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1
Punjab Cities Governance Improvement Project
Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab
REPORT
Waterworks Subdivision, Multan
November 2015
NEC Consultants (Pvt.) Ltd.
2
Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab
November 2015
NEC Consultants Pvt. Ltd Perfect SITE, 22 KM Ferozepur Road, Near Gujju Matta Metro Bus Station, Lahore +92-42-35273741-46, www.nec.com.pk [email protected]
This study was assigned by The Urban Unit, Punjab
3
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.
4
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 13 2.3 Pumping system efficiency improvement potential 16 2.4 Interventions for the improvement of WASA stations 18
LIST OF ANNEXURE
I Energy Audit Reports 2 Selected Pictures
LIST OF FIGURES
I Pumping system efficiency category 13 2A Unit electricity consumption trend 15 2B Unit electricity consumption trend 15 2C Unit electricity consumption trend 16
LIST OF TABLES
1 Detail of WASAs pumps 8 2 Detail of Waterworks subdivision 9 3 Typical overall pumping system efficiency classification 11 4 Detail of motor loading and pumping system efficiency 11 5 Detail of water discharge and electricity consumption 13 6 System energy efficiency potential of tube wells 16
7A Interventions & investment required in WASA stations- WaterworksSubdivision 19
7B Interventions & investment required in WASA stations- WaterworksSubdivision 21
7C Interventions & investment required in WASA stations- WaterworksSubdivision 23
7D Interventions & investment required in WASA stations- WaterworksSubdivision 25
7E Interventions & investment required in WASA stations- WaterworksSubdivision 27
5
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 m/s Meter Per Second m3/hr Cubic Meter Per Hour MCB Miniature Circuit Breaker MCCB Molded Case Circuit Breaker MEPCO Multan Electric Power Company 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
6
Overall Plant or Pumping System Efficiency
The ratio of the water horsepower (the overall output of the plant) to input horsepower (the power input). The overall output can also be defined as the amount of horsepower required to deliver the measured capacity (water gallons per minute) and the measured total head.
Pumping Water Level
The well’s operating water level below center line of discharge pipe as observed during test condition
Static Water Level The well’s water level obtained when pumping plant is at rest.
Suction Head Head measured above center line of pump suction intake. Most often obtained with calibrated bourdon tube pressure gauge (suction pressure) and converted to feet by conversion factor 2.31 ft. water/psi
Suction Lift The distance between pump discharge head and water level.
Total Head
The sum of the water head above and below the center line of the pump discharge pipe. For well applications, the Total Head is the sum of the Discharge Head and the Pumping Water Level. Total head is used in determination of water horsepower and pump performance.
Water Horsepower
The output horsepower of a water pump. It is the combination of flow rate and pressure.
7
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 Waterworks Subdivision, Multan 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.
8
On the basis of field measurements, efficiency of the pumping system was calculated and 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.
9
2.0 Energy Audit Findings There are 102 WASA water supply stations (36 were not in operation) in Waterworks Subdivision. The detail of these stations along with pumps installed capacity and actual discharge is given in Table-2:
Table-2: Detail of Waterworks Subdivision
# WASA Station
No. of Water Supply Pumps
Installed
Installed Capacity (Cusec)
Actual Discharge (Cusec)
1 Al-Jillan 01 4.0 2.71 2 Al-Sana Hotel 01 4.0 2.62 3 Ansar Colony-I 01 4.0 4.02 4 B.C.G Chowk (PM Package) 01 4.0 4.02
5 Board Office-Gulgasht Colony (PM Package) 01 4.0 3.76
6 Bagh Langey Khan-I 01 4.0 4.34 7 Baghchi Mirza Jan 01 4.0 4.33 8 Basti Khudadad (Phase-VI) 01 4.0 4.72 9 Bodla Town (Phase-VI) 01 4.0 4.66 10 Bosan Road PTCL Exchange 01 4.0 3.09 11 Chain Mari Farooq Pura 01 4.0 4.02 12 Chowk Shaheedan-I 01 4.0 3.43 13 Chowk Shaheedan-II (PM Package) 01 4.0 4.28 14 Circuit House 01 4.0 3.68 15 D-Block SRA-I 01 4.0 4.53 16 D-Block SRA-II 01 4.0 4.51 17 Dhobi Ghat-I 01 4.0 4.71 18 E-Block SRA (Phase-VI) 01 4.0 4.17 19 Eid Gah-I 01 4.0 4.51 20 G-Block SRAI 01 4.0 4.31 21 Grass Mandi 01 2.0 1.94 22 Gujjar Plot 01 4.0 4.22 23 Gulberg Colony 01 4.0 3.72 24 Gulshan Market-I 01 4.0 4.07 25 Hassan Parwana-II 01 4.0 3.61 26 Hassan Parwana-I 01 4.0 3.81 27 Kabootar Mandi 01 4.0 4.02 28 K-Block SRAI 01 4.0 3.43 29 Khar Pur 01 4.0 3.94 30 Kiri Daud Khan 01 4.0 3.82 31 Lodhi Colony-I 01 4.0 3.69 32 Lodhi colony-II (PM Package) 01 4.0 4.46 33 Lohari Gate-I 01 4.0 3.58 34 Lohari Gate-IV (PM Package) 01 4.0 3.58 35 Madina Colony-I 01 4.0 4.59 36 MDA Chowk-I 01 4.0 4.18 37 Mohammadi Ground Shah Shams 01 4.0 3.64 38 MDA Chowk-II 01 4.0 4.02 39 Mumtazabad-I 01 4.0 4.53
10
# WASA Station
No. of Water Supply Pumps
Installed
Installed Capacity (Cusec)
Actual Discharge (Cusec)
40 Mumtazabad-II 01 4.0 4.07 41 Mushtaq Colony (Phase-VI) 01 4.0 4.29 42 Muzaffarabad (Phase-VI) 01 4.0 5.35 43 Naqshband Colony 01 4.0 4.71 44 Nawab Pur Road 01 4.0 3.55 45 Nawan Shaher-I 01 4.0 4.78 46 New Shah Shamas Colony 01 4.0 3.77 47 Niaz Town (Phase-VI) 01 4.0 3.70 48 Pizza Hutt Gulberg 01 4.0 3.04 49 Pir Zahid Shah-I (Phase-VI) 01 4.0 5.17 50 Purana Burf Khana 01 4.0 3.68 51 Qasim Pur Colony-I 01 4.0 3.43 52 Qasim Pur Colony-II 01 4.0 4.17 53 Rasheed Abad 01 4.0 3.04 54 Sameejabad -Hassan Abad Gate-II 01 4.0 5.02 55 Sameejabad 01 4.0 3.19 56 Shah Shamas Park (PM Package) 01 4.0 4.22 57 Shalimar Colony (Phase-VI) 01 4.0 4.75 58 Shamasbad-I 01 4.0 3.65 59 Shamasbad (PM Package) 01 4.0 5.0 60 Siddique Abad 01 2.0 1.96 61 Silli Khana (PM Package) 01 4.0 3.19 62 Tibbi Sher Khan (PM Package) 01 4.0 3.57
63 Timber Market Ground (PM Package) 01 4.0 5.69
64 Tughlaq Town 01 4.0 3.72 65 W-Block New Multan-I 01 4.0 3.80 66 Willayatabad 01 4.0 2.84 Total 66 260.00 260.62
The installed capacity of WASA tube wells of Waterworks Subdivision is 58.08 million m3 per annum whereas actual discharge is 58.22 million m3 per annum, for average 06 hours per day operation and 365 days per year. 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.
11
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
D-Block SRA-I 84 69 EXCELLENT Eid Gah-I 74 70 EXCELLENT Gulberg Colony 58 72 EXCELLENT Hassan Parwana-I 50 89 EXCELLENT Naqshband Colony 96 70 EXCELLENT Shah Shamas Park (PM Package) 94 77 EXCELLENT Timber Market Ground (PM Package)
98 72 EXCELLENT
Tughlaq Town 74 72 EXCELLENT Bosan Road PTCL Exchange 75 66 GOOD G-Block SRAI 86 68 GOOD Gulshan Market-I 78 65 GOOD Kiri Daud Khan 71 65 GOOD Sameeja Abad 55 66 GOOD Board Office-Gulgasht Colony (PM Package) 81 51 FAIR
D-Block SRA-II 97 61 FAIR Khar Pur 101 58 FAIR Lodhi Colony-II (PM Package) 82 60 FAIR Madina Colony-I 85 63 FAIR Mohammadi Ground Shah Shams 70 62 FAIR Mumtazabad-II 79 60 FAIR Muzaffarabad (Phase-VI) 78 62 FAIR Sameejabad 55 66 FAIR Al-Jillan 79 39 LOW Al-Sana Hotel 93 31 LOW Ansar Colony-I 94 55 LOW B.C.G Chowk (PM Package) 100 44 LOW Bagh Langey Khan-I 96 51 LOW Baghchi Mirza Jan 84 56 LOW
12
WASA Station Motor Load (%)
Pumping System Efficiency (%)
Pumping System Efficiency Rating
Basti Khudadad (Phase-VI) 82 47 LOW Bodla Town (Phase-VI) 97 53 LOW Chain Mari Farooq Pura 79 42 LOW Chowk Shaheedan-I 77 52 LOW Chowk Shaheedan-II 82 48 LOW Circuit House 66 51 LOW Dhobi Ghat-I 78 57 LOW E-Block SRA (Phase-VI) 77 56 LOW Grass Mandi 93 39 LOW Gujjar Plot 80 55 LOW Hassan Parwana-II 96 51 LOW Kabootar Mandi 95 41 LOW K-Block SRAI 81 42 LOW Lodhi Colony-I 82 49 LOW Lohari Gate-I 96 45 LOW Lohari Gate-IV (PM Package) 87 47 LOW MDA Chowk-I 102 42 LOW MDA Chowk-II 82 49 LOW Mumtazabad-I 100 55 LOW Mushtaq Colony (Phase-VI) 89 47 LOW Nawab Pur Road 76 49 LOW Nawan Shaher-I 98 52 LOW New Shah Shamas Colony 95 47 LOW Niaz Town (Phase-VI) 81 59 LOW Pizza Hutt Gulberg 72 46 LOW Pir Zahid Shah-I (Phase-VI) 98 52 LOW Purana Burf Khana 105 48 LOW Qasim Pur Colony-I 95 37 LOW Qasim Pur Colony-II 103 52 LOW Rasheed Abad 68 46 LOW Sameejabad -Hassanabad Gate-II 95 47 LOW Shalimar Colony (Phase-VI) 77 54 LOW Shamasbad-I 79 56 LOW Shamasbad (PM Package) 98 36 LOW Siddique Abad 88 52 LOW Silli Khana (PM Package) 74 46 LOW Tibbi Sher Khan (PM Package) 84 50 LOW W-Block New Multan-I 100 39 LOW Willayatabad 73 42 LOW About 20% of the tube wells are under excellent and good category of pumping system efficiency whereas 80% are under fair and low category as illustrated in Fig-1.
13
Figure-1: Pumping System Efficiency Category
2.2 Electricity Consumption Trend The detail of annual water discharge and correspondingly electricity consumption and unit electricity consumption of each WASA 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 Al-Jillan 604,440 192,286 0.32 2 Al-Sana Hotel 584,730 224,578 0.38 3 Ansar Colony-I 897,900 226,779 0.25 4 B.C.G Chowk (PM Package) 897,900 241,458 0.27 5 Board Office-Gulgasht Colony 840,960 195,955 0.23 6 Bagh Langey Khan-I 970,170 233,385 0.24 7 Baghchi Mirza Jan 967,980 203,294 0.21 8 Basti Khudadad (Phase-VI) 1,055,580 198,157 0.19 9 Bodla Town (Phase-VI) 1,041,783 234,926 0.23
10 Bosan Road PTCL Exchange 689,850 182,745 0.26 11 Chain Mari Farooq Pura 897,900 191,552 0.21 12 Chowk Shaheedan-I 766,500 185,680 0.24 13 Chowk Shaheedan-II 957,030 198,157 0.21 14 Circuit House 821,250 159,259 0.19 15 D-Block SRA-I 1,011,780 203,294 0.20 16 D-Block SRA-II 1,007,400 235,220 0.23 17 Dhobi Ghat-I 1,051,200 189,350 0.18 18 E-Block SRA (Phase-VI) 930,750 187,148 0.20 19 Eid Gah-I 1,007,400 179,809 0.18 20 G-Block SRAI 963,600 209,166 0.22
Excellent 12%
Good 8%
Fair 14%
Low 66%
14
# WASA Station Annual Water
Discharge (m3)
Annual Electricity Consumption
(kWh)
Unit Electricity Consumption
(kWh/m3) 21 Grass Mandi 433,620 91,739 0.21 22 Gujjar Plot 941,700 193,753 0.21 23 Gulberg Colony 832,200 140,178 0.17 24 Gulshan Market-I 908,850 189,717 0.21 25 Hassan Parwana-II 851,910 233,385 0.27 26 Hassan Parwana-I 805,920 121,830 0.15 27 Kabootar Mandi 897,900 229,715 0.26 28 K-Block SRAI 766,500 195,060 0.25 29 Khar Pur 880,380 243,660 0.28 30 Kiri Daud Khan 854,100 171,736 0.20 31 Lodhi Colony-I 823,440 198,891 0.24 32 Lodhi Colony-II (PM Package) 996,450 198,157 0.20 33 Lohari Gate-I 799,350 233,385 0.29 34 Lohari Gate-IV (PM Package) 799,350 209,899 0.26 35 Madina Colony-I 1,024,920 204,762 0.20 36 MDA Chowk-I 932,940 246,595 0.26 37 Mohammadi Ground Shah Shams 812,490 170,268 0.21 38 MDA Chowk-II 897,900 198,891 0.22 39 Mumtazabad-I 1,011,780 241,898 0.24 40 Mumtazabad-II 908,850 192,286 0.21 41 Mushtaq Colony (Phase-VI) 959,220 215,037 0.22 42 Muzaffarabad (Phase-VI) 1,195,740 188,616 0.16 43 Naqshband Colony 1,051,200 231,917 0.22 44 Nawab Pur Road 792,780 183,479 0.23 45 Nawan Shaher-I 1,068,720 236,320 0.22 46 New Shah Shamas Colony 843,150 230,449 0.27 47 Niaz Town (Phase-VI) 825,630 195,955 0.24 48 Pizza Hutt Gulberg 678,900 175,405 0.26 49 Pir Zahid Shah-I (Phase-VI) 1,154,130 237,788 0.21 50 Purana Burf Khana 821,250 254,081 0.31 51 Qasim Pur Colony-I 766,500 228,908 0.30 52 Qasim Pur Colony-II 930,750 248,643 0.27 53 Rasheed Abad 678,900 163,663 0.24 54 Sameejabad -Hassan Abad Gate-II 1,121,280 230,155 0.21 55 Sameejabad 711,750 132,633 0.19 56 Shah Shamas Park (PM Package) 941,700 228,247 0.24 57 Shalimar Colony (Phase-VI) 1,062,150 185,680 0.17 58 Shamasbad-I 814,680 190,818 0.23 59 Shamasbad (PM Package) 1,116,900 236,320 0.21 60 Siddique Abad 437,562 87,336 0.20 61 Silli Khana (PM Package) 711,750 179,809 0.25 62 Tibbi Sher Khan (PM Package) 797,160 202,560 0.25 63 Timber Market Ground 1,270,200 237,788 0.19 64 Tughlaq Town 832,200 179,075 0.22 65 W-Block New Multan-I 849,720 242,192 0.29 66 Willayatabad 635,100 176,873 0.28 Total 58,215,675 13,277,750 0.23
15
Total annual energy cost of Waterworks subdivision is about Rs. 172.6 million. The unit electricity consumption trend for each WASA station is illustrated in Fig-2A, Fig-2B and Fig-2C. 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-2A: Unit Electricity Consumption Trend
Figure-2B: Unit Electricity Consumption Trend
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
kWh/m3
Optimum
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
kWh/m3
Optimum
16
Figure-2C: Unit Electricity Consumption Trend
About 76% of the tube wells consume electricity more than the 0.20 kWh/m3. In case if all the 66 tube wells consume optimum electricity, then annually Rs. 21.2 million (12%) can be saved.
