annually.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 300,000 PKR
No pressure guage Digital pressure guage is recommended
Motor is inefficient Replacement of motor is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SAMEEJABAD DISP-P2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Syed Tufail Shah 0313-6056714
iv) Total Number of Pumps Installed 7
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 7
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details NA
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model 350-500 D2 Serial 17-7015
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) 52 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 140 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 40
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 34 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range 400 Volts
iv) Current 118 Amperes
v) Power Factor (Cos ɸ) 0.87
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 22493/1328
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 500 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 350 KVAR OPERATIONAL
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 710 m3/hr 11.833 m3/min
Velocity in Pipe 1.99 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 58 meter
Electric Measurements Volt 379
Ampere 106
kW 53 Power Factor 0.77
vi) Motor Working on Loading Basis 71 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 84
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 34 ft
vi) Frictional Head (Suction and Discahrge) 10.69 ft
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viii) Total Dynamic Head of Pump (TDH) 42.69 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 33.70 hp
xiv) Brake Horsepower (bhp) (OEM Data) 140.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 71.05 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 24.07 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 47.43 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 11,360 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,146,400 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 311,180 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,045,335 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 973 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 27.03 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 84,107 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,093,385 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 47.4%. For pump attached with 100 HP motor, efficiency below 57.3% is considered to be LOW, (Above 66.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,093,385 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 100,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SAMEEJABAD DISP-P4
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 7
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 7
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 04
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model 350-500 D2 Serial 17-7011
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 20 Cusec 2,040 m3/hr
vi) Head (H) 52 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 140 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 40
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 34 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 200 hp 149 kW
iii) Voltage Range 400 Volts
iv) Current 266 Amperes
v) Power Factor (Cos ɸ) 0.86
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 985 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 355-S
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 22493/1328
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 500 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 350 KVAR
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,140 m3/hr 19 m3/min
Velocity in Pipe 3.19 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 58 meter
Electric Measurements Volt 385 384 382
Ampere 177 178 174
kW 95 Power Factor 0.82 0.83 0.8
vi) Motor Working on Loading Basis 64 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 985 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 84
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 34 ft
vi) Frictional Head (Suction and Discahrge) 27.29 ft
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viii) Total Dynamic Head of Pump (TDH) 59.29 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 75.16 hp
xiv) Brake Horsepower (bhp) (OEM Data) 140.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 127.35 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 53.68 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 59.02 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 18,240 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,657,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 557,775 kWh/yr
xxv) Annual Energy Expenditure on Pumping 7,251,072 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,256 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.08 kWh/m3
xxix) Potential of Energy Reduction 9.20 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 51,337 kWh/yr
xxxi) Annual Financial Saving on Pumping 667,379 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 59%. For pump attached with 200 HP motor, efficiency in the range 59.1-63.8% is considered to be FAIR, (Above 69.4% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 667,389 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 100,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SAMEEJABAD DISP P5
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Syed Tufail Shah 0313-6056714
iv) Total Number of Pumps Installed 7
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 7
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 05
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model 350-500 D2 Serial 17-7010
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 20 Cusec 2,040 m3/hr
vi) Head (H) 52 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 140 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 40
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 34 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 200 hp 149 kW
iii) Voltage Range 400 Volts
iv) Current 266 Amperes
v) Power Factor (Cos ɸ) 0.86
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 985 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 355-S
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 22493/1328
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 500 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 350 KVAR
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,134 m3/hr 18.9 m3/min
Velocity in Pipe 3.17 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 58 meter
Electric Measurements Volt 391 381 381
Ampere 176 173 178
kW 97 Power Factor 0.84 0.84 0.81
vi) Motor Working on Loading Basis 65 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 985 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 84
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 34 ft
vi) Frictional Head (Suction and Discahrge) 27.01 ft
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viii) Total Dynamic Head of Pump (TDH) 59.01 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 74.40 hp
