pcgip.urbanunit.gov.pkpcgip.urbanunit.gov.pk/docs/energy/Final Report Ravi Road.pdf · The project...

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Punjab Cities Governance Improvement Project

Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab

REPORT Ravi Road 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 13 2.4 Interventions for the improvement of WASA stations 14

LIST OF ANNEXURE

I Energy Audit Reports 2 Selected Pictures

LIST OF FIGURES

I Pumping system efficiency category 11 2 Unit electricity consumption trend 13

LIST OF TABLES

1 Detail of WASAs pumps 8 2 Detail of Ravi Road 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 12 6 System energy efficiency potential of pumps 13

7A Interventions & investment required in WASA stations-Ravi Road Subdivision 15

7B Interventions & investment required in WASA stations-Ravi Road Subdivision 17

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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 Ravi Road 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 20 WASA water supply stations and 09 wastewater disposal pumps in Ravi Road Subdivision. The detail of these stations along with pumps installed capacity and actual discharge is given in Table-2:

Table-2: Detail of Ravi Road Subdivision

# WASA Station

No. of Water Supply Pumps

Installed

Installed Capacity (Cusec)

Actual Discharge (Cusec)

1 Gulshan Riaz Colony 01 2.0 3.12 2 Shafiq Abad 01 2.0 0.68 3 Karim Park Old 01 4.0 5.04 4 Karim Park Block-03 01 4.0 4.10 5 Allah Wali Masjid 01 4.0 3.38 6 Rehmat Flour Mill 01 4.0 3.48 7 Yaseen Road 01 2.0 1.71 8 Ameen Park 01 2.0 2.20 9 Bagh Munshi Ladha 01 4.0 4.41 10 Shesh Mahal Road 01 3.0 4.62 11 Umer Park Old 01 2.0 0.15 12 Umer Park New 01 2.0 2.74 13 Adda Bajri Wala 01 4.0 2.94 14 Ravi Park-01 01 4.0 4.50 15 Munshi Hospital 01 4.0 4.73 16 Ibrahim Road 01 2.0 1.37 17 Salamat Mohallah 01 4.0 1.00 18 Sardar Chappal 01 4.0 0.26 19 Main Outfall New 01 5.0 4.65 20 Main Outfall Old 01 4.0 4.88 Total 20 66.0 59.96 Wastewater Disposal Pumps

21 Bagh Munshi Disposal-01 01 10.0 2.59 22 Bagh Munshi Disposal-02 01 20.0 7.49 23 Bagh Munshi Disposal-03 01 10.0 4.05 24 Bagh Munshi Disposal-04 01 20.0 7.95 25 Bagh Munshi Disposal-06 01 15.0 11.55 26 Marzi Pura disposal-01 01 5.0 1.66 27 Outfall Disposal-01 01 25.0 18.48 28 Outfall Disposal-02 01 25.0 19.85 29 Outfall Disposal-03 01 25.0 19.98 Total 09 155.0 93.60

The installed capacity of WASA tube wells of Ravi Road Subdivision is 39.31 million m3 per annum whereas actual discharge is 35.71 million m3 per annum, for average 16 hours per day operation and 365 days per year. This actual discharge is about 9% lesser than the installed capacity. The installed capacity of WASA disposal pumps of Ravi Road Subdivision is 69.24 million m3 per annum whereas actual discharge is 41.81 million m3 per annum, for average 12 hours per

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day operation and 365 days per year. This actual discharge is about 40% 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 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

Gulshan Riaz Colony 81 84 EXCELLENT Karim Park Old 90 79 EXCELLENT Karim Park Block-03 74 72 EXCELLENT Ameen Park 80 68 EXCELLENT Bagh Munshi Ladha 88 81 EXCELLENT Umer Park New 97 83 EXCELLENT Ravi Park-01 89 69 EXCELLENT Main Outfall New 84 84 EXCELLENT Main Outfall Old 91 74 EXCELLENT Munshi Hospital 90 77 GOOD Shafiq Abad 30 58 FAIR Rehmat Flour Mill 85 59 FAIR Shesh Mahal Road 98 63 FAIR Sardar Chappal 22 13 LOW Allah Wali Masjid 93 48 LOW Yaseen Road 85 49 LOW Umer Park Old 25 13 LOW Adda Bajri Wala 87 44 LOW Ibrahim Road 91 33 LOW Salamat Mohallah 60 21 LOW

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Disposal Pumps Bagh Munshi Disposal-02 44 33 LOW Bagh Munshi Disposal-01 31 26 LOW Bagh Munshi Disposal-03 48 31 LOW Bagh Munshi Disposal-04 47 27 LOW Bagh Munshi Disposal-06 91 50 LOW Marzi Pura disposal-01 39 37 LOW Outfall Disposal-01 86 30 LOW Outfall Disposal-02 93 31 LOW Outfall Disposal-03 94 31 LOW About 50% of the tube wells are under excellent and good category of pumping system efficiency whereas remaining 50% are under fair and low category as illustrated in Fig-1.

Figure-1: Pumping System Efficiency Category

All the operational disposal pumps are under low 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.