2.3 Pumping System Efficiency Improvement Potential
At waterworks subdivision Multan, fifty-four tube wells 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 Tube Wells
WASA Station Existing Pumping Efficiency
(%)
Improved Pumping Efficiency
(%)
Annual
(kWh)
Saving
(Rs)
Impeller Adjustment /Repair &
Maintenance
Impeller Adjustment
Intervention
Motor Replace
Pump Replace
Al-Jillan 39 65 75,994 987,925 Al-Sana Hotel 31 65 117,281 1,524,655 × Ansar Colony-I 59 65 32,860 427,178 × B.C.G Chowk 44 65 76,847 999,014 × Board Office-Gulgasht Colony 51 65 40,319 524,143 × Bagh Langey Khan-I 51 65 49,427 642,547 × Baghchi Mirza Jan 56 65 25,827 335,753 × Basti Khudadad 47 65 53,753 698,790 × Bodla Town 53 65 44,459 577,963 × Chain Mari Farooq Pura 41 65 68,345 888,489 × Chowk Shaheedan-I 51 65 38,373 498,847 ×
Chowk Shaheedan-II 48 65 50,933 662,130 × Circuit House 51 65 34,971 454,621 ×
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
kWh/m3
Optimum
×
17
WASA Station Existing Pumping Efficiency
(%)
Improved Pumping Efficiency
(%)
Annual
(kWh)
Saving
(Rs)
Impeller Adjustment /Repair &
Maintenance
Impeller Adjustment
Intervention
Motor Replace
Pump
Replace
D-Block SRA-II 61 65 15,828 205,762 × Dhobi Ghat-I 57 65 23,912 310,852 × E-Block SRA 56 65 25,056 325,722 × Grass Mandi 39 65 36,318 472,134 × Gujjar Plot 55 65 29,984 389,792 × Hassan Parwana-II 51 65 49,993 649,908 × Kabootar Mandi 40 65 49,993 649,908 × K-Block SRAI 42 65 68,288 887,749 × Khar Pur 58 65 23,374 303,856 × Lodhi Colony-I 49 65 48,748 633,721 × Lodhi Colony-II 60 65 17,219 223,853 × Lohari Gate-I 45 65 73,755 958,817 × Lohari Gate-IV 47 65 57,029 741,378 × Madina Colony-I 63 65 5,116 66,509 × MDA Chowk-I 42 65 85,230 1,107,991 × Mohammadi Ground Shah Shams
62 65 7,865 102,243 ×
MDA Chowk-II 49 65 47,585 618,606 × Mumtazabad-I 55 65 36,467 474,075 × Mumtazabad-II 60 65 14,699 191,086 × Mushtaq Colony 47 65 60,134 781,743 × Muzaffarabad 62 65 6,380 82,940 × Nawab Pur Road 49 65 44,029 572,374 × Nawan Shaher-I 52 65 47,668 619,690 × New Shah Shamas Colony 48 65 61,545 800,091 ×
Niaz Town 59 65 17,823 231,700 × Pizza Hutt Gulberg 46 65 52,349 680,537 × Pir Zahid Shah-I 52 65 46,886 609,524 × Purana Burf Khana 48 65 68,189 886,459 × Qasim Pur Colony-I 37 65 98,897 1,285,660 × Qasim Pur Colony-II 52 65 49,902 648,721 × Rasheed Abad 46 65 49,104 638,347 × Sameejabad -Hassanabad Gate-II 47 65 64,348 836,528 ×
Shalimar Colony 54 65 32,076 416,989 × Shamasbad-I 56 65 25,862 336,203 × Shamasbad 36 65 103,907 1,350,796 × Siddique Abad 52 62 13,658 177,551 × Silli Khana 47 65 50,519 656,744 × Tibbi Sher Khan 51 65 45,277 588,597 × W-Block New Multan-I 39 65 95,556 1,242,233 ×
Willayatabad 42 65 62,070 806,912 × Total 2,522,027 32,786,356
18
2.4 Interventions for the Improvement of WASA Stations Energy audit activity of Waterworks subdivision revealed that there are certain areas of electrical, mechanical and housekeeping which needs improvement. Table-7A, 7B, 7C, 7D and 7E presents detail of interventions and investment requirement in each WASA station for better, efficient and safe operation of WASA station. About Rs. 51.52 million are required to improve WASA stations of Waterworks subdivision, Multan.
19
Table-7A: Interventions & Investment Required in WASA Stations- Waterworks Subdivision
Intervention WASA Stations
Al-Jillan Al-
Sana Hotel
Ansar Colony-I
B.C.G Chowk
Board Office
Bagh Langey Khan-I
Baghchi Mirza Jan
Basti Khudadad
Bodla Town
Bosan Road PTCL
Chain Mari
Farooq Pura
Chowk Shaheedan-I
Chowk Shaheedan-II
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/install MCCB × Mechanical
20
Intervention WASA Stations
Al-Jillan Al-
Sana Hotel
Ansar Colony-I
B.C.G Chowk
Board Office
Bagh Langey Khan-I
Baghchi Mirza Jan
Basti Khudadad
Bodla Town
Bosan Road PTCL
Chain Mari
Farooq Pura
Chowk Shaheedan-I
Chowk Shaheedan-II
Replace damaged/install new flow meter
× × × × × × ×
Replace damaged/install new digital pressure gauge
× × × × × × × × × ×
Control gland leakage × × × × × × × × × × × × × Make operational/install new chlorinator
× × × × × × × × × × × × ×
Maintain ratchet plate Adjustment/ repair & maintenance 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) 0.82 1.04 0.72 0.84 0.72 0.84 0.72 0.84 0.72 0.77 0.84 0.84 0.84 Annual Saving (M. Rs) 0.99 1.52 0.43 1.00 0.52 0.64 0.34 0.70 0.58 - 0.89 0.50 0.66 Payback (Year) 0.83 0.68 1.68 0.84 1.37 1.31 2.14 1.21 1.24 - 0.95 1.69 1.27
21
Table-7B: Interventions & Investment Required in WASA Stations- Waterworks Subdivision Intervention WASA Stations Circuit
House D-Block SRA-I
D-Block SRA-II
Dhobi Ghat-I
E-Block SRA
Eid Gah-I
G-Block SRAI
Grass Mandi
Gujjar Plot
Gulberg Colony
Gulshan Market-I
Hassan Parwana
-II
Hassan Parwana-I
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
22
Intervention WASA Stations Circuit House
D-Block SRA-I
D-Block SRA-II
Dhobi Ghat-I
E-Block SRA
Eid Gah-I
G-Block SRAI
Grass Mandi
Gujjar Plot
Gulberg Colony
Gulshan Market-I
Hassan Parwana
-II
Hassan Parwana-I
Mechanical Replace damaged/install new flow meter
× × × × ×
Replace damaged/install new digital pressure gauge
× × × × × × × × × × ×
Control gland leakage × × × × × × × × × Make operational/install new chlorinator
× × × × × × × × × ×
Maintain ratchet plate Adjustment, repair & maintenance 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 0.72 0.61 0.74 0.72 0.74 0.72 0.82 0.72 0.67 0.74 0.84 0.71
Annual Saving (M. Rs) 0.45 0.21 - 0.31 0.33 - - 0.47 0.39 - - 0.65 - Payback (Year) 1.64 3.49 - 2.39 2.20 - - 1.73 1.84 - - 1.30 -
23
Table-7C: Interventions & Investment Required in WASA Stations- Waterworks Subdivision Intervention WASA Stations Kabootar
Mandi K-Block Khar Pur Kiri
Daud Khan
Lodhi Colony-
I
Lodhi colony-
II
Lohari Gate-I
Lohari Gate-
IV
Madina Colony-I
MDA Chowk-I
Mohammadi Ground shah
Shams
MDA Chowk-II
Mumtaz abad-I
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 × Replace/correct electrical meter × × × Replace change over × Replace main circuit breaker Mechanical Replace damaged/install new flow meter
× × × × × × × ×
24
Intervention WASA Stations Kabootar
Mandi K-Block Khar Pur Kiri
Daud Khan
Lodhi Colony-
I
Lodhi colony-
II
Lohari Gate-I
Lohari Gate-
IV
Madina Colony-I
MDA Chowk-I
Mohammadi Ground shah
Shams
MDA Chowk-II
Mumtaz abad-I
Replace damaged/install new digital pressure gauge
× × × × × × × × × ×
Control gland leakage × × × × × × × × × × × Make operational/install new chlorinator
× × × × × × × × × × × ×
Maintain ratchet plate × Adjustment, repair & maintenance 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 0.67 0.82 0.84 0.84 0.84 0.82 0.84 0.84 0.84 0.74 0.84 0.74 Annual Saving (M. Rs) 0.65 0.89 0.30 - 0.63 0.22 0.96 0.74 0.07 1.11 0.10 0.62 0.47 Payback (Year) 1.14 0.75 2.70 - 1.33 3.77 0.85 1.14 12.67 0.76 7.27 1.36 1.57
25
Table-7D: Interventions & Investment Required in WASA Stations- Waterworks Subdivision Intervention WASA Stations Mumta
zabad-II
Mushtaq Colony
Muzaffarabad
Naqsh-band
colony
Nawab Pur road
Nawan Shaher
-I
New Shah
Shamas
Niaz Town
Pizza Hutt
Pir Zahid Shah-I
Purana Burf
Khana
Qasim Pur
Colony-I
Qasim Pur
Colony-II 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 MCCB × × × Mechanical
26
Intervention WASA Stations Mumtazabad-
II
Mushtaq Colony
Muzaffarabad
Naqsh-band
colony
Nawab Pur road
Nawan Shaher
-I
New Shah
Shamas
Niaz Town
Pizza Hutt
Pir Zahid Shah-I
Purana Burf
Khana
Qasim Pur
Colony-I
Qasim Pur
Colony-II Replace damaged/install new flow meter
× × × × × ×
Replace damaged/install new digital pressure gauge
× × × × × × × × × × × ×
Control gland leakage × × × × × × × × × × × × Make operational/install new chlorinator
× × × × × × × × × × × × ×
Maintain ratchet plate × ×Adjustment, repair & maintenance 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 0.82 0.84 0.74 0.82 0.84 0.74 0.82 0.82 0.82 0.87 0.84 0.82 Annual Saving (M. Rs) 0.19 0.78 0.08 - 0.57 0.62 0.80 0.23 0.68 0.61 0.89 1.29 0.65 Payback (Year) 3.89 1.05 10.16 - 1.43 1.36 0.93 3.53 1.20 1.34 0.98 0.66 1.26
27
Table-7E: Interventions & Investment Required in WASA Stations- Waterworks Subdivision
Intervention WASA Stations Rasheed
Abad Sameeja-
bad -Hassan Abad
Sameej- abad
Shah Shamas
Park
Shali- mar
Colony
Shamasbad
-I
Shamasbad
Siddique Abad
Silli Khana
Tibbi Sher Khan
Timber Market
Tughlaq Town
W-Block
WillayatAbad
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
28
Intervention WASA Stations Rasheed
Abad Sameeja-
bad -Hassan Abad
Sameej- abad
Shah Shamas
Park
Shali- mar
Colony
Shamasbad
-I
Shamasbad
Siddique Abad
Silli Khana
Tibbi Sher Khan
Timber Market
Tughlaq Town
W-Block
WillayatAbad
Replace damaged/install new flow meter
× × × ×
Replace damaged/install new digital pressure gauge
× × × × × × × × × × × × ×
Control gland leakage × × × × × × × × × × × × × × Make operational/install new chlorinator
× × × × × × × × × × × × ×
Maintain ratchet plate × Adjustment, repair & maintenance 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) 0.71 0.77 0.74 0.79 0.82 0.82 0.72 0.48 0.84 0.82 0.84 0.67 0.72 0.76
Annual Saving (M. Rs) 0.64 0.84 - - 0.42 0.34 1.35 0.18 0.66 0.59 - - 1.24 0.81 Payback (Year) 1.11 0.92 - - 1.96 2.43 0.53 2.70 1.28 1.39 - - 0.58 0.94 Total Investment of Subdivision (M.Rs) = 51.52
29
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 GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station AL JILLAN
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact SAFDAR HUSSAIN 0303-0740604
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4360
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NOT VISIBLE
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 GOOD
Gland Leakage GOOD
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge INSTALLED-OPERATIONAL
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 276 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.51 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 23 meter
Electric Measurements
i) Voltage 386 389 385
ii) Ampere 147 149 140
iii) Power Factor 0.88 0.9 0.84
iv) Appearant Power (kVA) 98 100 90
v) Running Power (kW) 87 89 86 87.3
vi) Reactive Power (kVAr) 45 47 50
vi) Motor Working on Loading Basis 79
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,498 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 5.23 ft
vii) Dynamic Discharge Head (v+vi) 74.53 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 149.97 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 74.10
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,208
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 46.02 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 117.07 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 41.00 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 39.31 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.32 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,656 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 604,440 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 192,286 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,499,712 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 456 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
xxix) Potential of Energy Reduction 39.52
xxx) Reduced Annual Energy Consumption at Improved Efficiency 75,994
xxxi) Annual Financial Saving on Pumping 987,925
11 Summary of Findings
Efficiency of the pumping system is 39%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeller adjustments, repair and maintenance to increase its efficiency to 65%. This intervention will save Rs. 987,925 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 818,000 PKR
No PFI plant PFI plant is recommended is recommended
Chlorinator is recommendedNo chlorinator
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station AL SANA HOTEL
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact SHAUKAT SHAH 0304-7932115
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4042
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NA
iii) Meter Time and Date
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 50 KVAR-OPERATIONAL
Panel Condition/Issues GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter FAULTY
Pressure Gauge FAULTY
Bore Hole in Front of PaneNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 840 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 267 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.46 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 383 390 389
ii) Ampere 164 162 186
iii) Power Factor 0.93 0.88 0.89
iv) Appearant Power (kVA) 109 109 126
v) Running Power (kW) 102 91 113 102.0
vi) Reactive Power (kVAr) 39 62 58
vi) Motor Working on Loading Basis 93
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,496 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93.4
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 4.85 ft
vii) Dynamic Discharge Head (v+vi) 74.15 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 143.03 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 71.68
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,231
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) 42.46 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 136.73 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 37.74 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 31.06 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.38 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,602 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 584,730 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 224,578 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,919,511 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 559 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 52.22
xxx) Reduced Annual Energy Consumption at Improved Efficiency 117,281
xxxi) Annual Financial Saving on Pumping 1,524,655
11 Summary of Findings
Efficiency of the pumping system is 31%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires pump replacement, impeler adjustments, repair and maintenance to increase its efficiency to 65%. This intervention will save Rs 1,524,655 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 1,043,000 PKR
Replacement of pump is recommendedPump is inefficient
Chlorinator is recommendedNo chlorinator
Faulty pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
Faulty water flowmeter Water flowmeter is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station ANSAR COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M ZAHID 0300 6387489
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.46 BHP
ix) Speed (n) 1485 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)
177366
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 21892
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 55 KVAR
Panel Condition/Issues GOOD/NO V METER
Gland Leakage NO
Non Return Valve OK
Chlorinator FAULTY
Flow Meter INSTALLED
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1025 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z)
viii) Flow Measurement 410 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.56 m/sec
Pressure
i) Pressure at Discharge Side of Pump 35 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 420 425 424
ii) Ampere 177 178 156
iii) Power Factor 0.81 0.83 0.84
iv) Appearant Power (kVA) 129 130 114
v) Running Power (kW) 104 108 97 103.0
vi) Reactive Power (kVAr) 76 73 61
vi) Motor Working on Loading Basis 94
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,479 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 94.6
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) 16.4 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) 80.85 ft
vi) Discharge Side Frictional Head 5.49 ft
vii) Dynamic Discharge Head (v+vi) 86.34 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 168.34 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 110.08
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,318
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) 76.74 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.46 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 138.07 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 62.16 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 55.58 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,460 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 897,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 226,779 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,948,133 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 479 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.22 kWh/m3
xxix) Potential of Energy Reduction 14.49 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 32,860 kWh/yr
xxxi) Annual Financial Saving on Pumping 427,178 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 59%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is GOOD efficiency. This intervention will save 427,178 Rs annually.