xiv) Brake Horsepower (bhp) (OEM Data) 140.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 130.03 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 53.14 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 57.22 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.09 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 18,144 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,622,560 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 569,517 kWh/yr
xxv) Annual Energy Expenditure on Pumping 7,403,727 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,288 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.08 kWh/m3
xxix) Potential of Energy Reduction 11.97 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 68,156 kWh/yr
xxxi) Annual Financial Saving on Pumping 886,031 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 57.22%. For pump attached with 200 HP motor, efficiency below 59.1% is considered to be LOW, (Above 69.4% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 886,031 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SAMEEJABAD DISP P-6
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Syed Tufail Shah 0313-6056714
iv) Total Number of Pumps Installed 7
v) Total Number of Pumps in Operation 4
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 7
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 06
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model 350-500 D2 Serial 17-7012
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 52 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 110 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 40
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 150
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 34 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 400 Volts
iv) Current 203 Amperes
v) Power Factor (Cos ɸ) 0.84
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 988 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-S
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 22493/1328
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 500 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 350 KVAR
Panel Condition/Issues EXCELLENT
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring EXCELLENT
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,050 m3/hr 17.5 m3/min
Velocity in Pipe 2.94 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 58 meter
Electric Measurements Volt 393
Ampere 172
kW 94 Power Factor 0.85
vi) Motor Working on Loading Basis 84 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 988 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 84
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 34 ft
vi) Frictional Head (Suction and Discahrge) 23.19 ft
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viii) Total Dynamic Head of Pump (TDH) 55.19 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 64.43 hp
xiv) Brake Horsepower (bhp) (OEM Data) 110.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 126.01 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 58.58 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.14 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.09 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 16,800 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,132,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 551,903 kWh/yr
xxv) Annual Energy Expenditure on Pumping 7,174,745 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,335 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
xxix) Potential of Energy Reduction 21.33 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 117,722 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,530,384 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 51.14%. For pump attached with 150 HP motor, efficiency below 58.1% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,5360,384 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SURAJ MIANI P#2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M RAMZAN 0301 7664361
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 24 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 500
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 2
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 20
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1718.52/491.42
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250*2 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 400 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 825 m3/hr 13.75 m3/min
Velocity in Pipe 1.77 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 15 meter
Electric Measurements Volt 433 434 432
Ampere 80 88 83
kW 56 Power Factor 0.87 0.9 0.89
vi) Motor Working on Loading Basis 60 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller 0 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 7.57 ft
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viii) Total Dynamic Head of Pump (TDH) 47.57 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 43.63 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 75.07 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 58.13 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 24 hrs
xxi) Daily Pump flow 19,800 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,227,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 493,190 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,411,475 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 63 %
xxvii) Water Flow after Efficiency Improvement 894 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 7.73 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 38,144 kWh/yr
xxxi) Annual Financial Saving on Pumping 495,868 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 58.13%. For pump attached with 125 HP motor, efficiency between 58-63% is considered to be fair, . This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 63% (GOOD Efficiency range), with annual savings of 495,868 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 85,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SURAJ MIANI P#3
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M RAMZAN 0301 7664361
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 24 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 500
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 3
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 20
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1718.52/491.42
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250*2 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 400 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 625 m3/hr 10.417 m3/min
Velocity in Pipe 1.75 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 15 meter
Electric Measurements Volt 440 433 437
Ampere 72 71 70
kW 32 Power Factor 0.76 0.85 0.8
vi) Motor Working on Loading Basis 34 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 7.45 ft
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viii) Total Dynamic Head of Pump (TDH) 47.45 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 32.98 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 42.90 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 76.88 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 24 hrs
xxi) Daily Pump flow 15,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 5,475,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 281,823 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,663,700 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 68 %
