Energy Audit & Energy Efficiency Improvement Program for ...pcgip.urbanunit.gov.pk/docs/energy/Final Report Gulberg-Gulberg... · Energy Audit & Energy Efficiency Improvement gram

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Punjab Cities Governance Improvement Project

Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab

REPORT Gulberg Subdivision, Lahore

September 2015

NEC Consultants (Pvt.) Ltd.

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Energy Audit & Energy Efficiency Improvement Program for WASAs in Punjab

September 2015 NEC Consultants Pvt. Ltd Perfect SITE, 22 KM Ferozepur Road, Near Gujju Matta Metro Bus Station, Lahore +92-42-35273741-46, www.nec.com.pk [email protected] This study was assigned by The Urban Unit, Punjab

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DISCLAIMER No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or information storage and retrieval system, without prior written permission of the USPMSU. A publication of the Urban Sector Planning and Management Services Unit (Private) Limited, the opinion expressed in the document are solely those of the authors and publishing them does not in any way constitute an endorsement of the opinion by the USPMSU.

ACKNOWLEDGEMENTS This report has been prepared by The Urban Unit (Urban Sector Policy & Management Unit), P&D Department, Government of Punjab. The Urban Unit, under the Punjab Cities Governance Improvement Project (PCGIP)-DLI-4 is supporting WASA Lahore for implementing Energy Audit Management Opportunities. Energy management opportunities have been extracted from the energy audits of WASA pumps. The Team Dr. Nasir Javed Engr. Abid Hussainy Engr. Ali Raza Shafqat Ullah Muhammad Rizwan Kashif Shaukat Adnan Khan Editing & Layout By: Ms. Madiha Qamar Printed in Pakistan Copyright: Urban Sector Planning and Management Services Unit (Private) Limited.

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CONTENTS Contents 4 List of Annexure 4 List of Figures 4 List of Tables 4 List of Acronyms and Abbreviations 5 Glossary 5 1.0 Introduction 7

1.1 Background 7 1.2 Methodology 7 1.3 Scope 8

2.0 Energy Audit Findings 9 2.1 Pumping system efficiency 10 2.2 Electricity consumption trend 12 2.3 Pumping system efficiency improvement potential 14 2.4 Interventions for the improvement of WASA stations 15

LIST OF ANNEXURE

I Energy Audit Reports 2 Selected Pictures

LIST OF FIGURES

I Pumping system efficiency category 12 2 Unit electricity consumption trend 14

LIST OF TABLES

1 Detail of WASAs pumps 8 2 Detail of Gulberg subdivision 9 3 Typical overall pumping system efficiency classification 10 4 Detail of motor loading and pumping system efficiency 11 5 Detail of water discharge and electricity consumption 12 6 System energy efficiency potential of pumps 14

7A Interventions & investment required in WASA stations-Gulberg Subdivision 16

7B Interventions & investment required in WASA stations- Gulberg Subdivision 18

7C Interventions & investment required in WASA stations- Gulberg Subdivision 20

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LIST OF ACRONYMS AND ABBREVIATIONS

Bhp Brake Horsepower Cusec Cubic Feet per Second Ehp Electrical Horsepower Gpm Gallon Per Minute Hp Horsepower kVA Kilo Volt Ampere kW Kilo Watt kWh Kilo Watt Hour LESCO Lahore Electric Supply Company m/s Meter Per Second m3/hr Cubic Meter Per Hour MCB Fuses or Miniature Circuit Breaker Mm Millimeter MS Mild Steel Psig Pound Per Square Inch (Gauge) RPM Revolution Per Minute TDH Total Dynamic Head VFD Variable Frequency Drive WASA Water and Sanitation Agency Whp Water Horsepower

GLOSSARY

Discharge Pressure

The pressure obtained at center line of pump discharge pipe using a calibrated gauge (psig). Discharge pressure is converted to feet and expressed as “Discharge Head”.

Brake Horsepower

The output horsepower of a motor to a pump; may also be used to refer to the required input horsepower to the pump itself.