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 718,500 PKR
Replacement of relays is recommendedOver voltage current relays and over/under voltage relay is defective
Instal chlorinatorFaulty chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
Install V meterV meter is not installed
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station BAGH LANGAY KHAN
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact AJMAL 0305 3396009
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pre. Psig
viii) Power / HP / BHP 123.46 BHP
ix) Speed (n) 1485 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)
17-7410
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 3540
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 MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter FAULTY
Pressure Gauge FAULTY
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 443 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.69 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 360 351 354
ii) Ampere 188 197 156
iii) Power Factor 0.95 0.92 0.93
iv) Appearant Power (kVA) 116 120 112
v) Running Power (kW) 109 112 97 106.0
vi) Reactive Power (kVAr) 36 45 37
vi) Motor Working on Loading Basis 96
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 96
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 6.34 ft
vii) Dynamic Discharge Head (v+vi) 75.64 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 147.80 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 118.93
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,511
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) 72.80 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.46 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 142.09 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 58.97 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.23 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,658 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 970,170 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 233,385 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,034,001 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 562 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
xxix) Potential of Energy Reduction 21.18 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 49,427 kWh/yr
xxxi) Annual Financial Saving on Pumping 642,547 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 51%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save Rs. 642,547 annually.
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 843,000 PKR
No chlorinator Chlorinator is recommended
Digital pressure guage is recommendedDefective pressure guage
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
Faulty flow meter Flowmeter is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station BAGHEECHA MIRZA JAN
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact AMJAD 0311-6099289
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B12 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pre. Psig
viii) Power / HP / BHP 122.5 BHP
ix) Speed (n) 1485 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)
21-06-10-6687
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 22 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 28578
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 65 KVAR - OPERATIONAL
Panel Condition/Issues POOR
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator FAULTY
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge FAULTY
Bore Hole in Front of Pan NO
Wiring POOR
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 860 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 442 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.42 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 19 meter
ii) Pumping Water Level 24 meter
Electric Measurements
i) Voltage 404 401 399
ii) Ampere 136 137 143
iii) Power Factor 0.94 0.93 0.89
iv) Appearant Power (kVA) 75.4 78.1 80
v) Running Power (kW) 91 96 90 92.3
vi) Reactive Power (kVAr) 25 36 38
vi) Motor Working on Loading Basis 84
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,509 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93.4
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) 16.4 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) 50.82 ft
vi) Discharge Side Frictional Head 13.37 ft
vii) Dynamic Discharge Head (v+vi) 64.19 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 142.91 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 118.67
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,585
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) 70.23 hp
xiv) Brake Horsepower (bhp) (OEM Data) 122.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 123.77 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 57.33 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 56.74 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,652 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 967,980 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 203,294 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,642,825 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 506 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 12.70
xxx) Reduced Annual Energy Consumption at Improved Efficiency 25,827
xxxi) Annual Financial Saving on Pumping 335,753
11 Summary of Findings
Efficiency of the pumping system is 56%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save Rs. 335,753 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators12 Estimated Investment for Improvement Plan 718,000 PKR
Chlorinator is recommendedFaulty chlorinator
Faulty pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station BASTI KHUDADAD
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact MEHMOOD 0301-7876266
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4195
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 11 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NA
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 GOOD
Gland Leakage GOOD
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 482 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.64 m/sec
Pressure
i) Pressure at Discharge Side of Pump 11 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 378 373 375
ii) Ampere 171 170 172
iii) Power Factor 0.8 0.79 0.81
iv) Appearant Power (kVA) 112 110 112
v) Running Power (kW) 91 87 92 90.0
vi) Reactive Power (kVAr) 66 68 69
vi) Motor Working on Loading Basis 82
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,498 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.5
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) 16.4 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) 25.41 ft
vi) Discharge Side Frictional Head 15.62 ft
vii) Dynamic Discharge Head (v+vi) 41.03 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 106.63 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 129.41
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 2,062
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) 57.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 120.64 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 50.91 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 47.37 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.19 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,892 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,055,580 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 198,157 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,576,039 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 661 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.14 kWh/m3
xxix) Potential of Energy Reduction 27.13
xxx) Reduced Annual Energy Consumption at Improved Efficiency 53,753
xxxi) Annual Financial Saving on Pumping 698,790
11 Summary of Findings
Efficiency of the pumping system is 47%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments, repair and maintenance to increase its efficiency to 65%. This intervention will save Rs 698,790 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 843,000 PKR
Water flowmeter is recommendedNo water flow meter
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No PFI plant PFI plant is recommended is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer HUR/GUL
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station BCG CHOWK
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact ZAFAR ULLAH
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 6 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4075
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 3749
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 EXCELLENT
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring EXCELLENT
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 860 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 410 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.25 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 14 meter
ii) Pumping Water Level 19 meter
Electric Measurements
i) Voltage 348 346 359
ii) Ampere 207 202 185
iii) Power Factor 0.93 0.88 0.9
iv) Appearant Power (kVA) 125 120 116
v) Running Power (kW) 117 107 105 109.7
vi) Reactive Power (kVAr) 45 54 47
vi) Motor Working on Loading Basis 100
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,499 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.5
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 11.28 ft
vii) Dynamic Discharge Head (v+vi) 80.58 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 142.90 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 110.08
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,491
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) 65.14 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 147.01 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 57.90 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 44.31 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.27 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,460 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 897,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 241,458 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,138,951 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 601 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 31.83 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 76,847 kWh/yr
xxxi) Annual Financial Saving on Pumping 999,014 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 44%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. Motor is overloaded, after this intervention the load of the motor will be decreased. This intervention will save 999,014 Rs annually.
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 843,000 PKR
No chlorinator Chlorinator is recommended
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station BOARD OFFICE GULGASHT COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M ARSHAD 0308-9001576
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4422
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 32 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 13223/1324
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 60 KVAR
Panel Condition/Issues EXCELLENT
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator FAULTY
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring EXCELLENT
Housekeeping GOOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1025 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 384 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.46 m/sec
Pressure
i) Pressure at Discharge Side of Pump 32 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 397 399 397
ii) Ampere 142 131 140
iii) Power Factor 0.92 0.93 0.96
iv) Appearant Power (kVA) 98 91 97
v) Running Power (kW) 90 84 93 89.0
vi) Reactive Power (kVAr) 38 33 27
vi) Motor Working on Loading Basis 81
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.4
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) 16.4 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) 73.92 ft
vi) Discharge Side Frictional Head 4.74 ft
vii) Dynamic Discharge Head (v+vi) 78.66 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 144.26 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 103.09
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,467
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) 61.59 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 119.30 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 54.87 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.63 %
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 6 hrs
xxi) Daily Pump flow 2,304 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 840,960 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 195,955 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,547,416 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 483 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
xxix) Potential of Energy Reduction 20.58
xxx) Reduced Annual Energy Consumption at Improved Efficiency 40,319
xxxi) Annual Financial Saving on Pumping 524,143
11 Summary of Findings
Efficiency of the pumping system is 51%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save Rs. 524,143 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 718,000 PKR
No PFI display meter PFI display meter is recommended
Install chlorinatorFaulty chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Bodla Town
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Qazi Akthar abbas 0300-7376971
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B 14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.32 BHP
ix) Speed (n) 1485 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)
18-4365
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 1000 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 209.5
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 2509.35
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 40 kvar OPERATIONAL
Panel Condition/Issues GOOD
Gland Leakage MODIRATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1000 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 475.7 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.81 m/sec
Pressure
i) Pressure at Discharge Side of Pump 23 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 396.7 397.1 397.8
ii) Ampere 157.4 164.8 164.9
iii) Power Factor 0.96 0.95 0.96
iv) Appearant Power (kVA) 108.1 113.2 114.7
v) Running Power (kW) 103.9 105.6 110.6 106.7
vi) Reactive Power (kVAr) 29.33 33.34 31.24
vi) Motor Working on Loading Basis 97
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.9
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) 32.8 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) 53.13 ft
vi) Discharge Side Frictional Head 7.38 ft
vii) Dynamic Discharge Head (v+vi) 60.51 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 142.51 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 63.86
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,637
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 75.38 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.32 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 143.03 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 61.12 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 52.70 %
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 6 hrs
xxi) Daily Pump flow 2,854 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,041,783 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 234,926 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,054,037 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 587 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 18.92 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 44,459 kWh/yr
xxxi) Annual Financial Saving on Pumping 577,963 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 52.70%. For 150 HP motor efficiency <58.9% is LOW. This pumping system requires impeller adjustment, . This intervention will improve the efficiency from 52.70% to 65%. Which is in range of GOOD EFFICIENCY. This intervention will save 577,963 PKR annually.
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 718,000 PKR
Adjust impellerPumping system requires impeller adjustment
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No chlorinator Chlorinator is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 r Wastewater Disposal
3 r Waste Water Treatment Plant
4 r Water Treatment Plant
Name of Engineer IZHAR/WASEEM
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station PTCL
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact AJMAL 0300-5002711
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
r Submersible Deep Well Water Turbine Pumps Qty
r Centrifugal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 1
r Series
r Parallel
vii) Any Header / Tank / Reservoir
r Yes No
viii) Any Record Keeping
Time r Flow r Pressure
r Level r Quality of Water r Power Consumption
6 Maintenance Record r Electricity Bill r Fuel Consumption Data
viii) Daily Operational Time 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO r 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
r Submersible
r Overhung
r Between Bearing
ii) Mounting / Erection
r Horizontal Vertical
Foundation
iii) Concrete Bolted r Bolted
iv) Lubrication Type
r Oil Water
v) Cooling Type
r Water Cooled Air Cooled
vi) Number of Stages
r Single Multi 4
vii) Pump and Motor Assembly
Direct Coupled r Belt / Gear
viii) Source of Suction
Ground Water Aquafier r Overhead Tank r Underground Tank
r Pressurized Source
ix) Pump Discharge Destination
r Overhead Tank r Drain r On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF r Proportional
x) Pump Flow Control
Throttle r VFD Controlled
xi) Any Retrofits ?
r Impeller Detail
r Casing / Volute Detail
r Line Shaft (DW) Detail
r Column Sett. (DW) Detail
r Motor Replacement Detail
r Motor Rewinding Detail
xii) Self Priming
r Yes r No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
r Yes No
xiv) Flowmeter Available
r Yes No
xv) Flowmeter Working
r Working Properly r Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) ModelB14 B/4
Serial
iii) Certification Mark
iv) Year of Manufacture2009
v) Flowrate (Q) 4
Cusec 408 m3/hr
vi) Head (H)200
ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP112.25
BHP
ix) Speed (n)1485
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
r 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 r Yes No
ix) Suction Pressure (Not Valid incase of Tubewells)
18-4370
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1 r
r Strainer r
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 r Yes No (Installed by Team)
viii) Discharge Pressure 60 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
Efficiency Class
r IE3 r Eff 1
r IE2 r Eff 2
r IE1 r 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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1340.72
iii) Meter Time and Date
Correct r FALSE
r Lag by r Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
r Direct Online Star (Wye) - Delta
r Autotransformer Starter r Soft Starter
r 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 EXCELLENT/FAULTY (V) METER
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NOT INSTALLED
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanelNO
Wiring EXCELLENT
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe r Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes r No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1010 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 315 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.20 m/sec
Pressure
i) Pressure at Discharge Side of Pump 60 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 379 378 379
ii) Ampere 166 168 161
iii) Power Factor 0.75 0.75 0.77
iv) Appearant Power (kVA) 109 110 108
v) Running Power (kW) 82 83 84 83.0
vi) Reactive Power (kVAr) 71 73 69
vi) Motor Working on Loading Basis 75
r Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.1
Thermal Imaging
i) Motor r Motor Pump Coupling
r Pump Volute Casing r Pump Bearings
Electric Panels
Calculations
10
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) 138.6 ft
vi) Discharge Side Frictional Head 3.21 ft
vii) Dynamic Discharge Head (v+vi) 141.81 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 210.69 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 84.57
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce
1gpm/ft head 1,000
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) 73.79 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 111.26 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 65.74 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 66.32 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.26 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,890 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 689,850 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 182,745 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,375,680 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 309 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.27 kWh/m3
11 Summary of Findings
Efficiency of the pumping system is 66%. For 150 HP motor efficiency >=68% is 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 768,500 PKR
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
Replace faulty Volt meter by correct oneDefective Volt meter
Install chlorinatorFaulty chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station CHAIN MARRI
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact KHADIM 0303-4080802
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial 18-4023
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 13 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 2090
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 GOOD
Gland Leakage GOOD
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 870 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 410 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.25 m/sec
Pressure
i) Pressure at Discharge Side of Pump 13 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 390 388 389
ii) Ampere 172 185 189
iii) Power Factor 0.72 0.75 0.74
iv) Appearant Power (kVA) 116 125 122
v) Running Power (kW) 84 93 84 87.0
vi) Reactive Power (kVAr) 80 82 83
vi) Motor Working on Loading Basis 79
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,491 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 95
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) 16.4 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) 30.03 ft
vi) Discharge Side Frictional Head 11.33 ft
vii) Dynamic Discharge Head (v+vi) 41.36 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 106.96 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 110.08
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,897
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 48.76 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 116.62 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 43.44 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 41.81 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,460 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 897,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 191,552 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,490,171 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 637 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.14 kWh/m3
xxix) Potential of Energy Reduction 35.68
xxx) Reduced Annual Energy Consumption at Improved Efficiency 68,345
xxxi) Annual Financial Saving on Pumping 888,489
11 Summary of Findings
Efficiency of the pumping system is 41%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments, repair nad maintenance to increase its efficiency to 65%. This intervention will save Rs. 888,489 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 843,000 PKR
Water flowmeter is recommendedNo water flow meter
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No PFI plant PFI plant is recommended is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station CHOWK SHAHEEDAN-1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact MAJID 0345 7251218
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4143
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NOT VISIBLE
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 GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter FAULTY
Pressure Gauge FAULTY
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 267 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 350 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.92 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 380 377 377
ii) Ampere 164 174 164
iii) Power Factor 0.75 0.77 0.76
iv) Appearant Power (kVA) 110 114 108
v) Running Power (kW) 84 86 83 84.3
vi) Reactive Power (kVAr) 74 75 69
vi) Motor Working on Loading Basis 77
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.4
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 8.34 ft
vii) Dynamic Discharge Head (v+vi) 77.64 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 149.80 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 93.97
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,361
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 58.30 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 113.05 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 51.93 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.57 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,100 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 766,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 185,680 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,413,844 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 441 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
xxix) Potential of Energy Reduction 20.67 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 38,373 kWh/yr
xxxi) Annual Financial Saving on Pumping 498,847 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 51%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 498,847 Rs annually.
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 843,000 PKR
Water flow meter repairing or replacement is requiredWater flow meter is out of order
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
Faulty chlorinator Chlorinator is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
Faulty pressure guage Digital pressure guage is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station CHOWK SHAHEEDAN-2
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact MAJID 0345 7251218
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4191
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 18 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NOT VISIBLE
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 GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 437 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.66 m/sec
Pressure
i) Pressure at Discharge Side of Pump 18 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 364 363 366
ii) Ampere 173 180 170
iii) Power Factor 0.79 0.82 0.83
iv) Appearant Power (kVA) 109 110 107
v) Running Power (kW) 87 93 90 90.0
vi) Reactive Power (kVAr) 66 64 59
vi) Motor Working on Loading Basis 82
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,495 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.5
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) 16.4 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) 41.58 ft
vi) Discharge Side Frictional Head 6.17 ft
vii) Dynamic Discharge Head (v+vi) 47.75 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 119.91 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 117.32
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,798
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 58.26 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 120.64 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 51.79 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 48.29 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,622 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 957,030 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 198,157 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,576,039 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 588 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.15 kWh/m3
xxix) Potential of Energy Reduction 25.70 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 50,933 kWh/yr
xxxi) Annual Financial Saving on Pumping 662,130 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 48%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 662,130 Rs annually.