xxvii) Water Flow after Efficiency Improvement 553 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
11 Summary of Findings
Pumping system efficiency is 76%. For pump attached with 125 HP motor, efficiency above 69% is considered to be excellent. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 100,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SURAJ MIANI P#4
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M RAMZAN 0301 7664361
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 24 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 4
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 20
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1718.52/491.42
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250*2 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 400 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 811 m3/hr 13.517 m3/min
Velocity in Pipe 2.27 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 15 meter
Electric Measurements Volt 408 409 410
Ampere 106 110 116
kW 53 Power Factor 0.6 0.66 0.68
vi) Motor Working on Loading Basis 57 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 12.53 ft
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viii) Total Dynamic Head of Pump (TDH) 52.53 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 47.37 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 71.05 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 66.68 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 24 hrs
xxi) Daily Pump flow 19,464 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,104,360 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 466,769 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,068,003 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 63 %
xxvii) Water Flow after Efficiency Improvement 766 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
11 Summary of Findings
Pumping system efficiency is 66.68%. For pump attached with 125 HP motor, efficiency above 63% is considered to be good. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 100,000 PKR
No water flow meter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SURAJ MIANI P#6
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M RAMZAN 0301 7664361
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 24 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 500
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 6
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1718.52/491.42
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250*2 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 400 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 885 m3/hr 14.75 m3/min
Velocity in Pipe 2.48 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 431 427 434
Ampere 125 126 127
kW 79 Power Factor 0.7 0.74 0.72
vi) Motor Working on Loading Basis 85 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 15.03 ft
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viii) Total Dynamic Head of Pump (TDH) 55.03 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 54.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 105.90 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.14 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.09 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 24 hrs
xxi) Daily Pump flow 21,240 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,752,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 695,751 kWh/yr
xxv) Annual Energy Expenditure on Pumping 9,044,759 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 63 %
xxvii) Water Flow after Efficiency Improvement 1,090 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
xxix) Potential of Energy Reduction 18.83 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 131,028 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,703,358 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 51.14%. For pump attached with 125HP motor, efficiency below 58% is considered to be LOW. This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,703,358 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 85,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SURAJ MIANI P#8
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M RAMZAN 0301 7664361
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 24 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 500
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 8
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1718.52/491.42
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250*2 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 400 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 939 m3/hr 15.65 m3/min
Velocity in Pipe 2.63 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 419 420 422
Ampere 180 170 181
kW 113 Power Factor 0.97 0.98 0.97
vi) Motor Working on Loading Basis 121 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 16.92 ft
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viii) Total Dynamic Head of Pump (TDH) 56.92 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 59.42 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 151.47 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 39.23 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.12 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 24 hrs
xxi) Daily Pump flow 22,536 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 8,225,640 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 995,188 kWh/yr
xxv) Annual Energy Expenditure on Pumping 12,937,440 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 1,532 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
xxix) Potential of Energy Reduction 38.70 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 385,182 kWh/yr
xxxi) Annual Financial Saving on Pumping 5,007,372 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 39.23%. For pump attached with 125 HP motor, efficiency below 59% is considered to be LOW. This pumping system requires replacement of motor because motor is overloaded. After this adjustment its efficiency will be improved to 63% (GOOD Efficiency range), with annual savings of 5,007,372 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 300,000 PKR
No pressure guage Digital pressure guage is recommended
Motor is inefficient Replacement of motor is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station SURAJ MIANI P#9
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact M RAMZAN 0301 7664361
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 6
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 24 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 9
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 30
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 20
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 45 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1718.52/491.42
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1250*2 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 400 KVAr
Panel Condition/Issues GOOD
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring GOOD
Housekeeping OK
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 935 m3/hr 15.583 m3/min
Velocity in Pipe 2.62 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 15 meter
Electric Measurements Volt 423 425 430
Ampere 127 131 136
kW 67 Power Factor 0.7 0.76 0.8
vi) Motor Working on Loading Basis 72 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 45 ft
