energy audit & energy efficiency improvement program for...

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Punjab Cities Governance Improvement Project

Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab

REPORT Islampura Subdivision, Lahore

September 2015

NEC Consultants (Pvt.) Ltd.

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Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab

September 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 11 2.3 Pumping system efficiency improvement potential 12 2.4 Interventions for the improvement of WASA stations 13

LIST OF ANNEXURE

I Energy Audit Reports 2 Selected Pictures

LIST OF FIGURES

I Pumping system efficiency category 11 2 Unit electricity consumption trend 12

LIST OF TABLES

1 Detail of WASAs pumps 8 2 Detail of Islampura subdivision 9 3 Typical overall pumping system efficiency classification 10 4 Detail of motor loading and pumping system efficiency 10 5 Detail of water discharge and electricity consumption 11 6 System energy efficiency potential of pumps 13

7A Interventions & investment required in WASA stations-Islampura Subdivision 14

7B Interventions & investment required in WASA stations-Islampura Subdivision 16

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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 LESCO Lahore Electric Supply 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 Losses

Energy losses associated with moving water against rough 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 The ratio of the water horsepower (the overall output of the plant)

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or Pumping System Efficiency

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 Islampura Subdivision of Lahore city. 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 23 WASA water supply stations and 02 wastewater disposal pumps in Islampura Subdivision. The detail of these stations along with pumps installed capacity and actual discharge is given in Table-2:

Table-2: Detail of Islampura Subdivision

# WASA Station

No. of Water Supply Pumps

Installed

Installed Capacity (Cusec)

Actual Discharge (Cusec)

1 Rewaz Garden 01 4.0 3.91 2 Raj Garh Muslim Town 01 2.0 1.56 3 Bilal Park 01 4.0 2.35 4 Sodiwal Quarter 01 2.0 1.71 5 Rustam Park 01 4.0 3.43 6 Firdous Colony 01 4.0 2.30 7 Takia Mahmood Shah 01 2.0 2.60 8 E Block Gulshan Ravi 01 4.0 3.70 9 Moon Market 01 4.0 2.05 10 Sanda Patwar Khana 01 2.0 1.94 11 A Block Gulshan Ravi 01 4.0 2.74 12 Jahangir Park 01 4.0 3.87 13 Raffle Range 01 4.0 2.89 14 Zubair Park 01 4.0 2.64 15 B Block Gulshan Ravi 01 2.0 1.17 16 Malik Munir Park 01 4.0 3.57 17 Nonarian 01 4.0 3.67 18 Sodi Wal Park 01 4.0 1.91 19 Shaira Kot 01 2.0 1.56 20 Babu Sabu Dispensary 01 4.0 4.31 21 G Block Gulshan Ravi 01 4.0 2.89 22 Usman Park 01 4.0 4.06 23 Zubair Park Raj Garh 01 4.0 3.91 Total 23 80.0 64.74 Wastewater Disposal Pumps

24 Fazal Colony Disposal-01 01 2.0 1.96 25 Fazal Colony Disposal-02 01 2.0 2.0 Total 02 4.0 3.96

The installed capacity of WASA tube wells of Islampura Subdivision is 47.65 million m3 per annum whereas actual discharge is 38.56 million m3 per annum, for average 16 hours per day operation and 365 days per year. This actual discharge is about 19% lesser than the installed capacity. The installed capacity of WASA disposal pumps of Islampura Subdivision is 1.78 million m3 per annum whereas actual discharge is 1.76 million m3 per annum, for average 12 hours per day operation and 365 days per year. This actual discharge is about 1% lesser than the installed capacity.

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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 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.

Table-4: Detail of Motor Loading and Pumping System Efficiency

WASA Station Motor Load (%)

Pumping System Efficiency (%)

Pumping System Efficiency Rating

Rewaz Garden 83 73 EXCELLENT Takia Mahmood Shah 79 83 EXCELLENT A Block Gulshan Ravi 45 84 EXCELLENT B Block Gulshan Ravi 32 74 EXCELLENT Usman Park 85 71 EXCELLENT Jahangir Park 84 64 GOOD Babu Sabu Dispensary 88 67 GOOD Raj Garh Muslim Town 62 58 FAIR E Block Gulshan Ravi 88 56 FAIR Raffle Range 70 59 FAIR Nonarian 81 61 FAIR G Block Gulshan Ravi 67 60 FAIR Bilal Park 64 43 LOW Sodiwal Quarter 79 51 LOW Rustam Park 144 27 LOW Firdous Colony 57 50 LOW Moon Market 85 32 LOW Sanda Patwar Khana 88 52 LOW Zubair Park 79 48 LOW Malik Munir Park 89 47 LOW Sodi Wal Park 47 53 LOW Shaira Kot 85 42 LOW Zubair Park Raj Garh 87 54 LOW

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Disposal Pumps Fazal Colony Disposal-02 74 59 GOOD Fazal Colony Disposal-01 78 53 FAIR About 30% of the tube wells are under excellent and good category of pumping system efficiency whereas 70% are under fair and low category as illustrated in Fig-1.

Figure-1: Pumping System Efficiency Category

About 50% each of all the operational disposal pumps are under good and fair category of pumping system efficiency. 2.2 Electricity Consumption Trend The detail of annual water discharge and correspondingly electricity consumption and unit electricity consumption of each WASA 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 Rewaz Garden 2,330,160 541,335 0.23 2 Raj Garh Muslim Town 934,400 220,174 0.23 3 Bilal Park 1,401,600 413,517 0.29 4 Sodiwal Quarter 1,022,000 277,713 0.27 5 Rustam Park 2,044,000 951,453 0.46 6 Firdous Colony 1,372,400 375,177 0.27 7 Takia Mahmood Shah 1,553,440 277,126 0.17 8 E Block Gulshan Ravi 2,069,550 549,885 0.26 9 Moon Market 1,303,050 599,498 0.46