Deep Well Turbine Pump

A turbine pump installed inside a well casing below the pumping water level in the well.

Discharge Head Head measured above center line of pump discharge pipe.

Drawdown The measured distance that a well’s water level changes from standing/static level to operating pumping level during observed test conditions.

Dynamic Head The sum of the pressure and the pumping head developed by a pump

Friction Head The head required to overcome the fluid friction in a pipe or water system

Friction Losses

Energy losses associated with moving water against rough surfaces. In water pumping applications, it is the water pressure lost as a result of contact between moving water and a pipeline or open channel.

GPM per Foot The ratio of capacity (GPM) to drawdown feet is useful in

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Drawdown determining the well’s performance.

Head Alternate term for pressure. One pound per square inch (psi) = 2.31 feet of water head

Overall Plant or Pumping System Efficiency

The ratio of the water horsepower (the overall output of the plant) to input horsepower (the power input). The overall output can also be defined as the amount of horsepower required to deliver the measured capacity (water gallons per minute) and the measured total head.

Pumping Water Level

The well’s operating water level below center line of discharge pipe as observed during test condition

Static Water Level The well’s water level obtained when pumping plant is at rest.

Suction Head Head measured above center line of pump suction intake. Most often obtained with calibrated bourdon tube pressure gauge (suction pressure) and converted to feet by conversion factor 2.31 ft. water/psi

Suction Lift The distance between pump discharge head and water level.

Total Head

The sum of the water head above and below the center line of the pump discharge pipe. For well applications, the Total Head is the sum of the Discharge Head and the Pumping Water Level. Total head is used in determination of water horsepower and pump performance.

Water Horsepower

The output horsepower of a water pump. It is the combination of flow rate and pressure.

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1.0 Introduction 1.1 Background Energy Audit & Energy Efficiency Improvement gram Government of the Punjab, Pakistan with financial assistance from the World Bank, is implementing “Punjab Cities Governance Improvement Project (PCGIP)” for strengthening systems for improved planning, resource management, and accountability in five large cities of Punjab i.e. Lahore, Faisalabad, Multan, Gujranwala and Rawalpindi. The project utilizes a result-based approach and, consistent with this focus, the disbursement decisions to the city and its entities are based on achievement of pre-specified results, referred to as Disbursement linked Indicators (DLIs) which reflect priority elements in furthering the Government’s urban agenda, critical at the provincial level, within the existing legislative, regulative and policy framework of the Government. DLIs includes intermediate outcomes, incremental steps and results contributing to improved efficiency, effectiveness, accountability and service delivery during and beyond the project life by building capacities , system and processes . Disbursement Linked Indicator 4 (DLI -4) aims for improvements in own source revenue collection system that encourages the City Local Government (CDGs), Development Authorities (DAs) and Service providers (WASAs) to bring improved systems for revenue enhancement. This DLI is linked with the initiative of WASAs to carry out the Energy Audit for resources conservation and efficiency to improved service delivery, accountability and own source revenue. One of the proposed actions & initiatives to enhance revenue was to conduct energy audit of WASAs to reduce the power cost by various systematic analysis of the energy use and finding out the energy management opportunities. WASAs each year incur significant cost. It was Rs. 4,697 million in 2014 year for energy/Electricity bills, with an installed capacity of approximately 131 MW for 5,663 Million Gallons per Day (water management), which can be reduced through detailed energy audit and implementing its findings. In the context of existing scenario energy audit of WASAs is a technical and efficient way to obtain energy analysis and savings through improvements that optimize pumping systems of tube well stations and disposal stations to operate efficiently with significant cost saving. The Urban Planning and Management Services Unit, Pvt. Ltd. has assigned NEC Consultants Pvt. Ltd to conduct energy audits of WASAs in Punjab in five major cities of Lahore, Rawalpindi, Faisalabad, Multan and Gujranwala. This is the energy audit report of Gulberg Subdivision of Lahore city. 1.2 Methodology The primary and secondary sources were used to collect data for different WASAs and pumps installed there. The Urban Unit provided information and contact detail of all the WASAs. An energy audit report template was developed to collect field data from each WASA subdivision. Prior to start the on field measurements of each subdivision, meetings were conducted with the respective WASA management and briefed them about the activity. The technical team then collected data by on field measurements of each pump and recorded in their energy audit report template. On the basis of this energy audit report template, The Urban Unit also developed Android based software to record data of each pump online. This data was also recorded on line in this Android based application. On the basis of field measurements, efficiency of the pumping system was calculated and