vi) Frictional Head (Suction and Discahrge) 16.64 ft
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viii) Total Dynamic Head of Pump (TDH) 56.64 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 58.89 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 89.81 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 65.57 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 24 hrs
xxi) Daily Pump flow 22,440 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 8,190,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 590,067 kWh/yr
xxv) Annual Energy Expenditure on Pumping 7,670,871 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 927 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.07 kWh/m3
11 Summary of Findings
Pumping system efficiency is 65.57%. For pump attached with 150 HP motor, efficiency above 63% is considered to be good. This pumping system requires no interventation.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 100,000 PKR
No pressure guage Digital pressure guage is recommended
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Taqi Shah DISP P1
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact M Ijaz Qamar 0307 4082080
iv) Total Number of Pumps Installed 2
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 2
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 50
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 1.5 Cusec 153 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 6
ii) Enter Length of Suction Pipe (ft) 5
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 10
ii) Length of Discharge Pipe (ft) 720
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 30 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 15 hp 11 kW
iii) Voltage Range 400 Volts
iv) Current 21 Amperes
v) Power Factor (Cos ɸ) 0.86
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,460 RPM
vii) Reference Frequency Hz
viii) Insulation Class F
ix) Motor Frame Size 160
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading DEFECTIVE METER
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 50 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not Installed
Panel Condition/Issues Fair/ Defective A and V meter
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring Fair
Housekeeping poor
Motor Terminal Installed
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches
v) Pipe Perimeter 798 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 142 m3/hr 2.3667 m3/min Estimated
Velocity in Pipe 0.78 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 221 meter
Electric Measurements Volt 402 405 404
Ampere 18 17 17
kW 10 Power Factor 0.78 0.78 0.82
vi) Motor Working on Loading Basis 89 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 30 ft
vi) Frictional Head (Suction and Discahrge) 2.88 ft
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viii) Total Dynamic Head of Pump (TDH) 22.88 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 3.61 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 13.40 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 26.94 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 2,130 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 777,450 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 55,044 kWh/yr
xxv) Annual Energy Expenditure on Pumping 715,566 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 54 %
xxvii) Water Flow after Efficiency Improvement 285 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 50.10 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 27,579 kWh/yr
xxxi) Annual Financial Saving on Pumping 358,529 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 27%. For pump attached with 15 HP motor, efficiency below 47% is considered to be LOW, (Above 57% is GOOD). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 57% (GOOD Efficiency range), with annual savings of 358,529.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 101,000 PKR
No pressure guage Digital pressure guage is recommended
A&V meter defective Install new A&V meter
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Vihari Road DISP P2
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Khan Muhammad 0306-9550360
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 9
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 14 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model KVP 350-500 D2 Serial 16-8577
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 76 BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 21
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 20
ii) Length of Discharge Pipe (ft) 100
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 6 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 17471/2.90
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1000,750 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 710 KVAR NON-OPERATIONAL
Panel Condition/Issues POOR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring POOR
Housekeeping FAIR
Motor Terminal OPEN AND LOSE MOTOR CONNECTIONS
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 20 inches
v) Pipe Perimeter 1,595 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 882 m3/hr 14.7 m3/min
Velocity in Pipe 1.21 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 37 meter
Electric Measurements Volt 413 412 415
Ampere 106 108 77
kW 42 Power Factor 0.5 0.55 0.6
vi) Motor Working on Loading Basis 45 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.9
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 6 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 3.66 ft
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viii) Total Dynamic Head of Pump (TDH) 29.66 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 29.09 hp
xiv) Brake Horsepower (bhp) (OEM Data) 76.30 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 56.30 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 38.13 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.67 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 14 hrs
xxi) Daily Pump flow 12,348 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,507,020 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 215,771 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,805,020 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,110 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 20.51 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 44,250 kWh/yr
xxxi) Annual Financial Saving on Pumping 575,245 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 51.67%. For pump attached with 125 HP motor, efficiency below 58% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 575,245 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 801,000 PKR
No water flow meter Water flowmeter is recommended
A and V meter is recommendedA meter is faulty and V meter is not available
No pressure guage Digital pressure guage is recommended
Defective PFI plant PFI of 350 KVAR is recommended for disposal station
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Vihari Road DISP P-3
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Khan Muhammad 0306-9550360
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 9
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 14 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 03
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 21
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 20