10 Sanda Patwar Khana 1,011,780 273,310 0.27 11 A block Gulshan Ravi 1,533,000 280,722 0.18 12 Jahangir Park 2,306,800 544,271 0.23 13 Raffle Range 1,722,800 462,660 0.26 14 Zubair Park 1,773,900 585,884 0.33

Excellent 22%

Good 8%

Fair 22%

Low 48%

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15 B Block Gulshan Ravi 657,000 106,234 0.16 16 Malik Munir Park 2,398,050 660,523 0.27 17 Nonarian 2,463,750 601,736 0.24 18 Sodi Wal Park 1,138,800 313,528 0.27 19 Shaira Kot 876,000 280,172 0.31 20 Babu Sabu Dispensary 2,730,200 617,963 0.22 21 G Block Gulshan Ravi 1,615,125 419,047 0.25 22 Usman Park 2,272,125 526,547 0.23 23 Zubair Park Raj Garh 2,330,160 571,279 0.24 Total 38,860,090 10,449,754 0.26 Disposal Pumps

24 Fazal Colony Disposal-01 1,314,000 76,621 0.05 25 Fazal Colony Disposal-02 1,340,280 73,054 0.05 Total 2,654,280 149,675 0.05 Total annual energy cost of Islampura subdivision is about Rs. 138 million. The unit electricity consumption trend for each WASA station is illustrated in Fig-2. From figure, it is clear that 0.20 kWh/m3 is considered to be optimum figure for water supply pumps. This figure is based on NEC experience of conducting water turbine audits of different industries. WASA audits also reflect the similar figure.

Figure-2: Unit Electricity Consumption Trend

About 87% of the tube wells consume electricity more than the 0.20 kWh/m3. In case if all the 23 tube wells consume optimum electricity, then annually Rs. 35 million (26%) can be saved. 2.3 Pumping System Efficiency Improvement Potential The 16 tube wells and 01 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.

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

kWh/m3

Optimum

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Table-6: System Energy Efficiency Potential of Pumps

WASA Station Existing Pumping Efficiency

(%)

Improved Pumping Efficiency

(%)

Annual

(kWh)

Saving

(Rs)

Impeller

Adjustment /Repair &

Maintenance

Intervention

Motor Replace

Pump Replace

Raj Garh Muslim Town

58 65 23,061 299,789 ×

Bilal Park 43 65 139,698 1,816,075 × Sodiwal Quarter 51 65 60,878 791,418 × Rustam Park 27 65 557,507 7,247,597 × Firdous Colony 50 65 87,036 1,131,465 × E Block Gulshan Ravi

56 65 73,765 958,943 ×

Moon Market 32 65 304,122 3,953,591 × Sanda Patwar Khana

52 65 56,424 733,514 ×

Raffle Range 59 65 44,719 581,341 × Zubair Park 47 65 157,910 2,052,827 × Malik Munir Park

47 65 182,066 2,366,861 ×

Nonarian 61 65 35,448 460,821 × Sodi Wal Park 53 65 56,043 728,557 × Shaira Kot 42 65 98,721 1,283,374 × G Block Gulshan Ravi

60 65 30,634 398,238 ×

Zubair Park Raj Garh

54 65 93,793 1,219,306 ×

Fazal Colony Disposal-01

53 57 4,908 63,806 ×

Total 2,006,733 26,087,523 2.4 Interventions for the Improvement of WASA Stations Energy audit activity of Islampura subdivision 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 station for better, efficient and safe operation of WASA station. About Rs. 19.73 million are required to improve WASA stations of Islampura subdivision, Lahore.

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Table-7A: Interventions & Investment Required in WASA Stations- Islam Pura Subdivision

Intervention WASA Stations Rewaz Muslim

Town Bilal Park

Sodiwal Quart.

Rustom Firdous Takia Mahm.

E Block

Moon Sanda Patwar

G Block

A Block Jahangir

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 Rewaz Muslim

Town Bilal Park

Sodiwal Quart.

Rustom Firdous Takia Mahm.

E Block

Moon Sanda Patwar

G Block

A Block Jahangir

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)

0.86 0.48 0.84 0.48 0.80 0.74 0.44 0.80 3.7 0.74 0.83 0.74 0.74

Annual Saving (M. Rs) 0.29 1.8 0.79 7.2 1.1 0.95 3.9 0.73 0.39 Payback (Year) 1.65 0.46 0.60 0.11 0.84 0.94 1.01 2.12

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Table-7B: Interventions & Investment Required in WASA Stations- Islam Pura Subdivision Intervention WASA Stations Raffle Zubair

Park B

Block Malik Munir

Usman Nonarian Zubair Raj

Sodi Park

Shera Kot

Babu Sabu

Fazal Disp-

01

Fazal Disp-

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 Raffle Zubair

Park B

Block Malik Munir

Usman Nonarian Zubair Raj

Sodi Park

Shera Kot

Babu Sabu

Fazal Disp-

01

Fazal Disp-

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)

0.74 0.75 0.45 0.85 0.78 0.80 0.74 0.77 0.53 0.83 0.15 0.15

Annual Saving (M. Rs) 0.58 2.0 2.3 0.46 1.2 0.72 1.2 0.06 Payback (Year) 1.27 0.37 0.36 1.73 0.61 1.06 0.44 2.5 Total Investment of Subdivision (M.Rs) = 19.73