Excellent 45%

Good 5%

Fair 15%

Low 35%

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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 Gulshan Riaz Colony 1,862,960 285,346 0.15 2 Shafiq Abad 357,700 90,932 0.25 3 Karim Park Old 2,631,650 513,740 0.19 4 Karim Park Block-03 2,141,090 417,671 0.19 5 Allah Wali Masjid 1,762,950 522,474 0.29 6 Rehmat Flour Mill 1,814,050 484,303 0.26 7 Yaseen Road 894,250 262,007 0.29 8 Ameen Park 1,396,125 302,119 0.21 9 Bagh Munshi Ladha 2,299,500 497,300 0.21

10 Shesh Mahal Road 3,101,040 707,420 0.22 11 Umer Park Old 87,600 83,336 0.95 12 Umer Park New 1,533,000 313,033 0.20 13 Adda Bajri Wala 1,314,000 422,735 0.32 14 Ravi Park-01 2,014,800 431,542 0.21 15 Munshi Hospital 2,820,720 578,912 0.20 16 Ibrahim Road 868,700 340,610 0.39 17 Salamat Mohallah 483,990 314,849 0.65 18 Sardar Chappal 157,680 142,849 0.90 19 Main Outfall New 3,294,125 650,505 0.19 20 Main Outfall Old 3,453,630 701,402 0.20 Total 34,289,560 8,063,085 0.23 Disposal Pumps

21 Bagh Munshi Disposal-01 1,450,875 94,290 0.06 22 Bagh Munshi Disposal-02 4,182,900 218,303 0.05 23 Bagh Munshi Disposal-03 2,266,650 147,517 0.06 24 Bagh Munshi Disposal-04 4,440,225 288,593 0.06 25 Bagh Munshi Disposal-06 6,455,025 299,987 0.04 26 Marzi Pura disposal-01 931,298 97,207 0.10 27 Outfall Disposal-01 1,376,050 84,400 0.06 28 Outfall Disposal-02 1,478,250 91,886 0.06 29 Outfall Disposal-03 1,487,740 92,473 0.06 Total 24,069,013 1,414,656 0.05 Total annual energy cost of Ravi Road subdivision is about Rs. 123 million. The unit electricity consumption trend for each WASA station tube wells 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.

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Figure-2: Unit Electricity Consumption Trend

About 65% of the tube wells consume electricity more than the 0.20 kWh/m3. In case if all the 20 tube wells consume optimum electricity, then annually Rs. 16 million (15%) can be saved. 2.3 Pumping System Efficiency Improvement Potential The 10 tube wells and 09 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 Pumps

WASA Station Existing Pumping Efficiency

(%)

Improved Pumping Efficiency

(%)

Annual

(kWh)

Saving

(Rs)

Impeller

Adjustment /Repair &

Maintenance

Intervention

Motor Replace

Pump Replace

Shafiq Abad 58 65 9,298 120,880 × Allah Wali Masjid

47 65 138,096 1,795,252 ×

Rehmat Flour Mill

59 65 44,597 579,759 ×

Yaseen Road 49 65 65,114 846,479 × Shesh Mahal Road

63 65 23,031 299,408 ×

Umer Park Old 13 68 67,251 874,260 × × Adda Bajri Wala 44 68 152,272 1,979,538 × Ibrahim Road 32 65 169,650 2,205,453 × Salamat Mohallah

21 65 211,381 2,747,954 ×

Sardar Chappal 13 68 115,682 1,503,860 × × Bagh Munshi Disposal-01

26 61 53,567 696,369 ×

Bagh Munshi 33 64 105,734 1,374,542 ×

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

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

kWh/m3

Optimum

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Disposal-02 Bagh Munshi Disposal-03

31 61 72,669 944,697 ×

Bagh Munshi Disposal-04

27 64 166,201 2,160,616 ×

Bagh Munshi Disposal-06

50 61 56,064 728,830 ×

Marzi Pura disposal-01

37 61 38,790 504,275 ×

Outfall Disposal-01

30 63 44,078 573,013 ×

Outfall Disposal-02

31 63 47,324 615,206 ×

Outfall Disposal-03

31 63 47,504 617,547 ×

Total 1,628,303 21,167,938

2.4 Interventions for the Improvement of WASA Stations Energy audit activity of Ravi Road 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. 34.83 million are required to improve WASA stations of Ravi Road subdivision, Lahore.

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Table-7A: Interventions & Investment Required in WASA Stations- Ravi Road Subdivision

Intervention WASA Stations Gulshan

Riaz Shafiq Karim

Old Karim New

Allah Wali

Outfall New

Rehmat Flour

Yaseen Road

Ameen Park

Bagh Munshi

Shesh Mahel

Umer Old

Umer New

Adda Bajri

Ravi Park01

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 Gulshan

Riaz Shafiq Karim

Old Karim New

Allah Wali

Outfall New

Rehmat Flour

Yaseen Road

Ameen Park

Bagh Munshi

Shesh Mahel

Umer Old

Umer New

Adda Bajri

Ravi Park01

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)

0.78 0.80 0.71 0.89 0.76 0.83 0.78 0.55 0.44 0.94 0.84 3.2 0.45 0.77 0.80

Annual Saving (M. Rs) 0.12 1.8 0.58 0.85 0.29 0.87 1.9 Payback (Year) 6.66 0.42 1.34 0.64 2.89 3.6 0.4

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Table-7B: Interventions & Investment Required in WASA Stations- Ravi Road Subdivision Intervention WASA Stations Munshi Ibrahim Salamat Sardar Outfall

Old Bagh Disp-

01

Bagh Disp-02

Bagh Disp-03

Bagh Disp-

04

Bagh Disp-

06

Marzipur Disp-01

Outfal. Disp-

01

Outfal Disp-

02

Outfal. Disp-

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 Munshi Ibrahim Salamat Sardar Outfall

Old Bagh Disp-

01

Bagh Disp-02

Bagh Disp-03

Bagh Disp-

04

Bagh Disp-

06

Marzipur Disp-01

Outfal. Disp-

01

Outfal Disp-

02

Outfal. Disp-

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)