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 843,000 PKR
Water flowmeter is recommendedNo water flowmeter
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No chlorinator Chlorinator is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No pressure guage Digital pressure guage is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station CIRCUIT HOUSE
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M HASHIM 0300-7342629
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 88.7 BHP
ix) Speed (n) 1485 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)
14-0016
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 14813
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 40 Kvar-OPERATIONAL
Panel Condition/Issues POOR/NO V & A METER
Gland Leakage NO
Non Return Valve OK
Chlorinator FAULTY
Flow Meter FAULTY
Pressure Gauge FAULTY
Bore Hole in Front of PanNO
Wiring POOR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 375 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.06 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 14 meter
ii) Pumping Water Level 19 meter
Electric Measurements
i) Voltage 365 362 347
ii) Ampere 125 118 109
iii) Power Factor 0.94 0.97 0.94
iv) Appearant Power (kVA) 79 73 67
v) Running Power (kW) 74 75 68 72.3
vi) Reactive Power (kVAr) 61 62 55
vi) Motor Working on Loading Basis 66
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,494 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.2
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) 16.4 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) 46.2 ft
vi) Discharge Side Frictional Head 9.45 ft
vii) Dynamic Discharge Head (v+vi) 55.65 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 117.97 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 100.68
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,686
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 49.19 hp
xiv) Brake Horsepower (bhp) (OEM Data) 88.7 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 96.96 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 55.45 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 50.73 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.19 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,250 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 821,250 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 159,259 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,070,372 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 481 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.15 kWh/m3
xxix) Potential of Energy Reduction 21.96
xxx) Reduced Annual Energy Consumption at Improved Efficiency 34,971
xxxi) Annual Financial Saving on Pumping 454,621
11 Summary of Findings
Efficiency of the pumping system is 51%. For 150 HP motor efficiency <58% is LOW and efficiency ≥65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save Rs. 454,621 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 744,000 PKR
Water flowmeter is recommendedFaulty water flow meter
Chlorinator is recommendedFaulty chlorinator
Faulty pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No Volt and Ampere meter Volt and Ampere meter is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station D-Block New
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Azhar Javeed 0302-7499747
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model B14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.26 BHP
ix) Speed (n) 1485 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)
18-4027
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 35 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 209.5
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 2155.26
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 40 KVAR OPREATIONAL
Panel Condition/Issues FAIR
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring FAIR
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
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 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1010 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 460 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.75 m/sec
Pressure
i) Pressure at Discharge Side of Pump 35 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 19 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 390.8 392.5 394.6
ii) Ampere 160.9 173.1 163.8
iii) Power Factor 0.97 0.92 0.93
iv) Appearant Power (kVA) 111.7 118.2 115.2
v) Running Power (kW) 105.7 108.5 106.3 106.8
vi) Reactive Power (kVAr) 36.05 44.8 45.09
vi) Motor Working on Loading Basis 97
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93
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) 20.008 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) 80.85 ft
vi) Discharge Side Frictional Head 6.90 ft
vii) Dynamic Discharge Head (v+vi) 87.75 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 169.75 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 101.23
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,412
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) 86.82 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.26 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 143.21 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 70.44 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 60.63 %
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 6 hrs
xxi) Daily Pump flow 2,760 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,007,400 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 235,220 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,057,854 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 493 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.22 kWh/m3
xxix) Potential of Energy Reduction 6.73 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 15,828 kWh/yr
xxxi) Annual Financial Saving on Pumping 205,762 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 60.63%. For 150 HP motor efficiency between 58.9-63.1% is FAIR. This pumping system requires impeller adjustment . This intervention will improve the efficiency from 60.63% to 65%. Which is in range of GOOD EFFICIENCY. This intervention will save 205,762 PKR annually.
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 718,500 PKR
Replace faulty Ampere meter with correct oneDefective Ampere meter
Overload current relays and over/under voltage phase failure relay is not available Overload current relays and over/under phase failure voltage relays is recommended
Chlorinator is recommendedNo chlorinator
New rachet plate is recommendedFaulty rachet plate
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station D-Block Old
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Azhar Javeed 0302-7499747
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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 3
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
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model B14-B/3 Serial
iii) Certification Mark
iv) Year of Manufacture 2001
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 92.99 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)
14-5661
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 125 hp 93.75 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 173.5
v) Power Factor (Cos ɸ) 0.87
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,480 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 280-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1109.24
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 25 Kvar OPREATIONAL
Panel Condition/Issues GOOD
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator INSTALLED
Flow Meter INSTALLED
Pressure Gauge INSTALLED
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
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 860 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 462 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.53 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 19 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 402.5 399.5 400.2
ii) Ampere 133.9 141.1 133.3
iii) Power Factor 0.95 0.94 0.93
iv) Appearant Power (kVA) 93.46 97.82 92.49
v) Running Power (kW) 89.16 92.2 95.64 92.3
vi) Reactive Power (kVAr) 28.24 33.07 35.43
vi) Motor Working on Loading Basis 84
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,480 RPM
ii) Speed of Pump Impeller 1470 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 94.5
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) 20.008 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) 69.3 ft
vi) Discharge Side Frictional Head 14.65 ft
vii) Dynamic Discharge Head (v+vi) 83.95 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 165.95 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 101.67
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,434
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) 85.25 hp
xiv) Brake Horsepower (bhp) (OEM Data) 92.99 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 123.77 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 91.67 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 68.87 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,772 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,011,780 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 203,294 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,642,825 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 68.9%. For 125 HP motor efficiency >=66% is 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 608,500 PKR
Replace faulty A meter by correct oneDefective A meter
Over voltage current relays and over/under voltage relay is not available Over voltage current relays and over/under voltage relays is recommended
Chlorinator is recommendedDefective chlorinator
New rachet plate is recommendedFaulty rachet plate
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station DHOBI GHATT
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M SAEED 0301-7859065
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4360
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1316.68/18276.5
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 30 KVAR OPERATIONAL
Panel Condition/Issues EXCELLENT
Gland Leakage SIGNIFICANT
Non Return Valve
Chlorinator FAULTY
Flow Meter FAULTY
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring EXCELLENT
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 480 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.63 m/sec
Pressure
i) Pressure at Discharge Side of Pump 18 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 377 376 378
ii) Ampere 125 143 140
iii) Power Factor 0.94 0.95 0.95
iv) Appearant Power (kVA) 81 93 92
v) Running Power (kW) 82 88 88 86.0
vi) Reactive Power (kVAr) 26 30 27
vi) Motor Working on Loading Basis 78
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: 88.7
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) 16.4 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) 41.58 ft
vi) Discharge Side Frictional Head 15.49 ft
vii) Dynamic Discharge Head (v+vi) 57.07 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 122.67 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 128.87
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,808
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) 65.47 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 115.28 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 58.20 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 56.79 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.18 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,880 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,051,200 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 189,350 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,461,548 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 549 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.16 kWh/m3
xxix) Potential of Energy Reduction 12.63 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 23,912 kWh/yr
xxxi) Annual Financial Saving on Pumping 310,852 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 57%. For 150 HP motor efficiency =<58% is considered to be LOW AND ≥65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is GOOD efficiency. This intervention will save 310,852 Rs annually.
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 743,000 PKR
Faulty chlorinator Instal chlorinator
Faulty flowmeter Water flowmeter is recommended
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station E BLOCK
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact UMER KHAN 0321 6311052
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.46 BHP
ix) Speed (n) 1485 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)
18-4080
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 25 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1718
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 60 KVAR OPERATIONAL
Panel Condition/Issues EXCELLENT
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1025 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 425 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.62 m/sec
Pressure
i) Pressure at Discharge Side of Pump 25 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 424 424 421
ii) Ampere 133 134 115
iii) Power Factor 0.87 0.91 0.88
iv) Appearant Power (kVA) 99 98 81
v) Running Power (kW) 85 90 80 85.0
vi) Reactive Power (kVAr) 52 47 35
vi) Motor Working on Loading Basis 77
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.1
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) 13.12 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) 57.75 ft
vi) Discharge Side Frictional Head 5.84 ft
vii) Dynamic Discharge Head (v+vi) 63.59 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 135.75 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 142.63
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,577
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 64.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.46 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 113.94 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 51.96 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 56.30 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,550 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 930,750 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 187,148 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,432,926 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 491 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 13.39 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 25,056 kWh/yr
xxxi) Annual Financial Saving on Pumping 325,722 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 56%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is GOOD. This pumping system requires impeller adjustment to improve its efficiency to 65% which is in the range of GOOD. This intervention will save 325,722 Rs annually
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 718,000 PKR
No chlorinator Chlorinator is recommended
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station EID GAH 1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact ALI RAZA
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4268
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NO ENERGY METER
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 50 kvar OPERATIONAL
Panel Condition/Issues GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work DEMAGED
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 460 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.52 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 27 meter
Electric Measurements
i) Voltage 388 384 389
ii) Ampere 138 133 101
iii) Power Factor 0.92 0.87 0.86
iv) Appearant Power (kVA) 93 88 78
v) Running Power (kW) 85 77 83 81.7
vi) Reactive Power (kVAr) 37 44 40
vi) Motor Working on Loading Basis 74
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92
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) 22.96 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) 46.2 ft
vi) Discharge Side Frictional Head 14.64 ft
vii) Dynamic Discharge Head (v+vi) 60.84 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 149.40 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 88.21
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,527
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) 76.41 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 109.47 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 67.92 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 69.80 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.18 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,760 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,007,400 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 179,809 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,337,517 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 428 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
11 Summary of Findings
Efficiency of the pumping system is 69%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥68% is 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 743,000 PKR
Flowmeter is recommendedNo flowmeter
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No chlorinator Chlorinator is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station G BLOCK SHAH RUKN ALAM
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact FALAK SHEER 0346-7172261
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 121.8 BHP
ix) Speed (n) 1485 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)
17-7249
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 38 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
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 NA
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 45 KVAR OPERATIONAL
Panel Condition/Issues GOOD
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 440 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.68 m/sec
Pressure
i) Pressure at Discharge Side of Pump 38 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 19 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 418 416 410
ii) Ampere 108 161 158.4
iii) Power Factor 0.97 0.98 0.94
iv) Appearant Power (kVA) 76 116 112
v) Running Power (kW) 84 97 104 95.0
vi) Reactive Power (kVAr)
vi) Motor Working on Loading Basis 86
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 89
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) 19.68 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) 87.78 ft
vi) Discharge Side Frictional Head 6.32 ft
vii) Dynamic Discharge Head (v+vi) 94.10 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 176.10 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 98.44
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,343
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) 86.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 121.8 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 127.35 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 70.73 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 67.65 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,640 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 963,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 209,166 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,719,152 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 423 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.23 kWh/m3
11 Summary of Findings
Pumping system efficiency is 68%. For 150 HP motor efficiency >=65% is GOOD. 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 718,000 PKR
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No chlorinator Chlorinator is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station GRASS MANDI
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact HANIF 0303-6611375
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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 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
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B12 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 1999
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 74.96 BHP
ix) Speed (n) 1485 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)
15-6553
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 15 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 85
v) Power Factor (Cos ɸ) 0.87
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,470 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 2838
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 NOT INSTALLED
Panel Condition/Issues FAIR/FAULTY A METER
Gland Leakage GOOD
Non Return Valve OK
Chlorinator FAULTY
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring FAIR/FAULTY A METER
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 680 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 198 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.09 m/sec
Pressure
i) Pressure at Discharge Side of Pump 15 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 14 meter
ii) Pumping Water Level 19 meter
Electric Measurements
i) Voltage 403 394 396
ii) Ampere 70 42 66
iii) Power Factor 0.86 0.82 0.78
iv) Appearant Power (kVA) 49 40 46
v) Running Power (kW) 44 45 36 41.7
vi) Reactive Power (kVAr) 22 24 29
vi) Motor Working on Loading Basis 38
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,495 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.1
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) 16.4 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) 34.65 ft
vi) Discharge Side Frictional Head 2.65 ft
vii) Dynamic Discharge Head (v+vi) 37.30 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 99.62 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 53.16
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,390
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 21.93 hp
xiv) Brake Horsepower (bhp) (OEM Data) 74.96 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 55.85 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 29.26 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 39.27 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,188 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 433,620 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 91,739 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,192,611 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 328 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.13 kWh/m3
xxix) Potential of Energy Reduction 39.59
xxx) Reduced Annual Energy Consumption at Improved Efficiency 36,318
xxxi) Annual Financial Saving on Pumping 472,134
11 Summary of Findings
Efficiency of the pumping system is 39%. For 60 HP motor efficiency <56% is LOW and efficiency ≥65% is GOOD. This pumping system requires impeler adjustments, repair and maintenance to increase its efficiency to 65%. This intervention wil save 472,134 Rs annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 818,500 PKR
No PFI plant PFI plant is recommended is recommended
Voltmeter shoub be repaired or replaced with new one.Faulty Volt Meter
Chlorinator is recommendedFaulty chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station GUJJAR PLOT MUMTAZABAD
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact MAHBOOB AHMED 0302 7349511
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4159
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 22 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NP
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 50 Kvar
Panel Condition/Issues GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NOT INSTALLED
Flow Meter INSTALLED
Pressure Gauge NOT INSTALLED
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z)
viii) Flow Measurement 430 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.64 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 19 meter
ii) Pumping Water Level 24 meter
Electric Measurements
i) Voltage 418 420 418
ii) Ampere 149 139 142
iii) Power Factor 0.85 0.87 0.82
iv) Appearant Power (kVA) 107 101 103
v) Running Power (kW) 92 88 84 88.0
vi) Reactive Power (kVAr) 55 51 59
vi) Motor Working on Loading Basis 80
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,479 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.4
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) 16.4 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) 50.82 ft
vi) Discharge Side Frictional Head 6.02 ft
vii) Dynamic Discharge Head (v+vi) 56.84 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 135.56 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 115.44
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,588
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 64.81 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 117.96 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 57.74 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 54.94 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,580 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 941,700 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 193,753 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,518,794 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 509 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 15.48 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 29,984 kWh/yr
xxxi) Annual Financial Saving on Pumping 389,792 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 55%. For 150 HP motor efficiency <58% is considered to be LOW AND≥65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is GOOD efficiency. This intervention will save 389,792 Rs annually.