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ANNEXURE-1

Energy Audit Reports

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 REWAZ GARDEN

ii) Name of Subdivision ISLAM PURA

iii) Operator Name & Contact

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 1

Submersible Deep Well Water Turbine Pumps Qty

Centrifugal 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 16 hrs/day

ix) Annual Working Days 365 days

x) Source of Power

Energy Report of WASA Pumps

Primary LESCO Secondary

xi) In Case of Secondary Power Source Fuel Data Details

xii) Operational Hours of Secondary Power Source hrs/day

xiii) Availability of Chlorinator

Yes No

2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)

i) Type of Pump Deep Well

Submersible

Overhung

Between Bearing

ii) Mounting / Erection

Horizontal Vertical

Foundation

iii) Concrete Bolted Bolted

iv) Lubrication Type

Oil Water

v) Cooling Type

Water Cooled Air Cooled

vi) Number of Stages

Single Multi 4

vii) Pump and Motor Assembly

Direct Coupled Belt / Gear

viii) Source of Suction

Ground Water Aquafier Overhead Tank Underground Tank

Pressurized Source

ix) Pump Discharge Destination

Overhead Tank Drain On Ground Reservoir

Fresh Water Supply Network

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

NOT OPERATIONAL

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 Pumps Country Pakistan

ii) ModelB14B/4

Serial

iii) Certification Mark

iv) Year of Manufacture

v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft

vii) Discharge Pressure (P) Psig

viii) Power / HP / BHP 124.6

BHP

ix) Speed (n)1450

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) (Not Valid incase of Tubewells)

ii) Enter Length of Suction Pipe (ft) (Not Valid incase of Tubewells)

iii) Enter Fittings on Suction Pipe (Not Valid incase of Tubewells)

Fitting Type 1 Qty Type 2 Qty Type 3 Qty

Valves Foot Valve 1

Bends

Strainer 1

iv) Storage Capacity of Suction Source (Aquafier)

v) Working Volume of Source

vi) Suction Lift (from Datum Line)

viii) Availbility of Pressure Gauge Yes No

ix) Suction Pressure (Not Valid incase of Tubewells)

Discharge Side

Pipe Material of Construction MS Pipe

i) Diameter of Discharge Pipe 10 inch

ii) Length of Discharge Pipe (Not known as directly connected to network underground)

iii) Fittings on Discharge Pipe


Valves Control 1 Check 1

Bends Elbow 1

Strainer

iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))

v) Working Volume of Discharge Destination (Not known as directly connected to network underground))

vi) Discharge Elevation (from Datum Line) (In case of no gauge)

vii) Availbility of Pressure Gauge Yes No (Installed by Team)

viii) Discharge Pressure NA psig

6 Motor Nameplate Data

i) Manufacturer Siemens

ii) Rated kW / hp 150 hp 112.5 kW

iii) Voltage Range (Volts) 380 Volts

iv) Current (Ampere) 209

v) Power Factor (Cos ɸ) 0.86

Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed 1,485 RPM

vii) Reference Frequency 50 C/S

viii) Insulation Class F

ix) Motor Frame Size 315 S

x)

7 Electrical System Observations

i) Electrical Meter Reference Number

ii) Meter Reading 5020

iii) Meter Time and Date

Correct FALSE

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 fair

Gland Leakage YES

Non Return Valve faulty

Chlorinator Faulty

Flow Meter Installed but faulty

Pressure Gauge no

Bore Hole in Front of PanYES

Wiring Fair

Housekeeping Fair

Motor Terminal ok

Foundation/Civil work ok

Ratchet Plate faulty

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 (on which flowmeter is clamped)

v) Pipe Perimeter mm (on which flowmeter is clamped)

vi) Type of Clamping (V/N/Z) V

viii) Flow Measurement 399 m3/hr (Through Transit Time Ultrasonic Flowmeter)

Velocity in Pipe 2.19 m/sec

Pressure

i) Pressure at Discharge Side of Pump 22 psig

ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)

iii) Water Shutoff Head

Levels

i) Static Water Level 38 meter Estimated

ii) Pumping Water Level 43 meter (estimated due to gland leakage and catching of wire by suction)

Electric Measurements

i) Voltage 386 385.5 387

ii) Ampere 150 175 149

iii) Power Factor 0.81 0.86 0.92

iv) Appearant Power (kVA) 101.4 100.6 98.8

v) Running Power (kW) 92.2

vi) Reactive Power (kVAr) 50.5 62 64

vi) Motor Working on Loading Basis 83 %

Oversize Undersize Properly Sized

Speed

i) Speed of Motor 1,485 RPM

ii) Speed of Pump Impeller 1450 RPM

Noise Level

Noise Level (db(A)) Avg. Max: 89.5

Thermal Imaging

i) Motor Motor Pump Coupling

Pump Volute Casing Pump Bearings

Electric Panels

Calculations

10

i) Drawdown of Pump (Pumping water level - Static Water Level) 16.072 ft

ii) Static Suction Head (Only for WW Pump) ft

iii) Suction Side Frictional Head (Only for WW Pump) ft

iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft

v) Discharge Head (Pressure Gauge) 50.82 ft

vi) Discharge Side Frictional Head 11.76 ft

vii) Dynamic Discharge Head (v+vi) 62.58 ft

viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 203.62 ft

ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 109.31

x) Specific Speed of Pump

Ns = RPM x GPM0.5 / H0.75

impeller rpm necessary to produce 1gpm/ft head 1,128

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) 90.33 hp

xiv) Brake Horsepower (bhp) (OEM Data) 124.6 hp

xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 123.59 hp

xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 72.50 %

xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 73.09 %

xviii) Existing Specific Pumping Energy (En(pumping01)) 0.23 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 6,384 m3/day

xxii) Annual working days 365 days

xxiii) Annual Pump flow 2,330,160 m3/yr

xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 541,335 kWh/yr

xxv) Annual Energy Expenditure on Pumping 7,037,357 PKR/Yr

11 Summary of Findings

Pumping system efficiency is 73%. For pump attached with 150 HP motor, efficiency <69 is considered to be EXCELLENT. This pumping system requires no intervention.