0.72 2.5 3.7 4.9 0.71 3.2 0.18 0.18 4.0 0.08 0.28 0.48 0.18 0.18

Annual Saving (M. Rs) 2.2 2.7 1.5 0.69 1.3 0.94 2.1 0.73 0.50 0.57 0.61 0.61 Payback (Year) 1.13 1.37 3.26 4.63 0.13 0.19 1.9 0.10 0.56 0.84 0.29 0.29 Total Investment of Subdivision (M.Rs) = 34.83

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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 Gulshan Riaz Colony

ii) Name of Subdivision Ravi Road , Lahore

iii) Operator Name & Contact Mr. Ameer M Khan

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

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 5

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

Motor Replacement Detail

Motor Rewinding Detail

xii) Self Priming

Yes No NA (not applicable)

xiii) Non Clogging (In case of wastewater)

Yes No

3 Pump Nameplate Data

i) Make / Brand KSB Country Pakistan

ii) Model B12 B/5 Serial 21-8-10-10312

iii) Certification Mark

iv) Year of Manufacture 2009

v) Flowrate (Q) 2 Cusec 204 m3/hr

vi) Head (H) 210 ft

vii) Discharge Pressure (P) 2.3 Psig

viii) Power / HP / BHP 59.5 BHP

ix) Speed (n) 1,450 RPM

x) Maximum Pressure (Pmax)

xi) Maxiumum Allowable Temperature

4 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)

ix) Suction Pressure (Not Valid incase of Tubewells)

Discharge Side

Pipe Material of Construction MS Pipe

i) Diameter of Discharge Pipe 8 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)

5 Motor Nameplate Data

i) Manufacturer Siemens

ii) Rated kW / hp 80 hp 60 kW

iii) Voltage Range (Volts) 380 Volts

iv) Current (Ampere) 115

v) Power Factor (Cos ɸ) 0.85

Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed 1,488 RPM

vii) Reference Frequency 50 C/S

viii) Insulation Class F

ix) Motor Frame Size 315 S

6 Electrical & Mechanical System Observations

i) Electrical Meter Reference Number

ii) Meter Reading 31467.7

iii) Meter Time and Date

Correct FALSE

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 25 KVAR

Panel Condition/Issues

Gland Leakage Normal

Non Return Valve ok

Chlorinator NA

Flow Meter NA

Pressure Gauge NA

Bore Hole in Front of Panel No

Wiring Poor

Housekeeping fair

Motor Terminal Fair

Foundation/Civil work ok

Ratchet Plate ok

7 Field Measurements

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 (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 319 m3/hr (Through Transit Time Ultrasonic Flowmeter)

Velocity in Pipe 2.73 m/sec

Pressure

i) Pressure at Discharge Side of Pump 2.3 Psig

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

Levels

i) Static Water Level 35 meter

ii) Pumping Water Level 40 meter

Electric Measurements

i) Voltage 381 382.8 383.5

ii) Ampere 93 86 91

iii) Power Factor 0.79 0.78 0.83

iv) Appearant Power (kVA) 61 58 60.3

v) Running Power (kW) 48.6

vi) Reactive Power (kVAr) 37 35.5 33.5

vi) Motor Working on Loading Basis 81 %

Oversize Undersize Properly Sized

Poor/ Faulty A meter

Speed

i) Speed of Motor 1,495 RPM

ii) Speed of Pump Impeller 1,450 RPM

Noise Level

Noise Level (db(A)) Avg. Max: 88.2

Thermal Imaging

i) Motor Motor Pump Coupling

Pump Volute Casing Pump Bearings

Electric Panels

8 Calculations

i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 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) 5.313 ft

vi) Discharge Side Frictional Head 18.85 ft

vii) Dynamic Discharge Head (v+vi) 24.16 ft

viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 155.36 ft

ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 85.64

x) Specific Speed of Pump

Ns = RPM x GPM0.5 / H0.75

impeller rpm necessary to produce 1gpm/ft head 1,235

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) 55.10 hp

xiv) Brake Horsepower (bhp) (OEM Data) 59.5 hp

xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 65.15 hp

xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 92.61 %

xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 84.58 %

xviii) Existing Specific Pumping Energy (En(pumping01)) 0.15 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 5,104 m3/day

xxii) Annual working days 365 days

xxiii) Annual Pump flow 1,862,960 m3/yr

xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 285,346 kWh/yr

xxv) Annual Energy Expenditure on Pumping 3,709,496 PKR/Yr

xxvi) Pumping System Efficiency after Improvement 68 %

xxvii) Water Flow after Efficiency Improvement 256 m3/hr

xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3

9 Summary of Findings

Pumping system efficiency is 84%. For 80 HP motor efficiency >62% is considered to be excellent. This pumping system is efficient and requires no intervention.

10 Issues & Recommendations

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 783,500 PKR

Replace A meter Defective A meter

Pressure gauge is not installed Install digital pressure gauge at discahrge pipeline