ii) Length of Discharge Pipe (ft) 100
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 6 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 17471/2.90
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1000,750 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 710 KVAR NON-OPERATIONAL
Panel Condition/Issues POOR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring POOR
Housekeeping FAIR
Motor Terminal OPEN AND LOOSE MOTOR CONNECTIONS
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 20 inches
v) Pipe Perimeter 1,595 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 960 m3/hr 16 m3/min
Velocity in Pipe 1.32 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 37 meter
Electric Measurements Volt 385
Ampere 76
kW 48 Power Factor 0.96
vi) Motor Working on Loading Basis 51 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.9
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 6 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 4.34 ft
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viii) Total Dynamic Head of Pump (TDH) 30.34 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 32.38 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 64.34 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 50.33 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 14 hrs
xxi) Daily Pump flow 13,440 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,905,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 246,595 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,205,737 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,240 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 22.58 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 55,670 kWh/yr
xxxi) Annual Financial Saving on Pumping 723,708 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 50.33%. For pump attached with 125 HP motor, efficiency below 57% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 723,708 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
No water flow meter Water flowmeter is recommended
A and V meter is recommendedA meter is faulty and V meter is not available
No pressure guage Digital pressure guage is recommended
PFI plant is not working PFI of 350 KVAR is recommended for disposal station
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Vihari Road DISP P-4
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Khan Muhammad 0306-9550360
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 9
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 04
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model KVP 350/500 D2 Serial 16 - 8578
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 76 BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 21
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 32
ii) Length of Discharge Pipe (ft) 100
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 6 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 17471/2.90
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1000,750 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 710 KVAR NON-OPERATIONAL
Panel Condition/Issues FAIR/Faulty A and V meter
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring FAIR
Housekeeping FAIR
Motor Terminal NO TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 20 inches
v) Pipe Perimeter 1,595 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 980 m3/hr 16.333 m3/min
Velocity in Pipe 1.34 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 37 meter
Electric Measurements Volt 386 385 388
Ampere 116 104 83
kW 52 Power Factor 0.72 0.72 0.77
vi) Motor Working on Loading Basis 56 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.9
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 6 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 4.52 ft
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viii) Total Dynamic Head of Pump (TDH) 30.52 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 33.25 hp
xiv) Brake Horsepower (bhp) (OEM Data) 76.30 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 69.71 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 43.58 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 47.71 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 14,700 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 5,365,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 286,227 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,720,945 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,335 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 26.61 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 76,151 kWh/yr
xxxi) Annual Financial Saving on Pumping 989,969 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 47.7%. For pump attached with 125 HP motor, efficiency below 57% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this intervention its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 989,969 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 101,000 PKR
No water flow meter Water flowmeter is recommended
A and V meter is recommendedA meter is faulty and V meter is not available
No pressure guage Digital pressure guage is recommended
Defective PFI PFI of 350 KVAR is recommended for the disposal station
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Vihari Road DISP P-6
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Khan Muhammad 0306-9550360
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 9
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 06
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model KVP 350/500 D2 Serial 16 - 8579
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 76 BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 21
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 32
ii) Length of Discharge Pipe (ft) 100
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 6 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 17471/2.90
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1000,750 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 710 KVAR NON-OPERATIONAL
Panel Condition/Issues FAIR/Faulty A and V meter
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 32 inches
v) Pipe Perimeter 2,552 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,020 m3/hr 17 m3/min
Velocity in Pipe 0.55 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 37 meter
Electric Measurements Volt 400 397 400
Ampere 125 124 131
kW 59 Power Factor 0.7 0.7 0.77
vi) Motor Working on Loading Basis 63 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.9
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 6 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 0.73 ft
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viii) Total Dynamic Head of Pump (TDH) 26.73 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 30.31 hp
xiv) Brake Horsepower (bhp) (OEM Data) 76.30 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 79.09 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 39.73 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 38.33 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 15,300 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 5,584,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 324,757 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,221,841 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,730 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.03 kWh/m3