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 863,000 PKR

VFD is recommendedNo VFD installed

Attached water flow meter is faulty New water flow meter is recommended

No PFI pannel is installed PFI panel of 50 kVAR is recommended

Digital pressure guage is recommendedNo pressure guage is installed

Rectify the gland leakage issueLeakage at the pump gland

Chlorinator is not operational Attach chlorinator and make it operationalize






Name of Engineer

WASA Staff Name

i) Name of Pumping Station RAJ GHAR MUSLIM TOEN






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail




NOT OPERATIONAL



xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer





viii) Discharge Pressure 8 psig

6 Motor Nameplate Data NA


ii) Rated kW / hp 80 hp 60 kW

iii) Voltage Range (Volts) Volts

iv) Current (Ampere)

v) Power Factor (Cos ɸ)

Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM

vii) Reference Frequency C/S

viii) Insulation Class

ix) Motor Frame Size

x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 kVAr

Panel Condition/Issues Fair. Faulty A and V meter

Gland Leakage yes

Non Return Valve ok

Chlorinator No

Flow Meter No

Pressure Gauge No


Wiring Fair

Housekeeping Fair

Motor Terminal Open connection without terminal box


Ratchet Plate Faulty

Field Measurements

8 Flow Measurement






v) Pipe Perimeter 638 mm (on which flowmeter is clamped)




Pressure




Levels




i) Voltage 353.6 362.2 373

ii) Ampere 79.2 68.7 77.5




vi) Reactive Power (kVAr) 31 26.2 26.6



Speed

i) Speed of Motor 0 RPM


Noise Level

Noise Level (db(A)) Avg. Max: 89

Thermal Imaging



Electric Panels

Calculations

10












impeller rpm necessary to produce 1gpm/ft head 838














xxiii) Annual Pump flow 934,400 m3/yr



xxvi) Pumping System Efficiency after Improvement 65 %

xxvii) Water Flow after Efficiency Improvement 179 m3/hr

xxviii) Specific Energy Consumption at New Efficiency 0.21 kWh/m3

xxix) Potential of Energy Reduction 10.47 %

xxx) Reduced Annual Energy Consumption at Improved Efficiency 23,061 kWh/yr

xxxi) Annual Financial Saving on Pumping 299,789 PKR/Yr


Pumping system efficiency is 58%. For pump attached with 80 HP motor, efficiency 56-60 % is considered to be fair. To improve its efficiency upto 65 % which is good , this pumping system requires ampeller adjustment. This intervention will save 299,789 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Defective A and V meter Install new A and V meter

There is no pressure gauge installed at discahrge pipeline Digital pressure guage is recommended

No flow meter is available Water flow meter is recommended

No chlorinator is available Chlorinator is recommended

PFI panel control circuit is defective

It is recommended to change the control circuity of the panel which is included HRC fuses ,current transformer,magnatic connector,and control terminals for the control cct.Also reactive power factor regulator relay for auto swicting needs to reflected

Control leakageLeakage at the pump gland

No VFD installed VFD is recommended






Name of Engineer

WASA Staff Name

i) Name of Pumping Station BILAL PARK






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant Not Installed

Panel Condition/Issues Poor. ampere meter not working

Gland Leakage yes

Non Return Valve ok

Chlorinator Demaged

Flow Meter no

Pressure Gauge no


Wiring Poor

Housekeeping Fair

Motor Terminal Open connections without terminal box


Ratchet Plate faulty

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 383 378 377

ii) Ampere 161.5 175 174


iv) Appearant Power (kVA) 105 99.6 107


vi) Reactive Power (kVAr) 52.6 46.7 58.2



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10


































xxxi) Annual Financial Saving on Pumping 1,816,075 PKR/Yr


Pumping system efficiency is 43%. For pump attached with 150 HP motor, efficiency <58 % is considered to be LOW. To improve the efficiency to 65% which is GOOD this pumping system requires impeller adjustment, maintenance and repair. This intervention will save 1,816,075 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Control leakage for efficiency improvementLeakage at the pump gland was observed

No VFD installed VFD is recommended


Water flowmeter is not available New water flow meter is recommended

NO PFI is available Install PFI of 50 kVAr

New A and V meter are recommendedDefective A and V meter

Improve wiring conditionElectrical wiring is poor

Chlorinator is demaged New chlorinator is recommended






Name of Engineer

WASA Staff Name

i) Name of Pumping Station SODIWAL QUARTER






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power



xi) In Case of Secondary Power Source Fuel Data Details 100



Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail




NOT OPERATIONAL



xii) Self Priming



Yes No


Yes No





ii) ModelB12B/5

Serial


iv) Year of Manufacture2008

v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






21-08-10-10291

Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency




ix) Motor Frame Size 250 M

x)



ii) Meter Reading 20518.754


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 kVAr

Panel Condition/Issues GOOD

Gland Leakage moderate leakage

Non Return Valve ok

Chlorinator NOT OPERATIONAL

Flow Meter Magnetic Type (Faulty)

Pressure Gauge no


Wiring fair

Housekeeping fair

Motor Terminal ok


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 390 390.9 387

ii) Ampere 89.2 91.6 84.7





vi) Motor Working on Loading Basis 78.98 %


Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 50.7%. For pump attached with 80 HP motor, efficiency <58% is considered to be LOW. This pumping system requires impeler adjustment to increase its efficiency to 65% which is good. This intervention will save 791,418 rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Rectify pump gland leakage issueLeakage at the pump gland

No VFD installed


Magnetic flow meter was available but non operational New water flow meter is recommended

Defective PFI control unit

Chlorinator is not operational Attach new chlorinator







Name of Engineer

WASA Staff Name

i) Name of Pumping Station RUSTAM PARK (GR)






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power


Picture





Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail




NOT OPERATIONAL



xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft


viii) Power / HP / BHP 119

BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer





viii) Discharge Pressure psig





iv) Current (Ampere) 209.5


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr

Panel Condition/Issues Poor. Faulty A and V meter


Non Return Valve ok


Flow Meter no

Pressure Gauge no


Wiring poor

Housekeeping fair

Motor Terminal Open motor connections without terminal box


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure

i) Pressure at Discharge Side of Pump psig



Levels




i) Voltage 385 388.2

ii) Ampere 158.5 193.6

iii) Power Factor 0.83 0.8

iv) Appearant Power (kVA) 105.2 131.6

v) Running Power (kW) 162

vi) Reactive Power (kVAr) 73.5 58.2



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10





v) Discharge Head (Pressure Gauge) 0 ft












xiv) Brake Horsepower (bhp) (OEM Data) 119 hp



















Pumping system efficiency is 26%. For pump attached with 150 HP motor, efficiency <57% is considered to be LOW. This pumping system requires motor replacement. Also the motor is over loaded (144%). After this intervention 7,247,597 Rs annually will be saved