Install flowmeter No flowmeter

Replace PFI control unitPFI control is defective

No VFD installed Install VFD

There is moderate leakage at pump gland Remove leakage






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Shafiq Abad


iii) Operator Name & Contact




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 250




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



ii) Model B12/B5 Serial 21-06-10-48/3




vi) Head (H) 220 ft

vii) Discharge Pressure (P) 19.8 Psig





4 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1





Discharge Side







Bends Elbow 1

Strainer




5 Motor Nameplate Data NA

i) Manufacturer


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




ix) Motor Frame Size 250 M





Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant Not installed



Non Return Valve ok

Chlorinator NA

Flow Meter NA

Pressure Gauge NA


Wiring POOR

Housekeeping Poor

Motor Terminal No terminal box


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 359.4 361.2 362.4

ii) Ampere 101 102 101


iv) Appearant Power (kVA) 37 37 36.5


vi) Reactive Power (kVAr) 32.63

vi) Motor Working on Loading Basis 29.6 %


Poor

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations












impeller rpm necessary to produce 1gpm/ft head 532












xxi) Daily Pump flow 980 m3/day


xxiii) Annual Pump flow 357,700 m3/yr






xxix) Potential of Energy Reduction 10.23 %

xxx) Reduced Annual Energy Consumption at Improved Efficiency 9,298 kWh/yr

xxxi) Annual Financial Saving on Pumping 120,880 PKR/Yr


Pumping system efficiency is 58%. For pump attached with 150 HP motor, efficiency <58% is LOW. This pumping system requires ampeller adjustment to increase the efficiency upto 65% which is GOOD. This intervention will save 120,880 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Install flowmeter Flow meter is not available

Install PFIPFI is not installed








Name of Engineer

WASA Staff Name

i) Name of Pumping Station Karim Park new


iii) Operator Name & Contact Mr. Aamir Iqbal 0300-4688433




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture







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



ii) Model B14/B4 Serial 9972688500/300




vi) Head (H) 210 15

vii) Discharge Pressure (P) Psig





4 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1





Discharge Side







Bends Elbow 1

Strainer






ii) Rated kW / hp 150 hp 112.5 kW




Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency







ii) Meter Reading 3368


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR



Non Return Valve ok

Chlorinator ok

Flow Meter NA

Pressure Gauge NA


Wiring Excellent

Housekeeping Good

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure

i) Pressure at Discharge Side of Pump 15 Psig


Levels




i) Voltage 388 388 389

ii) Ampere 166 173 163


iv) Appearant Power (kVA) 111 116 110

v) Running Power (kW) 100

vi) Reactive Power (kVAr) 46 58 51



Excellent

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations


















xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 134 hp















Pumping system efficiency is 80%. For pump attached with 150 HP motor, efficiency >69% is considered to be excellent. This pumping system does not require any energy efficiency measure.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



No flowmeter Install Flowmeter


Install pressure guageNo pressure guage







Name of Engineer

WASA Staff Name

i) Name of Pumping Station Karim Park Blk #3


iii) Operator Name & Contact




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power





2 Pump Basic Information


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


i) Make / Brand Flow Pak Country

ii) Model 14 FMC/4SI Serial 14-1988




vi) Head (H) 210 ft


viii) Power / HP / 18.5 118.2 BHP




4 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







ii) Meter Reading Out of order


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve ok

Chlorinator Defected

Flow Meter NA

Pressure Gauge NA


Wiring Good

Housekeeping fair

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 423 414 428

ii) Ampere 131 184 154




vi) Reactive Power (kVAr) 74.6 98.4 55



Good/Defective A meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations






























Pumping system efficiency is 71%. For pumping system with motor 150 HP efficiency >69% is excellent. This pumping system doest not require any energy efficiency measure



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Install chlorinatorFaulty chlorinator

PFI plant of 50 KVAR is recommendedPFI plant is not installed


Defective A meter Install A meter






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Allah Wali Masjid


iii) Operator Name & Contact Mr. Ameer Afzal




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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



ii) Model B1/B4 Serial 21-05-10-4631




vi) Head (H) 220 ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 kvar



Non Return Valve ok

Chlorinator Faulty

Flow Meter NA

Pressure Gauge NA


Wiring Fair

Housekeeping Fair

Motor Terminal


Ratchet Plate Faulty


Flow Measurement










Pressure



Levels




i) Voltage 381 380 381

ii) Ampere 175 183 173




vi) Reactive Power (kVAr) 50 62.9 55



Good/ Defective A and V meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations


































xxxi) Annual Financial Saving on Pumping 1,795,252 PKR/Yr


Pumping system efficiency is 47%. For pump attached with 150 HP motor, efficiency below <58% is considered to be LOW (>68.9 is excellent). This pumping system requires impeler adjustment, repair and maintenance. This intervention will save 1,795,252 Rs annually



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Install flow meter No flow meter

Replace PFI control unitDefective PFI control




Install A and V meter Defective A and V meter

Defective chlorinator Install chlorinator






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Main Outfall NEW


iii) Operator Name & Contact Shaukat Ali 0300 4266838




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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


i) Make / Brand KSB Country

ii) Model B14 D/2 Serial 6102


iv) Year of Manufacture


vi) Head (H) ft



ix) Speed (n) RPM



4 Piping System

Suction Side


i) Enter Diameter of Suction Pipe (In) 10 (Not Valid incase of Tubewells)




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







ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR


Gland Leakage Significant

Non Return Valve Faulty

Chlorinator Faulty

Flow Meter NA'

Pressure Gauge NA'


Wiring Fair

Housekeeping Fair

Motor Terminal


Ratchet Plate ok'


Flow Measurement










Pressure



Levels




i) Voltage 363 365 375

ii) Ampere 167 168 174







Fair

Speed



Noise Level

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

Thermal Imaging



Electric Panels

8 Calculations






























Pumping system efficiency is 89%. For pump attached with 150 HP motor, efficiency >68.9 is 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)



No pressure guage Digital pressure guage is recommended

Flow meter is recommendedNo flow meter


No VFD VFD is recommended

Defective PFI control Install PFI control unit






Name of Engineer

WASA Staff Name

i) Name of Pumping Station REHMAT FLOOR MIL


iii) Operator Name & Contact Mr. Ameer Afzal 0344-4824971




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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







vi) Head (H) 220 ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR



Non Return Valve ok

Chlorinator faulty

Flow Meter NA

Pressure Gauge NA


Wiring Fair

Housekeeping Fair

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 384.5 383 384.5

ii) Ampere 164 163 167







Fair/Faulty A and V meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations




