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 718,000 PKR
No chlorinator Chlorinator is recommended
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station GULBERG COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact NASEER 0300-6350181
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/3 Serial
iii) Certification Mark
iv) Year of Manufacture 2001
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 89.76 BHP
ix) Speed (n) 1485 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)
14-5742
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 125 hp 93.75 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 173.5
v) Power Factor (Cos ɸ) 0.87
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 280 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 5997/465.5
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 30 KVAR
Panel Condition/Issues FAIR
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED AND OPERATIONAL
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 860 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 380 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.08 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 396 392 392
ii) Ampere 95 119 120
iii) Power Factor 0.96 0.93 0.96
iv) Appearant Power (kVA) 61 81 80
v) Running Power (kW) 70 42 79 63.7
vi) Reactive Power (kVAr) 20 24 21
vi) Motor Working on Loading Basis 58
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 9.74 ft
vii) Dynamic Discharge Head (v+vi) 79.04 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 144.64 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 102.02
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,422
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) 61.11 hp
xiv) Brake Horsepower (bhp) (OEM Data) 89.76 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 85.34 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 68.08 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 71.61 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.17 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,280 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 832,200 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 140,178 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,822,309 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 345 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
11 Summary of Findings
Efficiency of the pumping system is 71%. For 150 HP motor efficiency <58% is considered to be LOW AND >=68% is 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 668,000 PKR
Install PFI display meter No PFI display meter
Install chlorinatorNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Gulshan Market
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact SULTAN WALI 0305 2377115
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4272
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 37 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 6956/3461
iii) Meter Time and Date
Correct FALSE
Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition
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 50 kvar
Panel Condition/Issues FAIR
Gland Leakage NEGLIGIBLE
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring FAIR
Housekeeping GOOD
Motor Terminal PROPERLY CLOSED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 415 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.58 m/sec
Pressure
i) Pressure at Discharge Side of Pump 37 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tube wells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 449 430 428
ii) Ampere 155 104 113
iii) Power Factor 0.86 0.79 0.82
iv) Appearant Power (kVA) 111 88 89
v) Running Power (kW) 95.5 86 77 86.2
vi) Reactive Power (kVAr) 56 52 51
vi) Motor Working on Loading Basis 78
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.5
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) 22.96 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) 85.47 ft
vi) Discharge Side Frictional Head 5.57 ft
vii) Dynamic Discharge Head (v+vi) 91.04 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 163.20 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 79.58
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,381
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 75.30 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 115.50 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 67.09 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 65.19 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,490 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 908,850 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 189,717 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,466,319 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 414 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.21 kWh/m3
11 Summary of Findings
Pumping efficiency is 65.1% which is GOOD. For motor 150 Hp efficiency >=65% is GOOD. 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 743,000 PKR
Replacement of faulty relays is recommendedOver voltage current relays and over/under voltage relay is defective
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No water flow meter Water flowmeter is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer HUR/GUL
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station HASSAN PARWANA 1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact AHSAN RASHEED 0300-6425921
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/3 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 88.6 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)
14-5366
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 125 hp 93.75 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 173.5
v) Power Factor (Cos ɸ) 0.87
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 280 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NOT VISIBLE
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/FAULTY V METER
Gland Leakage SIGNIFICANT
Non Return Valve LEAKED
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge FAULTY
Bore Hole in Front of PanNO
Wiring FAIR/FAULTY A METER
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 840 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 368 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.02 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 350 346 353
ii) Ampere 120 129 135
iii) Power Factor 0.98 0.96 0.95
iv) Appearant Power (kVA) 68 62 64
v) Running Power (kW) 38 63 65 55.3
vi) Reactive Power (kVAr) 51 46 42
vi) Motor Working on Loading Basis 50
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,480 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.4
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) 22.96 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) 69.3 ft
vi) Discharge Side Frictional Head 9.33 ft
vii) Dynamic Discharge Head (v+vi) 78.63 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 160.63 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 70.57
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,294
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) 65.72 hp
xiv) Brake Horsepower (bhp) (OEM Data) 88.6 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 74.17 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 74.18 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 88.61 %
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 6 hrs
xxi) Daily Pump flow 2,208 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 805,920 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 121,830 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,583,787 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 270 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.21 kWh/m3
11 Summary of Findings
Efficiency of the pumping system is 88%. For 150 HP motor efficiency =<58% is considered to be LOW AND >=68% is EXCELLENT. This pumping system requires no adjustment
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 708,500 PKR
No chlorinator Chlorinator is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No PFI plant PFI plant of 50 KVAR is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer HUR/GUL
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station HASSAN PARWANA 2
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact AHSAN RASHEED 0300-6425921
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.46 BHP
ix) Speed (n) 1485 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)
17-7411
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 35 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 8878
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 GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 389 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.48 m/sec
Pressure
i) Pressure at Discharge Side of Pump 35 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 376 371 372
ii) Ampere 189 202 211
iii) Power Factor 0.84 0.81 0.85
iv) Appearant Power (kVA) 123 130 138
v) Running Power (kW) 102 100 116 106.0
vi) Reactive Power (kVAr) 69 82 73
vi) Motor Working on Loading Basis 96
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,498 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93.1
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) 22.96 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) 80.85 ft
vi) Discharge Side Frictional Head 4.95 ft
vii) Dynamic Discharge Head (v+vi) 85.80 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 167.80 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 74.60
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,318
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) 72.58 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.46 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 142.09 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 58.78 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.08 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.27 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,334 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 851,910 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 233,385 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,034,001 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 495 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.22 kWh/m3
xxix) Potential of Energy Reduction 21.42
xxx) Reduced Annual Energy Consumption at Improved Efficiency 49,993
xxxi) Annual Financial Saving on Pumping 649,908
11 Summary of Findings
.
Efficiency of the pumping system is 51%. For 150 HP motor efficiency =<58% is considered to be LOW AND >=68% is EXCELLENT. This pumping system requires impeller adjustment to increase its efficiency to 65% which is GOOD. This intervention will save Rs. 649,908 annually
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 843,000 PKR
No chlorinator Chlorinator is recommended
Water flow meter is recommendedNo water flow meter
No PFI plant PFI plant of 50 KVAR is recommended
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station KABOOTAR MANDI
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M NASIR
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2007
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 122.48 BHP
ix) Speed (n) 1485 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)
21-06-10-6688
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 12 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 88854
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/FAULTY A METER
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator FAULTY
Flow Meter FAULTY
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 870 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 410 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.56 m/sec
Pressure
i) Pressure at Discharge Side of Pump 12 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 23 meter
ii) Pumping Water Level 28 meter
Electric Measurements
i) Voltage 386 384 387
ii) Ampere 178 210 210
iii) Power Factor 0.8 0.77 0.8
iv) Appearant Power (kVA) 114 140 141
v) Running Power (kW) 93 109 111 104.3
vi) Reactive Power (kVAr) 70 89 86
vi) Motor Working on Loading Basis 95
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93.6
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) 16.4 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) 27.72 ft
vi) Discharge Side Frictional Head 5.55 ft
vii) Dynamic Discharge Head (v+vi) 33.27 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 125.11 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 110.08
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,647
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) 57.03 hp
xiv) Brake Horsepower (bhp) (OEM Data) 122.48 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 139.86 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 46.57 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 40.78 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.26 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,460 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 897,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 229,715 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,986,297 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 654 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.16 kWh/m3
xxix) Potential of Energy Reduction 37.26 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 85,596 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,112,752 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 40%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 1,112,752 Rs annually.
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 743,500 PKR
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
Instal chlorinatorFaulty chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
Defective Ampere meter Replace Ampere meter
Flowmeter is recommendedFaulty flowmeter
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station K-Block
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Mobeen Ahmad 0301-7423531
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model B14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4269
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 209.5
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 2285.55
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 30 KVAR OPREATIONAL
Panel Condition/Issues EXCELLENT
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 350 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.33 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 24 meter
Electric Measurements
i) Voltage 407 409.5 407.7
ii) Ampere 138 130.5 132.1
iii) Power Factor 0.93 0.95 0.93
iv) Appearant Power (kVA) 97.96 90.2 93.32
v) Running Power (kW) 92.32 86.93 86.53 88.6
vi) Reactive Power (kVAr) 32.3 28.04 34.25
vi) Motor Working on Loading Basis 81
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 94.4
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) 18.696 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) 46.2 ft
vi) Discharge Side Frictional Head 4.00 ft
vii) Dynamic Discharge Head (v+vi) 50.20 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 128.92 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 82.43
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,513
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) 50.17 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 118.76 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 44.59 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 42.24 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,100 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 766,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 195,060 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,535,776 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 539 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 35.01 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 68,288 kWh/yr
xxxi) Annual Financial Saving on Pumping 887,749 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 42%. For 150 HP motor efficiency <58.9% is LOW. This pumping system requires impeller adjustment, repair and maintenance. This intervention will improve the efficiency from 42% to 65% which is in range of GOOD efficiency. This intervention will save 887,749 PKR annually.
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 668,000 PKR
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station KHARPUR
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact ISRAR 0331-7020969
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4181
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 47 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 60/937.5
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 GOOD/FAULTY A & V METER
Gland Leakage NORMAL.
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 402 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.20 m/sec
Pressure
i) Pressure at Discharge Side of Pump 47 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 23 meter
Electric Measurements
i) Voltage 386 386 389
ii) Ampere 204 199 201
iii) Power Factor 0.77 0.8 0.79
iv) Appearant Power (kVA) 136 134 132
v) Running Power (kW) 112 110 110 110.7
vi) Reactive Power (kVAr) 85 81 82
vi) Motor Working on Loading Basis 101
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,483 RPM
ii) Speed of Pump Impeller 1480 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.1
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) 16.4 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) 108.57 ft
vi) Discharge Side Frictional Head 11.03 ft
vii) Dynamic Discharge Head (v+vi) 119.60 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 195.04 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 107.93
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,193
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) 87.18 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 148.35 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 77.66 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 58.76 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.28 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,412 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 880,380 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 243,660 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,167,574 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 445 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.25 kWh/m3
xxix) Potential of Energy Reduction 9.59
xxx) Reduced Annual Energy Consumption at Improved Efficiency 23,374
xxxi) Annual Financial Saving on Pumping 303,856
11 Summary of Findings
Efficiency of the pumping system is 58%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save Rs. 303,856 annually and also decrease motor loading.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 819,000 PKR
No PFI plant PFI plant is recommended is recommended
A and V meter is recommendedDefective A and V meter
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station KIRRI DAWOOD KHAN
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact KHALID ISMAEEL 0322-6238225
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B12 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4206
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading METER NA
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 EXCELLENT
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of Pan NO
Wiring EXCELLENT
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 390 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.14 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 19 meter
ii) Pumping Water Level 24 meter
Electric Measurements
i) Voltage 403 400 402
ii) Ampere 176 181 148
iii) Power Factor 0.73 0.66 0.58
iv) Appearant Power (kVA) 123 101 100
v) Running Power (kW) 91 83 60 78.0
vi) Reactive Power (kVAr) 84 89 85
vi) Motor Working on Loading Basis 71
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,508 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.6
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 10.43 ft
vii) Dynamic Discharge Head (v+vi) 79.73 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 158.45 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 104.71
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,378
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) 68.71 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 104.56 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 61.07 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 65.71 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,340 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 854,100 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 171,736 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,232,567 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 386 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
11 Summary of Findings
Efficiency of the pumping system is 65%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires no intervention.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators12 Estimated Investment for Improvement Plan 843,000 PKR
No water flowmeter Water flowmeter is recommended
PFI plant of 50 KVAR is recommendedNo Power Factor Improvement (PFI) plant
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station LODHI 1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact DOST MOHAMMAD
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pre . Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4270
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 29 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading DEFECTIVE
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 EXCELLENT
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter FAULTY
Pressure Gauge FAULTY
Bore Hole in Front of PanYES
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 980 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 376 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.06 m/sec
Pressure
i) Pressure at Discharge Side of Pump 29 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 392 393 395
ii) Ampere 146 150 158
iii) Power Factor 0.89 0.91 0.88
iv) Appearant Power (kVA) 99 101 109
v) Running Power (kW) 89 85 97 90.3
vi) Reactive Power (kVAr) 44 47 50
vi) Motor Working on Loading Basis 82
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,489 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90
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) 16.4 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) 66.99 ft
vi) Discharge Side Frictional Head 9.54 ft
vii) Dynamic Discharge Head (v+vi) 76.53 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 142.13 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 100.95
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,433
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 59.42 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 121.09 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 52.93 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 49.07 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,256 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 823,440 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 198,891 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,585,580 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 498 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 24.51 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 48,748 kWh/yr
xxxi) Annual Financial Saving on Pumping 633,721 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 49%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save Rs. 633,721 annually.
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 843,000 PKR
No chlorinator Chlorinator is recommended
Digital pressure guage is recommendedDefective pressure guage
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
Defective flow meter Flow meter is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station LODHI 2
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M IQBAL 0305 2411924
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pre . Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4361
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 2460
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 EXCELLENT
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring EXCELLENT
Housekeeping EXCELLENT
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 455 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.73 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 384 386 389
ii) Ampere 162 156 157
iii) Power Factor 0.85 0.84 0.87
iv) Appearant Power (kVA) 108 101 105
v) Running Power (kW) 92 86 92 90.0
vi) Reactive Power (kVAr) 57 53 49
vi) Motor Working on Loading Basis 82
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1480 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 6.64 ft
vii) Dynamic Discharge Head (v+vi) 75.94 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 141.54 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 122.16
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,614
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) 71.60 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 120.64 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 63.65 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 59.35 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,730 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 996,450 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 198,157 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,576,039 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 498 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 8.69 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 17,219 kWh/yr
xxxi) Annual Financial Saving on Pumping 223,853 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 60%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustmentincrease its efficiency up to 65% which is in the range of GOOD. This intervention will save Rs. 223,853 annually.
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 843,000 PKR
Digital pressure guage is recommendedNo pressure guage
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No flow meter No is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No chlorinator Chlorinator is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer HUR/GUL
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station LOHARI GATE-1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact KHALID 0321-6875277
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
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) r
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123 BHP
ix) Speed (n) 1485 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)
17-7488
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NA (ENERGY METER DISCONECTED)
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 GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge INSTALLED-OPERATIONAL
Bore Hole in Front of PanYES
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 365 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.39 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 387 383 385
ii) Ampere 164 171 175
iii) Power Factor 0.96 0.95 0.96
iv) Appearant Power (kVA) 106 115 110
v) Running Power (kW) 103 110 105 106.0
vi) Reactive Power (kVAr) 35 39 40
vi) Motor Working on Loading Basis 96
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 91 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.6
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 4.36 ft
vii) Dynamic Discharge Head (v+vi) 73.66 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 155.66 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 97.99
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,351
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 63.17 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 142.09 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 51.36 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 44.46 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.29 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,190 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 799,350 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 233,385 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,034,001 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 534 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
xxix) Potential of Energy Reduction 31.60 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 73,755 kWh/yr
xxxi) Annual Financial Saving on Pumping 958,817 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 45%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is GOOD efficiency. This intervention will save 958,817 Rs annually.
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 818,500 PKR
No PFI plant PFI plant of 50 KVAR is recommended
Install chlorinatorFaulty chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station LOHARI GATE 4
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact RAMZAN 0306-7628641
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.4 BHP
ix) Speed (n) 1485 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)
17-7489
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NOT VISIBLE
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 GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge FAULTY
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 365 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.39 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 23 meter
Electric Measurements
i) Voltage 382 384 382
ii) Ampere 162 152 150
iii) Power Factor 0.94 0.95 0.95
iv) Appearant Power (kVA) 105 96 100
v) Running Power (kW) 99 90 97 95.3
vi) Reactive Power (kVAr) 35 37 35
vi) Motor Working on Loading Basis 87
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,493 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 96.1
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 4.33 ft
vii) Dynamic Discharge Head (v+vi) 73.63 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 149.07 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 97.99
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,395
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) 60.50 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.4 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 127.79 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 49.02 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 47.34 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.26 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,190 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 799,350 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 209,899 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,728,693 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 501 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
xxix) Potential of Energy Reduction 27.17 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 57,029 kWh/yr
xxxi) Annual Financial Saving on Pumping 741,378 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 47%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 741,378 Rs annually.
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 843,000 PKR
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No chlorinator Chlorinator is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
Faulty pressure guage Digital pressure guage is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station MADINA COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact ASGHAR KHAN 0302-7380036
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B12 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4185
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 10094
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 GOOD
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of Pan NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1000 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 468 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.78 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 23 meter
Electric Measurements
i) Voltage 416 418 421
ii) Ampere 195 193 190
iii) Power Factor 0.67 0.66 0.68
iv) Appearant Power (kVA) 140 139 125
v) Running Power (kW) 95 93 91 93.0
vi) Reactive Power (kVAr) 103 105 97
vi) Motor Working on Loading Basis 85
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,500 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.2
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 7.09 ft
vii) Dynamic Discharge Head (v+vi) 76.39 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 151.83 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 125.65
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,558
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) 79.01 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 124.66 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 70.23 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 63.38 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,808 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,024,920 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 204,762 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,661,907 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 480 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.19 kWh/m3
xxix) Potential of Energy Reduction 2.50
xxx) Reduced Annual Energy Consumption at Improved Efficiency 5,116
xxxi) Annual Financial Saving on Pumping 66,509
11 Summary of Findings
Efficiency of the pumping system is 63%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save Rs. 66,509 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators12 Estimated Investment for Improvement Plan 843,000 PKR
PFI plant of 50 KVAR is recommendedNo Power Factor Improvement (PFI) plant
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No water flowmeter Water flowmeter is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station MDA COLONY-1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M AFZAL 0300-6338004
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4358
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 29 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 6533
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 GOOD/FAULTY A METER
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NO
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work FAIR
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 426 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.34 m/sec
Pressure
i) Pressure at Discharge Side of Pump 29 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 14 meter
ii) Pumping Water Level 17 meter
Electric Measurements
i) Voltage 377 377 373
ii) Ampere 183 170 188
iii) Power Factor 0.97 0.94 0.94
iv) Appearant Power (kVA) 120 111 122
v) Running Power (kW) 116 105 115 112.0
vi) Reactive Power (kVAr) 28 38 41
vi) Motor Working on Loading Basis 102
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,779 RPM
ii) Speed of Pump Impeller 1460 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.6
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) 9.84 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) 66.99 ft
vi) Discharge Side Frictional Head 12.07 ft
vii) Dynamic Discharge Head (v+vi) 79.06 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 134.82 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 190.62
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,598
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 63.86 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 150.13 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 56.76 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 42.53 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.26 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,556 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 932,940 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 246,595 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,205,737 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 651 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 34.56 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 85,230 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,107,991 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 42%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 1,107,991 Rs annually.