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



PFI pannel not oprational




Its recommended tha to replace the Volt meterVolt meter not Operational

No VFD installed Install VFD

Ampere meter not Operational Its recommended tha to replace the Ampere meter

Motor is over loaded Replace motor

Improve wiring conditionWiring is poor. Flashed panel

Chlorinator is demaged Attach new chlorinator

No water flow meter is available New water flow meter is recommended


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station FIRDOUS COLONY GR






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer










iv) Current (Ampere) 209.5


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr

Panel Condition/Issues Worst pannel,V & A meter not working


Non Return Valve

Chlorinator ok

Flow Meter no

Pressure Gauge no

Bore Hole in Front of Panno

Wiring open wiring

Housekeeping OK

Motor Terminal open and loose motor connections


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 387.4 386.7 385.9

ii) Ampere 160.4 184.5 94.5


iv) Appearant Power (kVA) 79.23 123 61





Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 49.92%. For pump attached with 150 HP motor, efficiency <58 % is considered to be LOW. To improve the efficiency to 65% which is GOOD this pumping system requires impeller adjustment, maintenance and repair. This intervention will save 1,131,465 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Improve housekeepingHousekeeping is poor

Improve wiring conditionWiring is not in safe condition

NO water flow meter Attach Water Flow meter and make it operationalize







There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station TAKYA MEHMOOD SHAH






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB12B/5

Serial



v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 kVAr



Non Return Valve ok

Chlorinator

Flow Meter defective

Pressure Gauge no


Wiring Good

Housekeeping OK

Motor Terminal OK


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 385.9 384.5 386

ii) Ampere 86.7 89.3 88.7


iv) Appearant Power (kVA) 58 59.4 59.3





Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 83%. For pump attached with 80 HP motor, efficiency of 83% is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)













Name of Engineer

WASA Staff Name

i) Name of Pumping Station E BLOCK GULSHAN RAVI






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading 198633& 160632


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 30 kVAr not operational

Panel Condition/Issues Poor, ampere meter not working


Non Return Valve

Chlorinator No

Flow Meter no

Pressure Gauge no


Wiring Poor

Housekeeping OK

Motor Terminal No terminal box


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 410.3 410.8 413

ii) Ampere 166 170 168.7


iv) Appearant Power (kVA) 112 120 118





Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 56.285%. For pump attached with 150 HP motor, efficiency <58 % is considered to be LOW. To improve the efficiency to 65% which is GOOD this pumping system requires impeller adjustment. This intervention will save 958,943 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)













Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station MOON MARKET






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr AND operational



Non Return Valve

Chlorinator ok

Flow Meter no

Pressure Gauge no


Wiring OK

Housekeeping OK

Motor Terminal OK


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 405.9 401.2

ii) Ampere 185.8 197.7

iii) Power Factor 0.73 0.71

iv) Appearant Power (kVA) 129 135.6


vi) Reactive Power (kVAr) 91.9 91.5



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 32.03%. For pump attached with 150 HP motor, efficiency <58 % is considered to be LOW. To improve the efficiency to 65% which is GOOD this pumping system requires pump to be replaced. This intervention will save Rs. 3,953,591 per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)


12 Estimated Investment for Improvement Plan 3,743,000 PKR








Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station SANDA PATWAR KHANA






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant



Non Return Valve ok

Chlorinator No

Flow Meter no

Pressure Gauge no


Wiring OK

Housekeeping OK

Motor Terminal open and loose motor connections


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 388.4 381.9 381.4

ii) Ampere 95 117.4 110







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 44.45% For pump attached with 80 HP motor, efficiency <58% is considered to be LOW. This pumping system requires impeller adjustment to increase its efficiency to 65% which is good. This intervention will save Rs. 733,514 annually.

12 Issues & Recommendations

ISSUES RECOMMENDATIONS

i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)

12 Financial Analysis / Indicators

Estimated Investment for Improvement Plan 743,000 PKR

Attach chlorinator and make it operationalize

Install digital pressure gauge at discahrge pipeline





There is no pressure gauge installed at discahrge pipeline

Chlorinator is not operational






Name of Engineer

WASA Staff Name

i) Name of Pumping Station G Block Gulshan Ravi

ii) Name of Subdivision Islam Pura , Lahore

iii) Operator Name & Contact N/A




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model B. 14 B/4 Serial



v) Flowrate (Q) 4 Cusec 408 m3/hr

vi) Head (H) 210 ft


viii) Power / HP / BHP 119 BHP

ix) Speed (n) 1,450 RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant Not installed

Panel Condition/Issues Poor


Non Return Valve

Chlorinator

Flow Meter no

Pressure Gauge no


Wiring Poor

Housekeeping Not good

Motor Terminal Open and lose motor connections


Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 365.3 369.5 377.5

ii) Ampere 150 132.2 133

iii) Power Factor 0.85

iv) Appearant Power (kVA) 88.73


vi) Reactive Power (kVAr) 45.06



Speed


ii) Speed of Pump Impeller 1,467 RPM

Noise Level


Thermal Imaging



Electric Panels

Calculations

10










i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



It is recommended to close motor connections in terminal box.Open and lose motor connections.