Pumping system efficiency is 59%. For pump attached with 150 HP motor, efficiency below 58% is considered to be LOW (>68.9 is excellent). This pumping system requires impeler adjustment. It is estimated that this intervention will save 579,759 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Install new PFI controlDefective PFI control

Replace A and V meter with correct oneFaulty A and V meter

No VFD installed VFD is recommended

No flow meter Flow meter is recommended

Pressure gauge is not installed Digital pressure guage is recommended






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Yasin Road


iii) Operator Name & Contact Mr. Inamul Haq




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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

3 Pump Nameplate Data NA


ii) Model Serial




vi) Head (H) ft


viii) Power / HP / BHP BHP

ix) Speed (n) RPM



4 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







ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant Not Installed


Gland Leakage yes

Non Return Valve ok

Chlorinator Faulty

Flow Meter NA

Pressure Gauge NA


Wiring Poor

Housekeeping fair

Motor Terminal




Flow Measurement










Pressure



Levels




i) Voltage 375 369 364

ii) Ampere 98 98 89


iv) Appearant Power (kVA) 64 60.5 59


vi) Reactive Power (kVAr) 35.8 31 27.8



Poor/No A and V meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations

















xiv) Brake Horsepower (bhp) (OEM Data) 0 hp


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

















Pumping system efficiency is 48%. For pump attached with 150 HP motor, efficiency below 58% is considered to be LOW (>68.9 is excellent). This pumping system requires impeler adjustment, repair and maintenace to increase efficiecy upto 65% which is GOOD. This intervention will save 846,479 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



New Chlorinator is recommendedFaulty Chlorinator

Pressure gauge is not installed Digital pressure guage is recommended

Install flow meter

Install A and V meter

No water flow meter


No A and V meter

PFI plant of 25 KVAR is recommendedNo PFI plant






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Amin Park

ii) Name of Subdivision Ravi Road, Lahore

iii) Operator Name & Contact Mr. Umer Agha




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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



ii) Model B12/B5 Serial 9972122091/390




vi) Head (H) 210

vii) Discharge Pressure (P) 17 Psig





4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 KVAR



Non Return Valve ok

Chlorinator NA

Flow Meter NA

Pressure Gauge NA


Wiring Fair

Housekeeping Fair

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 398 398 394

ii) Ampere 91 90 87


iv) Appearant Power (kVA) 63 62.2 59.5




Oversize . Undersize Properly Sized

Speed

Good



Noise Level


Thermal Imaging



Electric Panels

8 Calculations

































Pumping system efficiency is 67%. For pump attached with 150 HP motor, efficiency >65% is considered to be EXCELLENT. This pumpinbg system requires no intervention



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Chlorinator is recommemdedNo chlorinator


No water flow meter Water flow meter is recommended

Pressure gauge is not installed Digital pressre guage is recommended






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Bagh Munshi Ladha


iii) Operator Name & Contact Mr.Sumair Yousaf 0322-7275732




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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


i) Make / Brand FlowPak Country Pakistan

ii) Model 14FMC/4ST Serial 11 1961




vi) Head (H) 210 ft


viii) Power / HP / BHP 150 BHP




4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 20 KVARPanel Condition/Issues

Gland Leakage yes

Non Return Valve ok

Chlorinator NA

Flow Meter NA

Pressure Gauge NA


Wiring Fair

Housekeeping Fair

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 402 405 395

ii) Ampere 151 169 174




vi) Reactive Power (kVAr) 62 54

vi) Motor Working on Loading Basis 88.4 % 77


Speed

Fair



Noise Level


Thermal Imaging



Electric Panels

8 Calculations










i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Installed PFI is of 20 KVAR, which is under capacity PFI of 50 KVAR is recommended

Chlorinator is recommended No Chlorinator

Digital pressure guage is recommendedNo pressure guage








Name of Engineer

WASA Staff Name

i) Name of Pumping Station Sheshmehl Road

ii) Name of Subdivision .

iii) Operator Name & Contact Mr. Intikhab Haider




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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







vi) Head (H) 250 ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve ok

Chlorinator NA

Flow Meter NA'

Pressure Gauge NA


Wiring Poor

Housekeeping Poor

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 399 396 394

ii) Ampere 172 192 191







Speed

Poor. No A and V meter



Noise Level

Noise Level (db(A)) Avg. Max: 92

Thermal Imaging



Electric Panels

8 Calculations





v) Discharge Head (Pressure Gauge) 0 ft































Pumping system efficiency is 62%. For pump attached with 150 HP motor, efficiency below between 58-63% is considered to be FAIR (>63.5% is GOOD). This pumping system requires impeler adjustment. This intervention will save 299,408 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)

Financia Estimated Investment for Improvement Plan

12 844,000 PKR

Water flow meter is recommended No water flow meter

Install A and V meter No A and V meter


Defective PFI with no capacitors PFI of 50 KVAR is recommended


New chlorinator is recommendedFaulty chlorinator






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Umer Park Old


iii) Operator Name & Contact Mr. Rizwan Saleem 0300-4624314




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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



ii) Model Serial




vi) Head (H) ft






4 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







ii) Meter Reading 1794.19&65470.8


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant Not Installed


Gland Leakage Moderate

Non Return Valve ok

Chlorinator Faulty

Flow Meter NA

Pressure Gauge NA


Wiring Fair

Housekeeping Poor

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 388 381 378

ii) Ampere 41.2 48.2 53.6


iv) Appearant Power (kVA) 35.26 31.81 27.54





Fair/ No A and V meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations




































Pumping system efficiency is 13%. For pump attached with 80 HP motor, efficiency below 58% is considered to be LOW. This pumping system requires pump and motor replacement (motor is very old which needs to be replaced). This intervention will save 874,260 Rs annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)