xxix) Potential of Energy Reduction 41.03 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 133,248 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,732,227 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 38.3%. For pump attached with 125 HP motor, efficiency below 57% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,732,227 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 101,000 PKR
A and V meter is recommendedA meter is faulty and V meter is not available
No pressure guage Digital pressure guage is recommended
PFI plant is not working PFI of 350 KVAR is recommended for the disposal station
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Vihari Road DISP P-7
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Khan Muhammad 0306-9550360
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 9
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 18 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 07
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model KVP 350/500 D2 Serial 17 - 6584
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 102 BHP
ix) Speed (n) 738 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 21
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 32
ii) Length of Discharge Pipe (ft) 100
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 6 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 17471/2.90
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1000,750 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 710 KVAR NON-OPERATIONAL
Panel Condition/Issues POOR/NO V meter
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring POOR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 20 inches
v) Pipe Perimeter 1,595 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 980 m3/hr 16.333 m3/min
Velocity in Pipe 1.34 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 37 meter
Electric Measurements Volt 409 405 405
Ampere 132 140 134
kW 52 Power Factor 0.5 0.53 0.5
vi) Motor Working on Loading Basis 56 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.9
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 6 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 4.52 ft
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viii) Total Dynamic Head of Pump (TDH) 30.52 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 33.25 hp
xiv) Brake Horsepower (bhp) (OEM Data) 102.20 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 69.71 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 32.54 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 47.71 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 17,640 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,438,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 343,472 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,465,134 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,335 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 26.61 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 91,382 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,187,963 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 47.7%. For pump attached with 125 HP motor, efficiency below 57% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 1,187,963 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,500 PKR
No water flow meter Water flowmeter is recommended
PFI of 350 KVAR is recommended the disposal stationPFI plant is not working
No pressure guage Digital pressure guage is recommended
V meter is not available V meter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Vihari Road DISP P-9
ii) Name of Subdivision DISPOSAL DIVISION
iii) Operator Name & Contact Khan Muhammad 0306-9550360
iv) Total Number of Pumps Installed 9
v) Total Number of Pumps in Operation 6
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 9
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 9
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 21 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 09
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model KVP 350/500 D2 Serial 17 - 6586
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 15 Cusec 1,530 m3/hr
vi) Head (H) 50 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 102 BHP
ix) Speed (n) 738 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 18
ii) Enter Length of Suction Pipe (ft) 21
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 32
ii) Length of Discharge Pipe (ft) 100
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 32 ft
Suction Side Elevation 6 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 125 hp 93 kW
iii) Voltage Range 400 Volts
iv) Current 174.2 Amperes
v) Power Factor (Cos ɸ) 0.82
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 740 RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class F
ix) Motor Frame Size 315-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 17471/2.90
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 1000,750 KVA Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 710 KVAR NON-OPERATIONAL
Panel Condition/Issues POOR
Gland Leakage NA
Non Return Valve NA
Flow Meter NA
Pressure Gauge NA
Wiring POOR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 32 inches
v) Pipe Perimeter 2,552 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,020 m3/hr 17 m3/min
Velocity in Pipe 0.55 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 37 meter
Electric Measurements Volt 403
Ampere 140
kW 61 Power Factor 0.6
vi) Motor Working on Loading Basis 65 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 740 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.9
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 6 ft
v) Static Discahrge Head 32 ft
vi) Frictional Head (Suction and Discahrge) 0.73 ft
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viii) Total Dynamic Head of Pump (TDH) 26.73 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 30.31 hp
xiv) Brake Horsepower (bhp) (OEM Data) 102.20 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 81.77 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 29.66 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 37.07 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 21 hrs
xxi) Daily Pump flow 21,420 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,818,300 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 470,072 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,110,937 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 1,788 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.03 kWh/m3
xxix) Potential of Energy Reduction 42.96 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 201,960 kWh/yr
xxxi) Annual Financial Saving on Pumping 2,625,477 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 37.07%. For pump attached with 125 HP motor, efficiency below 54% is considered to be LOW, (Above 68.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance. After this adjustment its efficiency will be improved to 65% (GOOD Efficiency range), with annual savings of 2,625,477 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
Estimated Investment for Improvement Plan 100,500 PKR
No water flow meter Water flowmeter is recommended
V meter is recommended V meter is not available
No pressure guage Digital pressure guage is recommended
PFI plant is not working PFI is recommended for disposal station