No flow meter install new flow meter

Attached water flow meter is not working

Attach new water flow meter and properly record 24 hour flow reading. In case of variation in the water flow, the resaons should be investigated and problems be rectified

PFI panel is not installed Install PFI panel


Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline


Pump needs impeller adjustment to increase water flow rate Adjust impellers



Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station A BLOCK GULSHAN RAVI






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr

Panel Condition/Issues Execellent


Non Return Valve

Chlorinator

Flow Meter no

Pressure Gauge no


Wiring Ok

Housekeeping OK

Motor Terminal OK


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 376.9 374.4 383.4

ii) Ampere 95 110.4 96




vi) Reactive Power (kVAr) 42.4 44.8 34



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 84.77%. For pump attached with 150 HP motor, efficiency above 69% is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)









Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station JAHANGIR PARK






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail




NOT OPERATIONAL



xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






21-08-10-11318

Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAr

Panel Condition/Issues Poor. Ampere not working


Non Return Valve ok


Flow Meter Yes

Pressure Gauge no

Bore Hole in Front of Panel

Wiring poor

Housekeeping poor

Motor Terminal OK


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 410.2 412.3 414.6

ii) Ampere 202.8 193 193.3


iv) Appearant Power (kVA) 144 138 94.6


vi) Reactive Power (kVAr) 104 104 67.5



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 64%. For pump attached with 150 HP motor, efficiency of 64% is considered to be GOOD. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




It is recommended to change the control circuity of the panel which is included HRC fuses ,current transformer,magnatic connector,and control terminals for the control cct.Also reactive power factor regulator relay for auto swicting needs to reflectedPFI pannel not oprational








Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station RAFFLE RANGE






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft


viii) Power / HP / BHP BHP

ix) Speed (n) RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAR non operational

Panel Condition/Issues Poor .V & A meter not working

Gland Leakage ok

Non Return Valve ok

Chlorinator

Flow Meter no

Pressure Gauge no


Wiring poor .open wiring

Housekeeping OK

Motor Terminal No terminal box


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 385 387 389

ii) Ampere 143 161 167


iv) Appearant Power (kVA) 106.3 100 100.2





Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 58%. For pump attached with 150 HP motor, efficiency <58 % is considered to be LOW. To improve the efficiency to 65% which is GOOD this pumping system requires impeller adjustment. This intervention will save Rs. 581,341 annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)










Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station ZUBAIR PARK






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading 40025 & 5986


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr

Panel Condition/Issues Good ,Ampere meter not working


Non Return Valve not working

Chlorinator

Flow Meter no

Pressure Gauge no


Wiring ok

Housekeeping fair

Motor Terminal OK


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 413.2 408.7 409

ii) Ampere 182.2 199 182




vi) Reactive Power (kVAr) 92.5 105 101



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10










i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





Its recommended tha to replace the Ampere meterAmpere meter not Operational



replace NRV non return valve not operational



Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station B BLOCK GULSHAN RAVI






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial



v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n) RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer





viii) Discharge Pressure psig check







Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 kVAr

Panel Condition/Issues Fair


Non Return Valve ok

Chlorinator No

Flow Meter no

Pressure Gauge no

Bore Hole in Front of Panel

Wiring Poor

Housekeeping Poor

Motor Terminal open motor cables


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 394.7 388 397

ii) Ampere 42.4 53.5 42.4


iv) Appearant Power (kVA) 20.9 36 29.2


vi) Reactive Power (kVAr) 25.3 28.2 19 101



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10





v) Discharge Head (Pressure Gauge) 0 ft





















xxiii) Annual Pump flow 657,000 m3/yr




Pumping system efficiency is 74.18%. For pump attached with 80 HP motor, efficiency above 65.9% is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)















Name of Engineer

WASA Staff Name

i) Name of Pumping Station MALIK MUNIR PARK






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr

Panel Condition/Issues Fair,Ampere meter not working

Gland Leakage

Non Return Valve

Chlorinator

Flow Meter no

Pressure Gauge no


Wiring poor

Housekeeping fair

Motor Terminal ok


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 397 398.5 397

ii) Ampere 175 173 166







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10










i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)
















Name of Engineer

WASA Staff Name

i) Name of Pumping Station Usman Park

ii) Name of Subdivision Islam Pura , Lahore

iii) Operator Name & Contact N/A




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model B. 14 B/4 Serial


iv) Year of Manufacture 2009

v) Flowrate (Q) 4 Cusec 408 m3/hr

vi) Head (H) 210 ft


viii) Power / HP / BHP 124.6 BHP

ix) Speed (n) 1,450 RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50kvar(operational)

Panel Condition/Issues Average


Non Return Valve ok

Chlorinator

Flow Meter no

Pressure Gauge no


Wiring Fair

Housekeeping

Motor Terminal


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 388.5 389.5 387.2

ii) Ampere 177 168 170.2

iii) Power Factor 0.83

iv) Appearant Power (kVA) 115.5


vi) Reactive Power (kVAr) 64.59



Speed


ii) Speed of Pump Impeller 1,467 RPM

Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 70.61%. For pump attached with 150 HP motor, efficiency <69 is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Voltmeter is malfunctioning Replace voltmeter meter


Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline



Chlorinator is not avaialble Attach chlorinator and make it operationalize

Attached water flow meter is not working Attach new water flow meter


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station NONARIA






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n) RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr

Panel Condition/Issues GOOD,Volt meter not working


Non Return Valve

Chlorinator

Flow Meter

Pressure Gauge no


Wiring ok

Housekeeping Fair

Motor Terminal ok


Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 357.2 356.7 344.4

ii) Ampere 164 195 185.7







i) Speed

ii) Speed of Motor 1,488 RPM

Speed of Pump Impeller 1450 RPM

Noise Level


i) Thermal Imaging

Motor Motor Pump Coupling


Calculat Electric Panels

10 i)

ii) Drawdown of Pump (Pumping water level - Static Water Level) 16.072 ft

iii) Static Suction Head (Only for WW Pump) ft

iv) Suction Side Frictional Head (Only for WW Pump) ft

v) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft

vi) Discharge Head (Pressure Gauge) 27.72 ft

vii) Discharge Side Frictional Head 10.40 ft

viii) Dynamic Discharge Head (v+vi) 38.12 ft

ix) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 179.16 ft

x) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 102.73

xi) Specific Speed of Pump




xii) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr

xiii) Deviation of actual flow from the pump curve flow %

xiv) Water Horsepower (whp) (TDH x Actual Measured Flow) 74.70 hp

xv) Brake Horsepower (bhp) (OEM Data) 124.6 hp

xvi) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 122.12 hp

xvii) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 59.95 %

Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 61.17 %

xviii)