12 Estimated Investment for Improvement Plan 3,174,000 PKR

Replace pump (2 CUSEC)Pump is inefficient

Replace motor (80 HP)Motor is inefficient


No water flow meter water flow meter is recommended


PFI plant of 25 KVAR is recommendedNo PFI plant

Chlorinator is recommendedNo chlorinator

No A and V meter A and V meter is rcommended






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Umer Park New


iii) Operator Name & Contact Mr. M Asghar




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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







vi) Head (H) 210 ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 KVAR



Non Return Valve ok

Chlorinator ok

Flow Meter NA

Pressure Gauge NA


Wiring Fair

Housekeeping Fair

Motor Terminal


Ratchet Plate OK


Flow Measurement










Pressure



Levels




i) Voltage 390 388 404

ii) Ampere 108 101 116







Fair. No A and V meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations

































Pumping system efficiency is 80%. For pump attached with 80 HP motor, efficiency >68.9% is 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)




Replace defective A and V meter with correct oneFaulty A and V meter

Install PFI controlDefective PFI control








Name of Engineer

WASA Staff Name

i) Name of Pumping Station Adda Bajri Wala


iii) Operator Name & Contact Mr. M Sarfaraz 0346-4544690




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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







vi) Head (H) 220 ft






4 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








iii) Meter Time and Date .

Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR



Non Return Valve ok

Chlorinator ok

Flow Meter NA

Pressure Gauge NA


Wiring Poor

Housekeeping ok

Motor Terminal open motor connections


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 361.3 364.3 362.7

ii) Ampere 183 191 185







Poor/Faulty A and V meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations




































Pumping system efficiency is 43%. For pump attached with 150 HP motor, efficiency below 58% is considered to be LOW (>68.9 is excellent). This pumping system requires impeler adjustment, repair and maintenace. This intervention will save 1,979,535 Rs annually



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Install flow meter No flowmeter

Install new A and V meter


Faulty A and V meter

Defective PFI control Replace PFI control by new PFI control






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Ravi Park-1


iii) Operator Name & Contact Mr. Khurram Shehzad




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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







vi) Head (H) 220 ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR




Chlorinator Faulty

Flow Meter NA

Pressure Gauge NA


Wiring Poor

Housekeeping Poor

Motor Terminal No terminal box




Flow Measurement










Pressure



Levels




i) Voltage 385.2 387 386.4

ii) Ampere 183.6 176.3 163.9


iv) Appearant Power (kVA) 122.4 118.3 110



vi) Motor Working on Loading Basis 89 % 58


Poor/ Defective A and V meter

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations

































umping system efficiency is 68%. For pump attached with 150 HP motor, efficiency >63.5% is GOOD. This pumping system requiresn no intervention



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Chlorinator is recommended No chlorinator

Water flow meter is recommendedNo water flow meter


Defective PFI control Install new PFI control


Replace A and V meter by correct one Faulty A and V meter






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Munshi Hospital


iii) Operator Name & Contact Mr. M Saleem Butt




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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



ii) Model B14 B/4 Serial 997267125/300




vi) Head (H) 210 ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 kvar



Non Return Valve ok

Chlorinator Faulty

Flow Meter NA

Pressure Gauge NA


Wiring Fair

Housekeeping Fair

Motor Terminal ok


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 379.3 371.5 386.2

ii) Ampere 146.5 197 170.7







Good

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations

































Pumping system efficiency is 77%. For pump attached with 150 HP motor, efficiency >68.9 is 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)




Chlorinator is recommended Faulty chlorinator


No water flowmeter Water flowmeter is recommended






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Ibrahim Road


iii) Operator Name & Contact Mr. Imran Butt 0323-5024864




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 250




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



ii) Model Serial




vi) Head (H) ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25 KVAR




Chlorinator Faulty

Flow Meter NA

Pressure Gauge NA


Wiring Poor

Housekeeping Poor

Motor Terminal ok




Flow Measurement










24

Pressure



Levels




i) Voltage 384.6 373.4 389.7

ii) Ampere 95.4 89 88.3


iv) Appearant Power (kVA) 64.3 57 59


vi) Reactive Power (kVAr) 26.3 26 21



Speed




Noise Level


Thermal Imaging



Electric Panels

8 Calculations




































Pumping system efficiency is 33%. For pump attached with 150 HP motor, efficiency below 58% is considered to be LOW (>68.9 is excellent). This pumping system requires replacement of pump. It is estimated that the new pump will have efficiency of about 65%. This efficiency improvement will save about Rs.2,205,453 annually.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Replave A and V meter Faulty A and V meter




Replace pump (2 Cusec)Pump is inefficient

Faulty NRV Replace NRV






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Salamat Mohallah

ii) Name of Subdivision Ravi Road , Lahore 0301-4027664

iii) Operator Name & Contact Mr. Saleem Faisal Khan




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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



ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR




Chlorinator ok

Flow Meter NA

Pressure Gauge NA


Wiring Poor

Housekeeping Poor

Motor Terminal open motor terminals




Flow Measurement










Pressure



Levels




i) Voltage 374.9 370.2

ii) Ampere 112.3 146

iii) Power Factor 0.66 0.83

iv) Appearant Power (kVA) 73 91





Speed

Poor



Noise Level


Thermal Imaging



Electric Panels

8 Calculations




































Pumping system efficiency is 21%. For pump attached with 150 HP motor, efficiency below 58% is considered to be LOW (>68.9 is excellent). This pumping system requires replacement of pump. It is estimated that the new pump will have efficiency of about 65%. This efficiency improvement will save about Rs. 2,747,954 per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)