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Wahid ABAD DISP P1
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact Nabeel 0303 5408772
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 18 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 50
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model kw p 150/315 D-2 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 1.5 Cusec 153 m3/hr
vi) Head (H) 25 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 6 BHP
ix) Speed (n) 960 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 6
ii) Enter Length of Suction Pipe (ft) 25
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
16-8425
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 6
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 27 ft
Suction Side Elevation 5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 40 hp 30 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1383.58
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Installed 150 KVAR
Panel Condition/Issues poor/Faulty A and V meter
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring poor
Housekeeping fair
Motor Terminal Installed
Foundation/Civil work OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 6 inches
v) Pipe Perimeter 479 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 135 m3/hr 2.25 m3/min Estimated
Velocity in Pipe 2.06 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 17 meter
Electric Measurements Volt 418 419 417
Ampere 20 22 23
kW 13.8 Power Factor 0.84 0.89 0.88
vi) Motor Working on Loading Basis 46 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 5 ft
v) Static Discahrge Head 27 ft
vi) Frictional Head (Suction and Discahrge) 11.10 ft
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viii) Total Dynamic Head of Pump (TDH) 33.10 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 4.97 hp
xiv) Brake Horsepower (bhp) (OEM Data) 6.10 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 18.50 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 81.46 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 26.86 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.10 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 2,430 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 886,950 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 91,152 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,184,978 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 59 %
xxvii) Water Flow after Efficiency Improvement 297 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 54.47 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 49,654 kWh/yr
xxxi) Annual Financial Saving on Pumping 645,503 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 26%. For 1.5 cusec pump 10 HP motor is recommended. Installed motor is 40 HP which is oversize and needs to be replaced. This replacement will save 645,503 Rs annually.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 201,000 PKR
Oversize motor
Install VoltmeterVoltmeter not working
No pressure guage Digital pressure guage is recommended
Proper size motor is recommended
Ampere meter not working install Ampere meter
No water flow meter Water flowmeter is recommended
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Wahidabad Disposal
ii) Name of Subdivision DISPOSAL DIVISION MULTAN
iii) Operator Name & Contact Nabeel 0303 5408772
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 18 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details 50
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model kw p 100/250 D-2 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 40 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 13 BHP
ix) Speed (n) 1,450 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 5
ii) Enter Length of Suction Pipe (ft) 22
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
18-4035
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 6
ii) Length of Discharge Pipe (ft) 10
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 27 ft
Suction Side Elevation 10 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 20 hp 15 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1383.58
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant N/A
Panel Condition/Issues poor,V meter Faulty
Gland Leakage
Non Return Valve
Flow Meter Not Available
Pressure Gauge Not Available
Wiring poor
Housekeeping fair
Motor Terminal Installed
Foundation/Civil work not Good
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 5 inches
v) Pipe Perimeter 399 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 140 m3/hr 2.3333 m3/min Estimated
Velocity in Pipe 3.07 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 10 meter
Electric Measurements Volt 420 419 421
Ampere 21 22 19
kW 11.63 Power Factor 0.77 0.76 0.75
vi) Motor Working on Loading Basis 78 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 10 ft
v) Static Discahrge Head 27 ft
vi) Frictional Head (Suction and Discahrge) 23.89 ft
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viii) Total Dynamic Head of Pump (TDH) 40.89 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 6.37 hp
xiv) Brake Horsepower (bhp) (OEM Data) 13.48 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 15.59 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 47.22 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 40.83 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 2,520 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 919,800 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 76,819 kWh/yr
xxv) Annual Energy Expenditure on Pumping 998,644 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 57 %
xxvii) Water Flow after Efficiency Improvement 195 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.06 kWh/m3
xxix) Potential of Energy Reduction 28.37 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 21,795 kWh/yr
xxxi) Annual Financial Saving on Pumping 283,335 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 40%. For pump attached with 20 HP motor, efficiency below 44% is considered to be LOW, (Above 60.9% is EXCELLENT). This pumping system requires impeller adjustment, repair and maintenance . After this adjustment its efficiency will be improved to 57% (GOOD Efficiency range), with annual savings of 283,335 PKR.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 160,500 PKR
PFI plant of 25 KVAR is recommendedNo PFI plant is installed
No pressure guage Digital pressure guage is recommended
Voltmeter not working Install Voltmeter
No water flow meter Water flowmeter is recommended
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ANNEXURE-2
Selected Pictures
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Poor panel condition at Advag Vera
View of motor and pump at Advag Vera
Poor panel at Agha Pura View of pump at Chungi No.9
Outdated pump at Chungi No.9 Poor electric wiring at Kerri Jamandad
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Poor wiring at KeeriJamandad
Poor Panel condition at KeeriJamandad
View of motor at PuranaBarafKhana Poor electric wiring at Qadirabad
.
View of motor at Qadirabad Poor wiring at SurajMiani
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Poor wiring at SurajMiani Poor wiring at TotaTakki Shah
Poor panel at Vehari Road disposal Poor panel at Vehari Road disposal
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.
Poor panel at Wahidabad View of pump foundation at Wahidabad