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 843,000 PKR
Install PFI display meter No PFI display meter
Install chlorinatorNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No PFI plant PFI plant of 50 KVAR is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station MDA chowk
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M AFZAL
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/3 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 92.22 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)
14-5680
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 25 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 125 hp 93.75 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 173.5
v) Power Factor (Cos ɸ) 0.87
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 280 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 6533
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 POOR/ NO A METER
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator FAULTY
Flow Meter NA
Pressure Gauge INSTALLED-OPERATIONAL
Bore Hole in Front of PanNO
Wiring POOR
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 870 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 410 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.25 m/sec
Pressure
i) Pressure at Discharge Side of Pump 25 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 14 meter
ii) Pumping Water Level 19 meter
Electric Measurements
i) Voltage 355 376 369
ii) Ampere 141 163 156
iii) Power Factor 0.91 0.91 0.94
iv) Appearant Power (kVA) 89 106 99
v) Running Power (kW) 80 97 94 90.3
vi) Reactive Power (kVAr) 37 44 40
vi) Motor Working on Loading Basis 82
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,251 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 86
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) 16.4 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) 57.75 ft
vi) Discharge Side Frictional Head 11.28 ft
vii) Dynamic Discharge Head (v+vi) 69.03 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 131.35 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 110.08
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,626
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 59.88 hp
xiv) Brake Horsepower (bhp) (OEM Data) 92.22 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 121.09 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 64.93 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 49.45 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,460 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 897,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 198,891 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,585,580 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 539 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 23.93
xxx) Reduced Annual Energy Consumption at Improved Efficiency 47,585
xxxi) Annual Financial Saving on Pumping 618,606
11 Summary of Findings
Efficiency of the pumping system is 49%. For 125 HP motor efficiency <58% is LOW and efficiency >=63% is GOOD. This pumping system requires impeler adjustments, repair and maintenence to increase its efficiency to 65%. This intervention will save Rs. 618,606 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 843,500 PKR
Water flowmeter is recommendedNo water flow meter
Chlorinator is recommendedFaulty chlorinator
No PFI plant PFI pant of 50 KVAr is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No A meter A meter is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station MOHAMMADI GROUND SHAH SHAMS
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact HAFIZ ZAFAR 0304-7390827
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4205
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 2363
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 40 KVAR OPERATIONAL
Panel Condition/Issues FAIR
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 990 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 371 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.41 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 401 403 405
ii) Ampere 129 127 129
iii) Power Factor 0.87 0.73 0.79
iv) Appearant Power (kVA) 110 88 100
v) Running Power (kW) 88 68 76 77.3
vi) Reactive Power (kVAr) 37 59 56
vi) Motor Working on Loading Basis 70
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,498 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.5
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 4.50 ft
vii) Dynamic Discharge Head (v+vi) 73.80 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 155.80 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 99.60
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,361
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 64.27 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 103.66 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 57.26 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 62.00 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,226 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 812,490 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 170,268 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,213,485 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 389 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
xxix) Potential of Energy Reduction 4.62
xxx) Reduced Annual Energy Consumption at Improved Efficiency 7,865
xxxi) Annual Financial Saving on Pumping 102,243
11 Summary of Findings
Efficiency of the pumping system is 62%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save Rs 102,243 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 743,000 PKR
Water flowmeter is recommendedNo water flow meter
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station MUZAFARABAD
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact NAVEED 0306-7372866
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4196
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 10 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 178.26
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 GOOD
Gland Leakage GOOD
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 546 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.99 m/sec
Pressure
i) Pressure at Discharge Side of Pump 10 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 23 meter
Electric Measurements
i) Voltage 360 367 369
ii) Ampere 164 173 171
iii) Power Factor 0.78 0.76 0.75
iv) Appearant Power (kVA) 106 110 108
v) Running Power (kW) 88 85 84 85.7
vi) Reactive Power (kVAr) 63 71 70
vi) Motor Working on Loading Basis 78
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,497 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 89.2
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) 16.4 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) 23.1 ft
vi) Discharge Side Frictional Head 20.25 ft
vii) Dynamic Discharge Head (v+vi) 43.35 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 118.79 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 146.59
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 2,023
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) 72.12 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 114.83 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 64.25 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 62.80 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.16 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 3,276 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,195,740 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 188,616 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,452,007 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 565 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.15 kWh/m3
xxix) Potential of Energy Reduction 3.38
xxx) Reduced Annual Energy Consumption at Improved Efficiency 6,380
xxxi) Annual Financial Saving on Pumping 82,940
11 Summary of Findings
Efficiency of the pumping system is 62%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save 82,940 annually
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 843,000 PKR
No PFI plant PFI plant is recommended is recommended
Water flowmeter is recommendedNo water flow meter
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Mumtaz Abad # 1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Nadeem Khan 0300-7187646
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model B 14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.26 BHP
ix) Speed (n) 1485 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)
18-4028
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1592.35
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 60 KVAR OPERATIONAL
Panel Condition/Issues GOOD/
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 462 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.76 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 19 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 403.8 407.9 407.7
ii) Ampere 175.8 171.8 162.2
iii) Power Factor 0.9 0.91 0.92
iv) Appearant Power (kVA) 122.9 121.1 118
v) Running Power (kW) 110.1 110.4 109.1 109.9
vi) Reactive Power (kVAr) 55.3 49.53 43.54
vi) Motor Working on Loading Basis 100
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.3
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) 19.68 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) 69.3 ft
vi) Discharge Side Frictional Head 6.96 ft
vii) Dynamic Discharge Head (v+vi) 76.26 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 158.26 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 103.36
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,491
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) 81.30 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.26 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 147.27 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 65.96 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 55.20 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,772 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,011,780 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 241,898 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,144,676 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 544 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
xxix) Potential of Energy Reduction 15.08 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 36,467 kWh/yr
xxxi) Annual Financial Saving on Pumping 474,075 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 55.20%. For 150 HP motor efficiency <58.9% is LOW. This pumping system requires impeller adjustment. This intervention will improve the efficiency from 55.20% to 65%. Which is in range of GOOD EFFICIENCY. This intervention will save 474,075 PKR annually.
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 744,000 PKR
No water flow meter Water flowmeter is recommended
Chlorinator is recommendedNo chlorinator
Replace faulty A and V meter by correct oneDefective A and V meter
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station MUMTAZABAD 2
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact ABDUL RASHEED 0301-7429330
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4190
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 28 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1408
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 30 KVAR-OPERATIONAL
Panel Condition/Issues GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1000 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 415 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.58 m/sec
Pressure
i) Pressure at Discharge Side of Pump 28 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 421 422 423
ii) Ampere 130 130 130
iii) Power Factor 0.92 0.92 0.92
iv) Appearant Power (kVA) 95 95 95
v) Running Power (kW) 87 88 87 87.3
vi) Reactive Power (kVAr) 95 95 95
vi) Motor Working on Loading Basis 79
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1480 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 94.6
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) 16.4 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) 64.68 ft
vi) Discharge Side Frictional Head 5.63 ft
vii) Dynamic Discharge Head (v+vi) 70.31 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 152.31 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 111.42
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,459
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) 70.28 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 117.07 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 62.47 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 60.03 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,490 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 908,850 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 192,286 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,499,712 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 449 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
xxix) Potential of Energy Reduction 7.64 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 14,699 kWh/yr
xxxi) Annual Financial Saving on Pumping 191,086 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 60%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is GOOD efficiency. This intervention will save 191,086 Rs annually.
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 743,000 PKR
No water flow meter Water flowmeter is recommended
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station MUSHTAQ COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact AQEEL HUSSAIN 0301-2487272
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 110.88 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)
21-9-10-11077
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 22 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 209.5
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 1070/3177
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 POOR/DEFECTIVE MCCB
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1010 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 438 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.67 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 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 390 404 398
ii) Ampere 171 172 162
iii) Power Factor 0.87 0.83 0.84
iv) Appearant Power (kVA) 115 119 112
v) Running Power (kW) 100 99 94 97.7
vi) Reactive Power (kVAr) 55 65 64
vi) Motor Working on Loading Basis 89
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92
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) 16.4 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) 50.82 ft
vi) Discharge Side Frictional Head 6.18 ft
vii) Dynamic Discharge Head (v+vi) 57.00 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 125.88 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 117.59
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,694
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) 61.30 hp
xiv) Brake Horsepower (bhp) (OEM Data) 110.88 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 130.92 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 55.29 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 46.82 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,628 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 959,220 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 215,037 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,795,479 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 608 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.16 kWh/m3
xxix) Potential of Energy Reduction 27.96 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 60,134 kWh/yr
xxxi) Annual Financial Saving on Pumping 781,743 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 46.82%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenece to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 781,743 Rs annually.
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 818,000 PKR
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
Install chlorinatorNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
Faulty MCCB Replace MCCB
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station NAQASHBAND COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M SHAKEEL 0301-7488472
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 6 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2005
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 121.8 BHP
ix) Speed (n) 1485 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)
17-7250
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 48 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1920
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 50 KVAR
Panel Condition/Issues FAIR
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NOT INSTALLED
Flow Meter NOT INSTALLED
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 480 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.83 m/sec
Pressure
i) Pressure at Discharge Side of Pump 48 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 388 387 390
ii) Ampere 179 190 160
iii) Power Factor 0.95 0.92 0.93
iv) Appearant Power (kVA) 115 119 110
v) Running Power (kW) 110 108 98 105.3
vi) Reactive Power (kVAr) 36 44 38
vi) Motor Working on Loading Basis 96
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.2
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) 13.12 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) 110.88 ft
vi) Discharge Side Frictional Head 7.38 ft
vii) Dynamic Discharge Head (v+vi) 118.26 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 183.86 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 161.09
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,335
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) 98.13 hp
xiv) Brake Horsepower (bhp) (OEM Data) 121.8 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 141.20 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 80.56 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 69.50 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,880 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,051,200 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 231,917 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,014,920 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 449 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.24 kWh/m3
11 Summary of Findings
Efficiency of the pumping system is 69%. For 150 HP motor efficiency >=65% is good. 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 743,000 PKR
No water flowmeter Flowmeter is recommended
Install PFI display meter No PFI display meter
Install chlorinatorNo chlorinator
Faulty pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station NAWA SHER
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M YAR
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.46 BHP
ix) Speed (n) 1485 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)
17-7367
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 25 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,486 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 2422.81
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 (MCCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant NOT INSTALLED
Panel Condition/Issues GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanYES
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1000 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 488 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.86 m/sec
Pressure
i) Pressure at Discharge Side of Pump 25 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 372 370 373
ii) Ampere 172 179 176
iii) Power Factor 0.93 0.94 0.95
iv) Appearant Power (kVA) 111 115 113
v) Running Power (kW) 105 109 108 107.3
vi) Reactive Power (kVAr) 38 37 37
vi) Motor Working on Loading Basis 98
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,487 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.9
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) 16.4 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) 57.75 ft
vi) Discharge Side Frictional Head 7.68 ft
vii) Dynamic Discharge Head (v+vi) 65.43 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 137.59 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 131.02
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,673
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 74.66 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.46 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 143.88 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 60.47 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.89 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,928 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,068,720 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 236,320 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,072,165 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 611 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 20.17 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 47,668 kWh/yr
xxxi) Annual Financial Saving on Pumping 619,690 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 51.89%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is in the range of GOOD. Motor is also overloaded. After impeller adjustment the load of the motor will be decreased. This intervention will save 619,690 PKR annually.
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 843,000 PKR
It is recommended to change the panel position.Bore hole is in front of panel
No chlorinator Chlorinator is recommended
Water flowmeter is recommendedNo flowmeter
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station NAWAB PUR ROAD
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact HAFEEZ UR REHMAN 0304-4950426
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
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
Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4144
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 9328
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 GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of Pan NO
Wiring GOOD
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 840 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 362 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.98 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 13 meter
ii) Pumping Water Level 18 meter
Electric Measurements
i) Voltage 357 360 359
ii) Ampere 170 162 167
iii) Power Factor 0.8 0.81 0.85
iv) Appearant Power (kVA) 104 94 103
v) Running Power (kW) 86 75 89 83.3
vi) Reactive Power (kVAr) 65 59 57
vi) Motor Working on Loading Basis 76
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,497 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.7
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 8.77 ft
vii) Dynamic Discharge Head (v+vi) 78.07 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 137.11 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 97.19
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,480
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) 55.19 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 111.71 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 49.16 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 49.40 %
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 6 hrs
xxi) Daily Pump flow 2,172 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 792,780 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 183,479 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,385,221 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 476 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 24.00
xxx) Reduced Annual Energy Consumption at Improved Efficiency 44,029
xxxi) Annual Financial Saving on Pumping 572,374
11 Summary of Findings
Efficiency of the pumping system is 49.40%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments, repair and maintenance to increase its efficiency to 65%. This intervention will save 572,374 PKR annually.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators12 Estimated Investment for Improvement Plan 818,000 PKR
No PFI plant PFI plant of 50 KVAR is recommended
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station NEW SHAH SHAMS
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact ANSAR SHAHZAD 0305-8381898
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.45 BHP
ix) Speed (n) 1485 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)
17-7368
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1074
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 60 KVAR-OPERATIONAL
Panel Condition/Issues GOOD/NO A METER,FAULTY V METER
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
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 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1000 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 385 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.47 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 374 409 408
ii) Ampere 154 165 167
iii) Power Factor 0.91 0.93 0.89
iv) Appearant Power (kVA) 108 117 119
v) Running Power (kW) 100 106 108 104.7
vi) Reactive Power (kVAr) 42 41 43
vi) Motor Working on Loading Basis 95
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,497 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.6
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 4.85 ft
vii) Dynamic Discharge Head (v+vi) 74.15 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 156.15 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 103.36
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,384
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 66.84 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.45 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 140.30 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 54.14 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 47.64 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.27 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,310 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 843,150 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 230,449 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,995,838 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 525 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
xxix) Potential of Energy Reduction 26.71
xxx) Reduced Annual Energy Consumption at Improved Efficiency 61,545
xxxi) Annual Financial Saving on Pumping 800,091
11 Summary of Findings
Efficiency of the pumping system is 47.64%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save 800,091 PKR annually.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 744,000 PKR
Repair and maintenance of Ratchet plate is recommendedRatchet plate is not working
Replace faulty v meter by correct oneDefective V meter
A meter is not available A meter is recommended
No PFI display meter Install PFI display meter
Water flowmeter is recommendedNo water flow meter
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station NIAZ TOWN
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact RAMZAN 0306-7416926
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4202
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 41 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 541
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 GOOD
Gland Leakage NORMAL.
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1010 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 377 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.44 m/sec
Pressure
i) Pressure at Discharge Side of Pump 41 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 389 388 387
ii) Ampere 174 177 177
iii) Power Factor 0.75 0.74 0.76
iv) Appearant Power (kVA) 118 119 117
v) Running Power (kW) 89 88 90 89.0
vi) Reactive Power (kVAr) 76 80 82
vi) Motor Working on Loading Basis 81
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,503 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91
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) 16.4 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) 94.71 ft
vi) Discharge Side Frictional Head 4.58 ft
vii) Dynamic Discharge Head (v+vi) 99.29 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 168.17 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 101.22
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,296
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) 70.49 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 119.30 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 62.80 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 59.09 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,262 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 825,630 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 195,955 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,547,416 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 415 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.22 kWh/m3
xxix) Potential of Energy Reduction 9.10
xxx) Reduced Annual Energy Consumption at Improved Efficiency 17,823
xxxi) Annual Financial Saving on Pumping 231,700
11 Summary of Findings
Efficiency of the pumping system is 59.09%. For 150 HP motor efficiency between 58.1-63.4% is FAIR and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save 231,700 PKR annually.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 818,000 PKR
No power factor improvement (PFI) plant is installed PFI of 50 KVAR is recommended
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station PEER ZAHID-1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M GULNAWAZ 0314-6242270
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.46 BHP
ix) Speed (n) 1485 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)
18-4095
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 25 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 5919
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/DEFECTIVE MCCB
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge INSTALLED-OPERATIONAL
Bore Hole in Front of PanNO
Wiring POOR
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1030 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 527 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.01 m/sec
Pressure
i) Pressure at Discharge Side of Pump 25 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 14 meter
ii) Pumping Water Level 19 meter
Electric Measurements
i) Voltage 374 381 378
ii) Ampere 213 201 197
iii) Power Factor 0.81 0.83 0.78
iv) Appearant Power (kVA) 137 133 129
v) Running Power (kW) 113 110 101 108.0
vi) Reactive Power (kVAr) 80 73 80
vi) Motor Working on Loading Basis 98
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,415 RPM
ii) Speed of Pump Impeller 1460 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.5
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) 16.4 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) 57.75 ft
vi) Discharge Side Frictional Head 8.86 ft
vii) Dynamic Discharge Head (v+vi) 66.61 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 128.93 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 141.49
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,838
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 75.55 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.46 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 144.77 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 61.19 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 52.18 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 3,162 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,154,130 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 237,788 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,091,247 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 656 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 19.72 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 46,886 kWh/yr
xxxi) Annual Financial Saving on Pumping 609,524 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 52.18%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 609,524 PKR annually.