Name of Engineer

WASA Staff Name

i) Name of Pumping Station Sardar Chappal


iii) Operator Name & Contact Mr. Ghulam Dastgir 0324-9422532




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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



ii) Model B14 B/4 Serial 15--1097




vi) Head (H) 210 ft






4 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









Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR




Chlorinator OK

Flow Meter NA'

Pressure Gauge NA'


Wiring Poor

Housekeeping Poor

Motor Terminal ok




Flow Measurement










Pressure



Levels




i) Voltage 382.9 408.1 421.2

ii) Ampere 83 87.2 74








Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations




































Pumping system efficiency is 14.3%. For pump attached with 150 HP motor, efficiency below 58% is considered to be LOW (>68.9 is excellent). This pumping system requires replacement of pump and motor (motor is very old which need to be replaced). It is estimated that the new pump and motor will have efficiency of about 65%. This efficiency improvement will save about Rs. 1,326,018 Rs per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Replace motor (150 HP)Motor is inefficient













Name of Engineer

WASA Staff Name

i) Name of Pumping Station Main Outfall Old


iii) Operator Name & Contact Shaukat Ali 0300 4266838




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power







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


i) Make / Brand KSB Country

ii) Model B14 B/4 Serial 9972673821/700




vi) Head (H) 210 ft



ix) Speed (n) RPM



4 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







ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50 KVAR


Gland Leakage Significant

Non Return Valve ok

Chlorinator ok

Flow Meter NA'

Pressure Gauge NA'


Wiring Excellent

Housekeeping Good

Motor Terminal


Ratchet Plate ok


Flow Measurement










Pressure



Levels




i) Voltage 350 353 349

ii) Ampere 182 189 190






Oversize . Undersize Properly Sized

Excellent

Speed



Noise Level


Thermal Imaging



Electric Panels

8 Calculations










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 Bagh munshi Ladha Disposal Station Pump no 1


iii) Operator Name & Contact Safdar




vii) Types of Pumps

Standard Deep Well Water Turbine Pumps Qty



Submersible Disposal Pump Qty 6


Independent 6

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power





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

xiv) Flowmeter Available

Yes No

xv) Flowmeter Working

Working Properly Malfunctioning (Damaged)



ii) Model KRTK 300-400/506 UNGI-K Serial



v) Flowrate (Q) 10 Cusec 1,020 m3/hr

vi) Head (H)35

ft



ix) Speed (n)981

RPM



5 Piping System

Suction Side


i) Enter Diameter of Suction Pipe (In) 12

ii) Enter Length of Suction Pipe (ft) 2

iii) Enter Fittings on Suction Pipe


Valves Flow control 1

Bends

Strainer 1

viii) Availbility of Pressure Gauge Yes No

ix) Suction Pressure

9971428577/000100

Discharge Side


i) Diameter of Discharge Pipe (in) 12

ii) Length of Discharge Pipe (ft) 55 estimated



Valves Non return 1 1

Bends 1

Strainer

vi) Discharge Elevation (from Datum Line) 35 ft

Suction Side Elevation 17 ft

vii) Availbility of Pressure Gauge Yes No

viii) Discharge Pressure psig




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


ix) Motor Frame Size

x)

7 Electrical System Observations


ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues good

Gland Leakage

Non Return Valve

Flow Meter Not installed

Pressure Gauge Not installed

Wiring fair

Housekeeping

Motor Terminal

Foundation/Civil work

Field Measurements

8 Flow Measurement





iv) Pipe Diameter 12 inches

v) Pipe Perimeter 957 mm


viii) Flow Measurement 265 m3/hr 4.4167 m3/min


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 400.3 401.5 400.9

Ampere 48.7 58.4 43

kW 17.13 Power Factor 0.65



Speed

i) Speed of Motor 0 RPM

ii) Speed of Pump Impeller RPM

Noise Level


Thermal Imaging



Electric Panels

10 Calculations

ii) Static Suction Head (Only for WW Pump) 17 ft

v) Static Discahrge Head 35 ft

vi) Frictional Head (Suction and Discahrge) 2.53 ft

viii) Total Dynamic Head of Pump (TDH) 20.53 ft

x) Specific Speed of PumpNs = RPM x GPM0.5 / H0.75 impeller rpm necessary to produce 1gpm/ft head 0
























Pumping system efficiency is 26.35%. For pump attached with 75 HP motor, efficiency < 56% is considered to be LOW, (above 61% is Good). This pumping system efficiency is less than 30% so pump must be changed to improve efficiency from 26.35% to 61% with annual savings of 696,369 PKR.