xix) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3

xx) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh

xxi) Daily Operational Time of Pump 18 hrs

xxii) Daily Pump flow 6,750 m3/day

xxiii) Annual working days 365 days

xxiv) Annual Pump flow 2,463,750 m3/yr

xxv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 601,736 kWh/yr

xxvi) Annual Energy Expenditure on Pumping 7,822,571 PKR/Yr

xxvii) Pumping System Efficiency after Improvement 65 %

xxviii) Water Flow after Efficiency Improvement 398 m3/hr

xxix) Specific Energy Consumption at New Efficiency 0.23 kWh/m3

xxx) Potential of Energy Reduction 5.89 %

xxxi) Reduced Annual Energy Consumption at Improved Efficiency 35,448 kWh/yr

Annual Financial Saving on Pumping 460,821 PKR/Yr

Summary of Findings11


The pumping efficiency is in the range of FAIR. This system needs impeller adjustment.

12 i) ISSUES RECOMMENDATIONS

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)

Financia



Its recommended tha to replace the volt metervolt meter not Operational













Name of Engineer

WASA Staff Name

i) Name of Pumping Station ZUBAIR PARK RAJGHAR






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail




NOT OPERATIONAL



xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






21-08-10-11318

Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR

Panel Condition/Issues Good/Faulty A meter


Non Return Valve ok


Flow Meter no

Pressure Gauge no


Wiring Good

Housekeeping Fair

Motor Terminal open motor connection


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 396.6 392.4 389.2

ii) Ampere 191 193.4 179.4







i) Speed



Noise Level


i) Thermal Imaging




10 i)





















xviii)














Annual Financial Saving on Pumping 1,219,306 PKR/Yr



Pumping system efficiency is 54%. For pump attached with 150 HP motor, efficiency <58.1% is considered to be (LOW). To improve its efficiency upto 65 % (GOOD) This pumping system requires impeler adjustment. This intervention will save 1,219,306 Rs annually.


ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)

Financia


Install A meter Faulty A meter

Defective chlorinator Replace Chlorinator

No flow meter available Install flow meter








Name of Engineer

WASA Staff Name

i) Name of Pumping Station SODIWALL PARK






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial


iv) Year of Manufacture118.6

v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kVAr non operational

Panel Condition/Issues Execellent


Non Return Valve

Chlorinator

Flow Meter no

Pressure Gauge no


Wiring ok

Housekeeping OK



Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 423 426 425

ii) Ampere 146.5 116.8 116.4




vi) Reactive Power (kVAr) 79 65.5 71.5



i) Speed



Noise Level

Noise Level (db(A)) Avg. Max:

i) Thermal Imaging




10 i)





















xviii)














Annual Financial Saving on Pumping 728,557 PKR/Yr


mping syste




ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)

Financia














Name of Engineer

WASA Staff Name

i) Name of Pumping Station SHERA KOT






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB12B/5

Serial



v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 kVAr non operational

Panel Condition/Issues Poor ,volt &Ampere meter not worknig


Non Return Valve

Chlorinator no

Flow Meter no

Pressure Gauge no


Wiring Poor

Housekeeping OK



Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 375.6 399.5 395.8

ii) Ampere 98.3 92 90.6







i) Speed



Noise Level


i) Thermal Imaging




10 i)





















xviii)






xxiv) Annual Pump flow 876,000 m3/yr








Annual Financial Saving on Pumping 1,283,374 PKR/Yr


mping syste


Pumping system efficiency is 42.12%. For pump attached with 80 HP motor, efficiency 56-60 % is considered to be fair. To improve its efficiency upto 65 % which is good , this pumping system requires ampeler adjustment and repair and maintenance. This intervention will save 1,283,374 Rs annually.


ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)

Financia


















Name of Engineer

WASA Staff Name

i) Name of Pumping Station Babu sabu dispensry






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) ModelB14B/4

Serial



v) Flowrate (Q) 4

Cusec 408 m3/hr

vi) Head (H)210

ft



BHP

ix) Speed (n)1450

RPM



5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






21-08-10-11318

Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant Installed but non operational

Panel Condition/Issues Poor ,volt &Ampere meter not worknig


Non Return Valve ok


Flow Meter no

Pressure Gauge no


Wiring Poor

Housekeeping OK



Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 375.5 378.1 376

ii) Ampere 218 193 151.1







i) Speed



Noise Level


i) Thermal Imaging




10 i)





















xviii)









11


Pumping system efficiency is 67.43%. For pump attached with 150 HP motor, efficiency of 67% is considered to be GOOD. This pumping system requires no intervention.


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viii)

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xvii)

xviii)

Financia

















Name of Engineer

WASA Staff Name

i) Name of Pumping Station Fazal Colny Disposal pump no 1

ii) Name of Subdivision Islam Pura / Lahore

iii) Operator Name & Contact NA




vii) Types of Pumps

Standard Deep Well Water Turbine Pumps Qty


Centrifugal Pump Qty 2

Submersible Disposal Pump Qty


Independent 2

Series

Parallel


Yes No


Time Flow Pressure



viii) Daily Operational Time 18 hrs/day Estimated


x) Source of Power



xi) In Case of Secondary Power Source Fuel Data Details Not Available


2 Pump Basic Information Pump # 01


Horizontal Vertical Submersible

Foundation


iv)