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 818,000 PKR
New MCCB is recommendedMCCB is defective
No chlorinator Install chlorinator
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No PFI plant PFI plant of 50 KVAR is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station PIZZA HUTT GULBERG COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Naseer Ahmed 0302-4030234
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4421
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1127.58/6666.51
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 EXCELLENT/FAULTY (A) METER
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator FAULTY
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring EXCELLENT
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1030 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 310 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.18 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 397.8 397.5 390
ii) Ampere 119.7 155.1 117.1
iii) Power Factor 0.9 0.87 0.89
iv) Appearant Power (kVA) 82.4 106 64
v) Running Power (kW) 74 94 71 79.7
vi) Reactive Power (kVAr) 35 51 30
vi) Motor Working on Loading Basis 72
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,479 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.6
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 3.11 ft
vii) Dynamic Discharge Head (v+vi) 72.41 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 141.29 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 83.23
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,307
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 48.70 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 106.79 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 43.38 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 45.60 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.26 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,860 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 678,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 175,405 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,280,271 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 442 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 29.84 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 52,349 kWh/yr
xxxi) Annual Financial Saving on Pumping 680,537 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 46%. For 150 HP motor efficiency <58% is LOW and efficiency ≥65% is GOOD. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency to 65%. This intervention will save Rs. 680,537 anually.
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 818,500 PKR
Replace faulty A meter by correct oneDefective A meter
Faulty chlorinator Instal chlorinator
Installation of relays is recommendedOver current relays and over/under voltage relay is not installed
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Gulratan/Hur
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Purana Baraf Khana
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Mr Mukhtar Hussain 0302-7558991
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2007
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 122.48 BHP
ix) Speed (n) 1486 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)
21-06-10-6689
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 41 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 378776.8
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 FLASHED/FAULTY (A) METER
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge INSTALLED-OPERATIONAL
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping FAIR
Motor Terminal OPEN CONNECTION WITHOUT TERMINL BOX
Foundation/Civil work VIBRATION
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 860 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 375 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.06 m/sec
Pressure
i) Pressure at Discharge Side of Pump 41 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 377 380.1 382.5
ii) Ampere 207 219 201
iii) Power Factor 0.78 0.89 0.83
iv) Appearant Power (kVA) 135.2 144.3 132.8
v) Running Power (kW) 106.7 128.3 111.2 115.4
vi) Reactive Power (kVAr) 83.1 65 71.5
vi) Motor Working on Loading Basis 105
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,479 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 100
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) 16.4 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) 94.71 ft
vi) Discharge Side Frictional Head 9.56 ft
vii) Dynamic Discharge Head (v+vi) 104.27 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 176.43 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 100.68
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,238
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) 73.56 hp
xiv) Brake Horsepower (bhp) (OEM Data) 122.48 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 154.69 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 60.06 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 47.56 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.31 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,250 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 821,250 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 254,081 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,303,054 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 513 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.23 kWh/m3
xxix) Potential of Energy Reduction 26.84
xxx) Reduced Annual Energy Consumption at Improved Efficiency 68,189
xxxi) Annual Financial Saving on Pumping 886,459
11 Summary of Findings
Efficiency of the pumping system is 47.56%. For 150 HP motor efficiency < 58 % is considered to be LOW. This pumping system requires impeller adjustment, repair and maintenance to improve its efficiency to 65 % which is GOOD. This intervention will save 886,459 PKR annually.
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 868,500 PKR
Replace faulty A meter by correct oneDefective A meter
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No Digital pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No chlorinator Chlorinator is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Qasim Pur Colony # 1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M.Iqbal 0306-7831030
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.16 BHP
ix) Speed (n) 1485 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)
18-4096
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 716
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 SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED(NON-OPERATIONAL)
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring FAIR
Housekeeping VERY POOR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work POOR
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1010 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 350 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.33 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 416.2 416.6 420.1
ii) Ampere 182.6 190.5 190.3
iii) Power Factor 0.71 0.72 0.74
iv) Appearant Power (kVA) 133.4 136.5 141.4
v) Running Power (kW) 102.6 105.2 104.1 104.0
vi) Reactive Power (kVAr) 96.2 95.84 91.64
vi) Motor Working on Loading Basis 95
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.1
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) 16.4 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) 46.2 ft
vi) Discharge Side Frictional Head 4.01 ft
vii) Dynamic Discharge Head (v+vi) 50.21 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 132.21 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 93.97
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,485
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) 51.45 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.16 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 139.37 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 41.78 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 36.92 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.30 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,100 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 766,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 228,908 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,975,802 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 616 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 43.20 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 98,897 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,285,660 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 36.92%. For 150 HP motor efficiency <58.9% is LOW. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65%. This intervention will improve the efficiency from 36.92% to 65%. Which is in range of GOOD EFFICIENCY. This intervention will save 1,285,660 PKR annually.
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 843,500 PKR
Replace faulty A meter by correct oneDefective A meter
No PFI display meter Install PFI display meter
Water flow meter is not working New water flowmeter is recommended
Chlorinator is recommendedNo chlorinator
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Qasim Pur Colony II
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact H.Zia-ul-Rehman 0300-9294924
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B 14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.46 BHP
ix) Speed (n) 1485 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)
17-7412
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 34 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1385.09
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 GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator FAULTY
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
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 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1025 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 425 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.62 m/sec
Pressure
i) Pressure at Discharge Side of Pump 34 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 407.6 411.2 401.2
ii) Ampere 223.7 185.3 218.6
iii) Power Factor 0.76 0.82 0.77
iv) Appearant Power (kVA) 159.9 132.4 152.4
v) Running Power (kW) 121 99.59 118.2 112.9
vi) Reactive Power (kVAr) 101.2 81.26 97.02
vi) Motor Working on Loading Basis 103
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.9
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) 16.4 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) 78.54 ft
vi) Discharge Side Frictional Head 5.90 ft
vii) Dynamic Discharge Head (v+vi) 84.44 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 166.44 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 114.10
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,377
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) 78.65 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.46 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 151.38 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 63.70 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 51.95 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.27 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,550 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 930,750 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 248,643 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,232,356 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 532 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.21 kWh/m3
xxix) Potential of Energy Reduction 20.07 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 49,902 kWh/yr
xxxi) Annual Financial Saving on Pumping 648,721 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 51.95%. For 150 HP motor efficiency <58.1% is LOW. This pumping system requires impeller adjustment. This intervention will improve the efficiency from 51.95% to 65%. Which is in range of GOOD EFFICIENCY. This intervention will save 648,721 PKR annually.
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 818,000 PKR
Chlorinator is recommendedDefective chlorinator
Faulty MCCB Replace MCCB
Over voltage current relays and over/under voltage relay is defective Replacement of faulty relays is recommended
New rachet plate is recommendedFaulty rachet plate
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station RASHEEDABAD COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Thair Naqvee 0300-0691746
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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 3
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
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/3 Serial
iii) Certification Mark
iv) Year of Manufacture 2001
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 89.76 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)
14-5743
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 125 hp 93.75 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 173.5
v) Power Factor (Cos ɸ) 0.87
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,480 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 280-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 2911.6
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 70 Kvar-OPERATIONAL
Panel Condition/Issues FAIR
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator INSTALLED AND OPERATIONAL
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge INSTALLED-NON OPERATIONAL
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 860 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 310 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.70 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 24 meter
Electric Measurements
i) Voltage 377 388 382
ii) Ampere 118 108 113
iii) Power Factor 0.98 0.99 0.97
iv) Appearant Power (kVA) 77 73 75
v) Running Power (kW) 77 72 74 74.3
vi) Reactive Power (kVAr) 13.2 9.7 12.2
vi) Motor Working on Loading Basis 68
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,480 RPM
ii) Speed of Pump Impeller 1470 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90
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) 19.68 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) 46.2 ft
vi) Discharge Side Frictional Head 6.61 ft
vii) Dynamic Discharge Head (v+vi) 52.81 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 131.53 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 69.36
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,398
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 45.34 hp
xiv) Brake Horsepower (bhp) (OEM Data) 89.76 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 99.64 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 50.51 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 45.50 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,860 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 678,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 163,663 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,127,617 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 443 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 30.00 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 49,104 kWh/yr
xxxi) Annual Financial Saving on Pumping 638,347 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 45.50%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 638,347 PKR annually.
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 710,500 PKR
No PFI display meter Install PFI display meter
Replace faulty A meter by correct oneDefective A meter
Faulty pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Hassan Abad Gate 2
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Waseem Iqbal 0300-7349917
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country PAK
ii) Model B 14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.32 BHP
ix) Speed (n) 1485 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)
18-4364
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 15 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 209.5
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 1296.98/13548.55
iii) Meter Time and Date
Correct FALSE
Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition
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 40 KVAR OPERATIONAL
Panel Condition/Issues EXCELLENT
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1000 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 512 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.95 m/sec
Pressure
i) Pressure at Discharge Side of Pump 15 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 402.1 400.8 402.2
ii) Ampere 153.3 156.5 157.9
iii) Power Factor 0.96 0.96 0.97
iv) Appearant Power (kVA) 106.7 108.6 110.1
v) Running Power (kW) 102.6 104.5 106.5 104.5
vi) Reactive Power (kVAr) 27.86 29.56 27.12
vi) Motor Working on Loading Basis 95
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.6
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) 16.4 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) 34.65 ft
vi) Discharge Side Frictional Head 8.45 ft
vii) Dynamic Discharge Head (v+vi) 43.10 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 115.26 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 137.46
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,991
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) 65.62 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.32 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 140.13 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 53.21 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 46.83 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 3,072 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,121,280 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 230,155 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,992,021 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 711 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.15 kWh/m3
xxix) Potential of Energy Reduction 27.96 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 64,348 kWh/yr
xxxi) Annual Financial Saving on Pumping 836,528 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 46.83%. For 150 HP motor efficiency <58% is LOW. This pumping system requires impeller adjustment, repair and maintenance . This intervention will improve the efficiency from 46.83% to 65%. Which is in range of GOOD EFFICIENCY. This intervention will save 836,528 PKR annually.
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 768,000 PKR
No chlorinator Chlorinator is recommended
Install PFI display meter No PFI display meter
Impeller adjustment, repair and maintenance is recommendedPumping system requires impeller adjustment, repair and maintenance
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Shah Shams Park
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Zeeshan 0310-6662009
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14-B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4367
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 65 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 209.5
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 994.27
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 GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1010 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 430 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.64 m/sec
Pressure
i) Pressure at Discharge Side of Pump 65 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 378.7 378.4 380.4
ii) Ampere 184.5 188.1 190.2
iii) Power Factor 0.84 0.85 0.85
iv) Appearant Power (kVA) 121.1 119.9 124.3
v) Running Power (kW) 101.2 102.2 107.6 103.7
vi) Reactive Power (kVAr) 67.34 61.7 65.55
vi) Motor Working on Loading Basis 94
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91
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) 16.4 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) 150.15 ft
vi) Discharge Side Frictional Head 5.95 ft
vii) Dynamic Discharge Head (v+vi) 156.10 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 224.98 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 115.44
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,105
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) 107.57 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 138.96 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 95.83 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 77.41 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,580 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 941,700 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 228,247 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,967,215 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 77.41%. For 150 HP motor efficiency ≥68.9% is 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 793,000 PKR
Replacement of faulty relays is recommendedOver voltage current relays and over/under voltage relay is defective
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No water flow meter Water flowmeter is recommended
Chlorinator is recommendedNo chlorinator
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station SHALIMAR COLONY
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Khan ASAIQ HASSAN 0303-7559385
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4371
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NO METER IS AVAILABLE (DIRECT CONNECTED)
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 GOOD
Gland Leakage NO
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1005 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 485 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.85 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 13 meter
ii) Pumping Water Level 18 meter
Electric Measurements
i) Voltage 383 380 380
ii) Ampere 169 183 171
iii) Power Factor 0.78 0.75 0.73
iv) Appearant Power (kVA) 113 121 109
v) Running Power (kW) 89 90 74 84.3
vi) Reactive Power (kVAr) 71 81 75
vi) Motor Working on Loading Basis 77
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.6
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) 16.4 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) 46.2 ft
vi) Discharge Side Frictional Head 7.48 ft
vii) Dynamic Discharge Head (v+vi) 53.68 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 112.72 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 130.21
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,937
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) 60.79 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 113.05 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 54.15 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 53.77 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.17 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,910 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,062,150 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 185,680 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,413,844 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 586 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.14 kWh/m3
xxix) Potential of Energy Reduction 17.27 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 32,076 kWh/yr
xxxi) Annual Financial Saving on Pumping 416,989 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 53.77%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥65% is good. This pumping system requires impeller adjustment to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 416,989 Rs annually.
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 818,000 PKR
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No chlorinator Chlorinator is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station SHAMSABAD-1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M ASIF 0307-7873747
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4058
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 38 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 209.5
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 2139/16081
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 GOOD
Gland Leakage SIGNIFICANT
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
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 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1025 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 372 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.42 m/sec
Pressure
i) Pressure at Discharge Side of Pump 38 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 383 387 391
ii) Ampere 164 153 139
iii) Power Factor 0.86 0.82 0.85
iv) Appearant Power (kVA) 109 103 94
v) Running Power (kW) 95 84 81 86.7
vi) Reactive Power (kVAr) 56 59 49
vi) Motor Working on Loading Basis 79
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,479 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.1
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) 16.4 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) 87.78 ft
vi) Discharge Side Frictional Head 4.45 ft
vii) Dynamic Discharge Head (v+vi) 92.23 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 157.83 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 99.87
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,318
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) 65.28 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 116.18 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 58.16 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 56.19 %
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 6 hrs
xxi) Daily Pump flow 2,232 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 814,680 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 190,818 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,480,630 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 430 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
xxix) Potential of Energy Reduction 13.55
xxx) Reduced Annual Energy Consumption at Improved Efficiency 25,862
xxxi) Annual Financial Saving on Pumping 336,203
11 Summary of Findings
Efficiency of the pumping system is 56%. For 150 HP motor efficiency <58% is LOW and efficiency ≥65% is GOOD. This pumping system requires impeller adjustments to increase its efficiency to 65%. This intervention will save 336,203 PKR annually.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 818,000 PKR
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No power factor improvement (PFI) plant is installed PFI of 50 KVAR is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station SHAMSABAD 2
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M DILSHAD 0343-6850041
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 123.26 BHP
ix) Speed (n) 1485 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)
18-4026
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 51 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 161/6164
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 60 Kvar-OPERATIONAL
Panel Condition/Issues GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPRATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring FAIR
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 510 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.94 m/sec
Pressure
i) Pressure at Discharge Side of Pump 8 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 15 meter
ii) Pumping Water Level 20 meter
Electric Measurements
i) Voltage 376 373 380
ii) Ampere 187 167 158
iii) Power Factor 0.95 0.95 0.99
iv) Appearant Power (kVA) 123 108 104
v) Running Power (kW) 116 102 104 107.3
vi) Reactive Power (kVAr) 38 37 27
vi) Motor Working on Loading Basis 98
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,479 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.1
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) 16.4 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) 18.48 ft
vi) Discharge Side Frictional Head 8.33 ft
vii) Dynamic Discharge Head (v+vi) 26.81 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 92.41 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 136.92
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 2,305
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 52.40 hp
xiv) Brake Horsepower (bhp) (OEM Data) 123.26 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 143.88 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 42.51 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 36.42 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 3,060 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,116,900 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 236,320 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,072,165 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 910 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.12 kWh/m3
xxix) Potential of Energy Reduction 43.97 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 103,907 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,350,796 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 36.42%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. Motor is also overloaded. After impeller adjustment, repair and maintenance the load of the motor will be decreased. This intervention will save 1,350,796 Rs annually.