Issues & Recommendations

12 ISSUES RECOMMENDATIONS

i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



No water flow meter Install water flow meter

voltmeter is not installed

PFI of 100 kvar is recommanded for disposalno PFI PANEL

No pressure gauge Install digital pressure gauge

install new voltmeter

pumping system efficiency is less than 30% installed new pump






Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 6

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H)35

ft



ix) Speed (n)735

RPM



5 Piping System

Suction Side







Bends

Strainer 1



9971428577/000300

Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring fair

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement






v) Pipe Perimeter 1,595 mm




Pressure





Ampere 123 120 87




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations























xxvii) Water Flow after Efficiency Improvement 1,482 m3/hr






Pumping system efficiency is 33.%. For pump attached with 120 HP motor, efficiency < 58% is considered to be LOW, (above 64% is Good). This pumping system need impeller adjustment and need repair and maintenance which will improve efficiency from 33% to 64% with annual savings of 1,374,542 PKR.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



install voltmetervolt meter is not available


pumping syetem need impeller adjustment adjust impeller and aslo need maintenance and repair







Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 6

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H)35

ft



ix) Speed (n) 981 RPM



5 Piping System

Suction Side







Bends

Strainer 1



9971428577/000101

Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring fair

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement










Pressure





Ampere 61 54.7 60




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations





























Pumping system efficiency is 30.95.%. For pump attached with 75 HP motor, efficiency < 56% is considered to be LOW, (above 61% is Good). This pumping system need impeller adjustment and need repair and maintenance which will improve efficiency from 30.95% to 61% with annual savings of 944,697 PKR.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)











Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 6

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H)35

ft






5 Piping System

Suction Side







Bends

Strainer 1



9971428577/000301

Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring fair

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement










Pressure





Ampere 122 120 104.4




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations





























Pumping system efficiency is 26.93%. For pump attached with 150 HP motor, efficiency < 58% is considered to be LOW, (above 63% is Good). This pumping system efficiency is less than 30% so pump must be changed to improve efficiency from 26.93% to 63% with annual savings of 2,160,616 PKR.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




pumping system efficiency is less than 30% installed new pump







Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 6

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model EPL 0100478913 Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



5731208

Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring fair

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement








viii) Flow Measurement 1,179 m3/hr 19.65 m3/min


Pressure




Electric Measurements Volt 384.5 385 385

Ampere 91.3 105.9 104.7




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations





























Pumping system efficiency is 49.60%. For pump attached with 80 HP motor, efficiency < 56% is considered to be LOW, (above 61% is Good). This pumping system need impeller adjustment which will improve efficiency from 49.06% to 61% with annual savings of 728,830 PKR.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





pump needs impeller adjustment adjust impeller






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Marzipura Disposal Station Pump no 1


iii) Operator Name & Contact Pervez Naseem




vii) Types of Pumps



Centrifugal Pump Qty 2



Independent 3

Series

Parallel


Yes No


Time Flow Pressure



viii) Daily Operational Time 15 hrs/day Estimated


x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model KWPZ2007315 Serial




vi) Head (H)76

ft



ix) Speed (n)1450

RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues poor

Gland Leakage

Non Return Valve



Wiring fair

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement










Pressure





Ampere 42.7 35.6 36




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations





























Pumping system efficiency is 36.66%. For pump attached with 80 HP motor, efficiency < 56% is considered to be LOW, (above 61% is Good). This pumping system need impeller adjustment and need repair and maintenance which will improve efficiency from 33.66% to 61% with annual savings of 504,275 PKR.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



no PFI PLANT PFI of 50 KVAR is recommanded for disposal


ammeter is not available

install voltmetervolt meter is not available


install ammeter







Name of Engineer

WASA Staff Name

i) Name of Pumping Station Out fall Disposal Station pump no 1

ii) Name of Subdivision Ravi road , Lahore

iii) Operator Name & Contact Abbas




vii) Types of Pumps




Submersible Disposal Pump Qty


Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power


3344338052







Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No




i) Make / Brand Country Pakistan

ii) Model Serial




vi) Head (H) 40 ft






5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer








iii) Voltage Range 380 Volts

iv) Current 245 Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed 888 RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues Excellent

Gland Leakage

Non Return Valve



Wiring Good

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement










Pressure




Electric Measurements Volt 365

Ampere 231

kW 115 Power Factor 0.77



Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations































Pumping system efficiency is 30.10%. For pump attached with 180HP motor, efficiency <59% is considered to be low (> 69 is excellent). This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 30.10% to 63% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 573,013 per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




PFI of 150 kvar is recommanded for disposalNo PFI installed


pump needs impeller adjustment adjust impeller,repair and also need maintenance






Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power


3344338052







Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 40 ft






5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer











Standard

Ambient Temp oC


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










Gland Leakage

Non Return Valve



Wiring Good

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement










Pressure




Electric Measurements Volt 384 384

Ampere 253 253




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations






i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)











Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power


3344338052







Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 40 ft






5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer











Standard

Ambient Temp oC


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










Gland Leakage

Non Return Valve



Wiring Good

Housekeeping

Motor Terminal


Field Measurements

8 Flow Measurement










Pressure




Electric Measurements Volt 362

Ampere 244

kW 126 Power Factor 0.81



Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations






i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)






ANNEXURE-2

Selected Pictures

Poor housekeeping at Outfall disposal 1

View of pump at Outfall disposal 1

Poor panel with defective PFI at Bajri Adda

Open motor connections at Bajri Adda

Good electric panels at Bagh Musnhi Ladha disposal

Poor View of discharge pipe line at Gulshan Riaz Colony

Poor housekeeping at Ibrahim Road

Poor pump at Merzipura disposal

Outdated electric wiring at Merzipura disposal Close view of outdated wiring at Merzipura disposal

Open pump at motor at Ravi Park 1 Cloth washing and bathing at Ravi Park 1

.

Poor housekeeping at Ravi Park 1

Gland leakage at Salamat Mohalla

Poor electric panel at Salamat Mohalla

Open motor connections at Shafiqabad

pcgip.urbanunit.gov.pkpcgip.urbanunit.gov.pk/docs/energy/Final Report Ravi Road.pdf · The project...

Documents

Transcript of pcgip.urbanunit.gov.pkpcgip.urbanunit.gov.pk/docs/energy/Final Report Ravi Road.pdf · The project...