v) Cooling Type



Single Multi




Wet Well Overhead Tank Underground Tank

Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No




i) Make / BrandKSB

Country Pakistan

ii) Model Serial



v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H) ft


viii) Power / HP / BHP BHP Estimated

ix) Speed (n) RPM



5 Piping System

Suction Side


i) Enter Diameter of Suction Pipe (In) 6

ii) Enter Length of Suction Pipe (ft) 20

iii) Enter Fittings on Suction Pipe


Valves Flow control 1

Bends

Strainer 1


ix) Suction Pressure

Discharge Side


i) Diameter of Discharge Pipe (in) 6

ii) Length of Discharge Pipe (ft) 15 Estimated



Valves Non return 1 1

Bends 1

Strainer

vi) Discharge Elevation (from Datum Line) 25 ft

Suction Side Elevation 11 ft

vii) Availbility of Pressure Gauge Yes No





iii) Voltage Range Volts

iv) Current Amperes


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 50 Hz



x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant not installed

Panel Condition/Issues poor

Gland Leakage

Non Return Valve

Flow Meter Not installed

Pressure Gauge Not installed

Wiring poor

Housekeeping

Motor Terminal

Foundation/Civil work

Field Measurements

8 Flow Measurement





iv) Pipe Diameter 6 inches

v) Pipe Perimeter 479 mm


viii) Flow Measurement 200 m3/hr 3.3333 m3/min Estimated


Pressure


ii) Pressure at Suction Side of Pump

ii) Total Length (Suction+Discahrge Pipe) 11 meter

Electric Measurements Volt 370.8 377.9 372.6

Ampere 20.9 19.9 21.6

kW 11.6 Power Factor 0.84 0.89 0.87



Speed


ii) Speed of Pump Impeller RPM

Noise Level


Thermal Imaging



Electric Panels

10 Calculations

ii) Static Suction Head (Only for WW Pump) 11 ft

v) Static Discahrge Head 25 ft

vi) Frictional Head (Suction and Discahrge) 23.30 ft

viii) Total Dynamic Head of Pump (TDH) 37.30 ft










xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %









xxv) Annual Energy Expenditure on Pumping 996,068 PKR/Yr








Pumping system efficiency is 53.35%. For pump attached with 20 HP motor, efficiency in between 50 to 57 is considered to be fair (> 60.9 is excellent). This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 53.35% to 57% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 63,506 per year.



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viii)

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Adjust impellerPumping system need impeller adjustment

install ammeterAmmeter not working

No pressure gauge Install digital pressure gauge

no PFI plant installed Install PFI plant

No water flow meter Install water flow meter






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Fazal Colny Disposal pump no 2

ii) Name of Subdivision Islam Pura / Lahore

iii) Operator Name & Contact NA




vii) Types of Pumps

Standard Deep Well Water Turbine Pumps Qty


Centrifugal Pump Qty 2

Submersible Disposal Pump Qty


Independent 2

Series

Parallel


Yes No


Time Flow Pressure



viii) Daily Operational Time 18 hrs/day Estimated


x) Source of Power



xi) In Case of Secondary Power Source Fuel Data Details Not Available


2 Pump Basic Information Pump # 02


Horizontal Vertical Submersible

Foundation


iv)

v) Cooling Type



Single Multi




Wet Well Overhead Tank Underground Tank

Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No




i) Make / BrandKSB

Country Pakistan

ii) Model Serial



v) Flowrate (Q) 2

Cusec 204 m3/hr

vi) Head (H) ft


viii) Power / HP / BHP BHP Estimated

ix) Speed (n) RPM



5 Piping System

Suction Side


i) Enter Diameter of Suction Pipe (In) 6

ii) Enter Length of Suction Pipe (ft) 20

iii) Enter Fittings on Suction Pipe


Valves Flow control 1

Bends

Strainer 1


ix) Suction Pressure

Discharge Side


i) Diameter of Discharge Pipe (in) 6

ii) Length of Discharge Pipe (ft) 15 Estimated



Valves Non return 1 1

Bends 1

Strainer

vi) Discharge Elevation (from Datum Line) 25 ft

Suction Side Elevation 11 ft

vii) Availbility of Pressure Gauge Yes No





iii) Voltage Range Volts

iv) Current Amperes


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 50 Hz



x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant not installed

Panel Condition/Issues poor

Gland Leakage

Non Return Valve

Flow Meter Not installed

Pressure Gauge Not installed

Wiring poor

Housekeeping

Motor Terminal

Foundation/Civil work

Field Measurements

8 Flow Measurement





iv) Pipe Diameter 6 inches

v) Pipe Perimeter 479 mm


viii) Flow Measurement 204 m3/hr 3.4 m3/min Estimated


Pressure


ii) Pressure at Suction Side of Pump

ii) Total Length (Suction+Discahrge Pipe) 11 meter

Electric Measurements Volt 376.1 370.2 368

Ampere 19.2 20 21.9

kW 11.06 Power Factor 0.85 0.76 0.84



Speed


ii) Speed of Pump Impeller RPM

Noise Level


Thermal Imaging



Electric Panels

10 Calculations

ii) Static Suction Head (Only for WW Pump) 11 ft

v) Static Discahrge Head 25 ft

vi) Frictional Head (Suction and Discahrge) 24.24 ft

viii) Total Dynamic Head of Pump (TDH) 38.24 ft










xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %









xxv) Annual Energy Expenditure on Pumping 949,700 PKR/Yr


Pumping system efficiency is 58.51%. For pump attached with 20 HP motor, efficiency abov 57% is considered to be Good. This pumping system does not require any intervention.



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xvii)

xviii)



Install VoltmeterVoltmeter not available

install ammeterAmmeter not working

No pressure gauge Install digital pressure gauge

no PFI plant installed Install PFI plant

No water flow meter Install water flow meter

ANNEXURE-2

Selected Pictures

Gland leakage at Riwaz Garden Open motor connections at Raj Garh Muslim

Park

Poor and flashed panel at Bilal park Faulty chlorinator at Bilal Park

No terminal box at Riffle Range Defective chlorinator at Riffle range

Faulty flowmeter at Zubair Park View of motor at B Block Qadaffi Park

Discharge pipeline at Qadaffi Park Poor panel at Qadaffi Park

View of installed flowmeter at Jahangir Park

Defective flowmeter at Moon market

Poor motor connections at E Block Poor and flashed panel at E Block

Poor house keeping at E Block

Poor panel at Firdous Colony

Risk of short circuit at WASA Colony A block

Flashed electric meter at WASA Colony

Poor electric wiring at Rustam Park View of pumps at Islampura disposal

energy audit & energy efficiency improvement program for...

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