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 718,000 PKR
No chlorinator Chlorinator is recommended
Install PFI display meter No PFI display meter
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station SIDDIQUEABAD
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact FAREED 0333-6163344
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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 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
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B12 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 1999
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 44.96 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)
15-6554
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 20 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 85
v) Power Factor (Cos ɸ) 0.87
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,470 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 223-M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 3188
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/FAULTY V METER
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of Pan NO
Wiring FAIR
Housekeeping FAIR
Motor Terminal OPEN AND LOSE MOTOR CONNECTIONS
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter 680 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 199.8 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.71 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 410 409 411
ii) Ampere 68 71 72
iii) Power Factor 0.79 0.81 0.8
iv) Appearant Power (kVA) 48 51 50
v) Running Power (kW) 38 41 40 39.7
vi) Reactive Power (kVAr) 30 28 32
vi) Motor Working on Loading Basis 88
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,489 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 87.4
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) 16.4 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) 46.2 ft
vi) Discharge Side Frictional Head 6.83 ft
vii) Dynamic Discharge Head (v+vi) 53.03 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 125.19 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 53.64
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,177
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) 27.81 hp
xiv) Brake Horsepower (bhp) (OEM Data) 44.96 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 53.17 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 61.86 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 52.30 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,199 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 437,562 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 87,336 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,135,365 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 62 %
xxvii) Water Flow after Efficiency Improvement 237 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 15.64
xxx) Reduced Annual Energy Consumption at Improved Efficiency 13,658
xxxi) Annual Financial Saving on Pumping 177,551
11 Summary of Findings
Efficiency of the pumping system is 52.30%. For 60 HP motor efficiency <56% is LOW and efficiency >=62% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 62%. This intervention will save 177,551 PKR annually.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators12 Estimated Investment for Improvement Plan 478,500 PKR
Faulty V meter V meter is recommended
PFI plant of 25 KVAR is recommendedNo power factor improvement (PFI) plant
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station SILLY KHANA
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact MEHMOOD AHMED 0300-6331499
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pre . Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4146
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 12046.02
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 GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanYES
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 325 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.24 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 380 379 381
ii) Ampere 131 151 131
iii) Power Factor 0.9 0.91 0.92
iv) Appearant Power (kVA) 86 99 80
v) Running Power (kW) 78 90 77 81.7
vi) Reactive Power (kVAr) 37 40 39
vi) Motor Working on Loading Basis 74
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.2
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 3.41 ft
vii) Dynamic Discharge Head (v+vi) 72.71 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 141.59 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 87.25
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,369
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) 51.17 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 109.47 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 45.58 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 46.74 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,950 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 711,750 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 179,809 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,337,517 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 452 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 28.10 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 50,519 kWh/yr
xxxi) Annual Financial Saving on Pumping 656,744 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 46.74%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 656,744 PKR annually.
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 843,000 PKR
Change panel location is recommendedBore hole is in front of panel
No chlorinator Chlorinator is recommended
Digital pressure guage is recommendedNo pressure guage
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No flow meter Flowmeter is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 r Wastewater Disposal
3 r Waste Water Treatment Plant
4 r Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station Smeejabad
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Waqas Saeed 0300-7392696
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
r Submersible Deep Well Water Turbine Pumps Qty
r Centrifugal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 1
r Series
r Parallel
vii) Any Header / Tank / Reservoir
r Yes No
viii) Any Record Keeping
Time r Flow r Pressure
r Level r Quality of Water r Power Consumption
Maintenance Record r Electricity Bill r Fuel Consumption Data
viii) Daily Operational Time 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
r Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
r Submersible
r Overhung
r Between Bearing
ii) Mounting / Erection
r Horizontal Vertical
Foundation
iii) Concrete Bolted r Bolted
iv) Lubrication Type
r Oil Water
v) Cooling Type
r Water Cooled Air Cooled
vi) Number of Stages
r Single Multi 4
vii) Pump and Motor Assembly
Direct Coupled r Belt / Gear
viii) Source of Suction
Ground Water Aquafier r Overhead Tank r Underground Tank
r Pressurized Source
ix) Pump Discharge Destination
r Overhead Tank r Drain r On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF r Proportional
x) Pump Flow Control
Throttle r VFD Controlled
xi) Any Retrofits ?
r Impeller Detail
r Casing / Volute Detail
r Line Shaft (DW) Detail
r Column Sett. (DW) Detail
r Motor Replacement Detail
r Motor Rewinding Detail
xii) Self Priming
r Yes r No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
r Yes No
xiv) Flowmeter Available
Yes r No
xv) Flowmeter Working
r Working Properly Malfunctioning (Out of order)
3 Pump Nameplate Data (there was no pump nameplate)
i) Make / Brand Country PAK
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) (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
r 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 r 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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1 r
r Strainer r
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 r Yes No (Installed by Team)
viii) Discharge Pressure 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
Efficiency Class
r IE3 r Eff 1
r IE2 r Eff 2
r IE1 r 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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 449
iii) Meter Time and Date
Correct r FALSE
r Lag by r Lead by
iv) Transformer Rating (kVA) 200 Condition ok
Pump O & M Cost
v) Motor Starting Method
r Direct Online Star (Wye) - Delta
r Autotransformer Starter r Soft Starter
r Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding r Fuses or Miniature Circuit Breaker (MCB)
r Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 60 kvar OPREATIONAL
Panel Condition/Issues POOR
Gland Leakage NORMAL
Non Return Valve OK
Chlorinator OK
Flow Meter INSTALLED- NON OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of Panel NO
Wiring POOR
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED IN TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe r Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes r No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 850 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 325 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.78 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 17 meter
ii) Pumping Water Level 22 meter
Electric Measurements
i) Voltage 421 421 433
ii) Ampere 96 133 98
iii) Power Factor 0.81 0.86 0.84
iv) Appearant Power (kVA) 68.02 96.56 72.08
v) Running Power (kW) 52.4 84.32 44 60.2
vi) Reactive Power (kVAr) 39.08 47.54 38.47
vi) Motor Working on Loading Basis 55
r Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,485 RPM
ii) Speed of Pump Impeller 1470 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.9
Thermal Imaging
i) Motor r Motor Pump Coupling
r Pump Volute Casing r Pump Bearings
Electric Panels
Calculations
10
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) 69.3 ft
vi) Discharge Side Frictional Head 7.20 ft
vii) Dynamic Discharge Head (v+vi) 76.50 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 148.66 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 87.25
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce
1gpm/ft head 1,306
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) 53.72 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 80.75 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 66.52 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.19 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,950 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 711,750 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 132,633 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,724,229 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 66.52%. For 150 HP motor efficiency between 65.1% to 68.9% is in GOOD range. 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 743,500 PKR
Install PFI display meter No PFI display meter
Replace faulty A meter by correct oneDefective A meter
No chlorinator Chlorinator is recommended
Faulty MCCB Replace MCCB
Water flow meter is not working New water flowmeter is recommended
Improve wiring condition by making safe and proper connections with
contactors and breakers Poor wiring condition
Replacement of faulty relays is recommendedOver voltage current relays and over/under voltage relay is defective
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station TIBBI SHER KHAN
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact ALLAH DITA 0301-2168200
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4193
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 13071
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 GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 980 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 364 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.00 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 23 meter
Electric Measurements
i) Voltage 375 374 377
ii) Ampere 176 180 181
iii) Power Factor 0.77 0.81 0.85
iv) Appearant Power (kVA) 115 116 114
v) Running Power (kW) 89 90 97 92.0
vi) Reactive Power (kVAr) 72 74 73
vi) Motor Working on Loading Basis 84
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,557 RPM
ii) Speed of Pump Impeller 1485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.2
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 9.05 ft
vii) Dynamic Discharge Head (v+vi) 78.35 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 153.79 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 97.73
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,361
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) 62.24 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 123.32 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 55.45 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 50.47 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,184 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 797,160 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 202,560 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,633,284 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 469 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.20 kWh/m3
xxix) Potential of Energy Reduction 22.35
xxx) Reduced Annual Energy Consumption at Improved Efficiency 45,277
xxxi) Annual Financial Saving on Pumping 588,597
11 Summary of Findings
Efficiency of the pumping system is 50.47%. For 150 HP motor efficiency <58% is LOW and efficiency >=65% is GOOD. This pumping system requires impeler adjustments to increase its efficiency to 65%. This intervention will save 588,597 PKR annually.
Issues & Recommendations
12 ISSUES RECOMMENDATIONSi)
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 818,000 PKR
Chlorinator is recommendedNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
No power factor improvement (PFI) plant is installed PFI of 50 KVAR is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station TIMBER MARKET 1
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact JAVED ALI SHAH 0311-7522976
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.5 BHP
ix) Speed (n) 1485 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)
18-4204
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 2006
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 GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping GOOD
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1010 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 580 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.21 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 25 meter
Electric Measurements
i) Voltage 414 411 417
ii) Ampere 220 226 230
iii) Power Factor 0.92 0.88 0.89
iv) Appearant Power (kVA) 142 136 135
v) Running Power (kW) 111 108 105 108.0
vi) Reactive Power (kVAr) 100 98 101
vi) Motor Working on Loading Basis 98
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,492 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.4
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 10.94 ft
vii) Dynamic Discharge Head (v+vi) 80.24 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 162.24 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 155.72
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,612
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) 104.63 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 144.77 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 93.00 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 72.27 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.19 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 3,480 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,270,200 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 237,788 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,091,247 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 72.27%. For 150 HP motor efficiency >=68.9% 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 843,000 PKR
No chlorinator Chlorinator is recommended
Water flowmeter is recommendedNo flowmeter
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station TUGHLAQ TOWN
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact Faiaz 0307-7442332
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 200 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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)
18-4194
Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 12 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 42 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 1049
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 50 KVAR OPERATIONAL
Panel Condition/Issues GOOD
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NO
Bore Hole in Front of PanNO
Wiring GOOD
Housekeeping FAIR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 1020 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 380 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.45 m/sec
Pressure
i) Pressure at Discharge Side of Pump 42 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 20 meter
ii) Pumping Water Level 26 meter
Electric Measurements
i) Voltage 404 402 405
ii) Ampere 133.3 122 137
iii) Power Factor 0.86 0.88 0.92
iv) Appearant Power (kVA) 94 86 96
v) Running Power (kW) 81 75 88 81.3
vi) Reactive Power (kVAr) 47 40 39
vi) Motor Working on Loading Basis 74
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 91.8
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) 19.68 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) 97.02 ft
vi) Discharge Side Frictional Head 4.74 ft
vii) Dynamic Discharge Head (v+vi) 101.76 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 187.04 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 85.02
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,173
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) 79.03 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 109.03 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 70.40 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 72.48 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,280 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 832,200 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 179,075 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,327,976 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 72.5%. For 150 HP motor efficiency <58% is considered to be LOW AND ≥65% is good. 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 668,000 PKR
No chlorinator Chlorinator is recommended
Install PFI display meter No PFI display meter
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer Izhar/Waseem
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station W BLOCK
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact AZMAT ALI
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 6 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
Primary MEPCO 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial 17-6556
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 112.25 BHP
ix) Speed (n) 1485 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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 24 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.84
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading 3449/58014
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 60 Kvar OPERATIONAL
Panel Condition/Issues POOR/FAULTY VOLT METER
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of Pan NO
Wiring POOR
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter 860 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 388 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.13 m/sec
Pressure
i) Pressure at Discharge Side of Pump 24 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 18 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 425 430 426
ii) Ampere 171 163 201
iii) Power Factor 0.82 0.82 0.87
iv) Appearant Power (kVA) 125 116 149
v) Running Power (kW) 102 98 130 110.0
vi) Reactive Power (kVAr) 71 66 73
vi) Motor Working on Loading Basis 100
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 90.6
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) 9.84 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) 55.44 ft
vi) Discharge Side Frictional Head 10.19 ft
vii) Dynamic Discharge Head (v+vi) 65.63 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 134.51 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 173.61
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,517
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 58.03 hp
xiv) Brake Horsepower (bhp) (OEM Data) 112.25 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 147.45 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 51.70 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 39.35 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.29 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 2,328 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 849,720 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 242,192 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,148,492 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 641 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.17 kWh/m3
xxix) Potential of Energy Reduction 39.45 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 95,556 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,242,233 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 39.35%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 1,242,233 PKR annually.
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 718,500 PKR
Install PFI display meter No PFI display meter
Instal chlorinatorNo chlorinator
No pressure guage Digital pressure guage is recommended
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
Defective V meter Replace V meter
1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer GUL/HUR
WASA Staff Name Mr Mumtaz Jaskni
i) Name of Pumping Station WILAYATABAD
ii) Name of Subdivision Waterworks
iii) Operator Name & Contact M HAFEEZ 0302 3567544
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 6 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
Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country PAK
ii) Model B14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2009
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 160 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 88.6 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)
14-6209
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
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
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 30 psig
6 Motor Nameplate Data
i) Manufacturer SEIMENS
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 214
v) Power Factor (Cos ɸ) 0.86
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
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading NOT VISIBLE
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 POOR/DEFECTIVE A AND V METER
Gland Leakage MODERATE
Non Return Valve OK
Chlorinator NA
Flow Meter INSTALLED-OPERATIONAL
Pressure Gauge NA
Bore Hole in Front of PanNO
Wiring POOR
Housekeeping POOR
Motor Terminal PROPERLY CONNECTED WITH TERMINAL BOX
Foundation/Civil work OK
Ratchet Plate OK
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 12 inches (on which flowmeter is clamped)
v) Pipe Perimeter 840 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) Z
viii) Flow Measurement 290 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.10 m/sec
Pressure
i) Pressure at Discharge Side of Pump 30 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
iii) Water Shutoff Head
Levels
i) Static Water Level 16 meter
ii) Pumping Water Level 21 meter
Electric Measurements
i) Voltage 428 425 426
ii) Ampere 135 140 146
iii) Power Factor 0.78 0.74 0.78
iv) Appearant Power (kVA) 100 104 103
v) Running Power (kW) 79 78 84 80.3
vi) Reactive Power (kVAr) 63 69 66
vi) Motor Working on Loading Basis 73
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,489 RPM
ii) Speed of Pump Impeller 1450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 92.4
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) 16.4 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) 69.3 ft
vi) Discharge Side Frictional Head 2.72 ft
vii) Dynamic Discharge Head (v+vi) 72.02 ft
viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 140.90 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 77.86
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,267
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 45.43 hp
xiv) Brake Horsepower (bhp) (OEM Data) 88.6 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 107.69 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 51.28 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 42.19 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.28 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 6 hrs
xxi) Daily Pump flow 1,740 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 635,100 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 176,873 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,299,353 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 447 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.18 kWh/m3
xxix) Potential of Energy Reduction 35.09 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 62,070 kWh/yr
xxxi) Annual Financial Saving on Pumping 806,912 PKR/Yr
11 Summary of Findings
Efficiency of the pumping system is 42%. For 150 HP motor efficiency <58% is considered to be LOW AND >=65% is good. This pumping system requires impeller adjustment, repair and maintenance to increase its efficiency up to 65% which is in the range of GOOD. This intervention will save 806,912 Rs annually.
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 759,000 PKR
No chlorinator Chlorinator is recommended
PFI of 50 KVAR is recommendedNo power factor improvement (PFI) plant is installed
Defective A and V meter Replace A and V meter
No variable frequency drive (VFD) Variable frequency drive (VFD) is recommended
ANNEXURE-2
Selected Pictures
RPM Measurement at Al Jillan Sound Measurement at Al Sana Hotel
Flow Measurement at Grass Mandi View of pump and motor at Al Sana Hotel
Electric panel at Ansar Colony Faulty MCB at Circuit House
View of discharge pipeline at Kabootar Mandi
Pannel condition at Lodhi Colony II
Gland leakage at Lohari Gate I Gland leakage at Lohari Gate IV
Poor panel condition at MDA 2 Significant gland leakage at Naqashband Colony
Faulty V meter at Bosan Road PTCL
Pannel condition at Qasimpur Colony II
Pressure measurement at Tughlaq Town Faulty V meter at W block
Poor panel condition at Wilayatabad Electric panel at Gulshan Market