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energy efficiency opportunities were identified. 1.3 Scope The scope of the this assignment is to conduct energy audits of about 1,600 fresh water supply and wastewater disposal pumps installed at different WASA stations in five major cities of Lahore, Rawalpindi, Multan, Faisalabad and Gujranwala. The detail of these pumps is given in Table-1.

Table-1: Detail of WASAs Pumps

WASA Population

Served (Million)

Total Water Connections

Total Sewerage

Connections

Total Supply

Stations

Total Disposal Stations

Total No. of Pump

Sets WASA Lahore 5.48 587,595 583,532 491 99 776

WASA Gujranwala 0.54 29,375 97,236 66 23 112

WASA Faisalabad 1.55 110,452 217,002 87 43 222

WASA Multan 1.2 43,996 175,615 102 21 161

WASA Rawalpindi 1.17 92,468 38,437 362 - 362

Total 9.94 863,886 1,111,822 1,108 186 1,633 The efficiency of each pumping system was evaluated and energy efficiency improvement opportunities were identified for those pumping systems whose efficiencies were not at required level. The detail of reports prepared is as under:

- The energy audit report of each pump was prepared. - On the basis of each pump report, summary report of findings of each WASA

subdivision was prepared. - On the basis of each subdivision summary report, one consolidated report of each city

for energy efficiency improvement opportunities of the WASAs was prepared.

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2.0 Energy Audit Findings There are 24 WASA water supply stations and 19 wastewater disposal pumps in Gulberg Subdivision. The detail of these stations along with pumps installed capacity and actual discharge is given in Table-2:

Table-2: Detail of Gulberg Subdivision

# WASA Station

No. of Water Supply Pumps

Installed

Installed Capacity (Cusec)

Actual Discharge (Cusec)

1 C II Block 01 4.0 4.18 2 E1 Block 01 2.0 2.35 3 B Block 01 4.0 3.62 4 C Block 01 4.0 4.18 5 E1 Block 01 2.0 2.35 6 FCC 01 2.0 2.11 7 G Block 01 4.0 4.41 8 Ghalib Market 01 4.0 2.54 9 Gurumanget 01 4.0 3.28 10 Henery K Old 01 2.0 1.56 11 Ittehad Colony 01 2.0 1.87 12 Jail Road 01 2.0 1.96 13 Jinnah Park 01 2.0 2.20 14 K Block 01 2.0 1.76 15 Khan Colony 01 2.0 1.56 16 Mecca Colony Street-22 01 2.0 1.81 17 Mecca Colony Old 01 4.0 2.45 18 Nawaz Sharif Colony 01 4.0 4.18 19 Nisar Press 01 2.0 1.75 20 P Block 01 2.0 1.24 21 Q Block 01 4.0 3.74 22 Qurban Line 01 2.0 1.90 23 Saint Marry 01 2.0 1.85 24 T Block 01 2.0 1.83 Total 24 66.0 60.68 Wastewater Disposal Pumps

25 Arfa-01 01 25.0 14.55 26 Arfa-02 01 25.0 16.17 27 Arfa-03 01 10.0 7.84 28 Arfa-04 01 6.0 5.73 29 Arfa-05 01 6.0 5.73 30 Centre Point Disposal 01 6.0 3.01 31 G Block-01 01 25.0 13.43 32 G Block-03 01 25.0 16.47 33 Gurumanget-01 01 25.0 10.5 34 Kalma Chowk-01 01 8.0 5.88 35 Kalma Chowk-02 01 6.0 5.64 36 Kalma Chowk-03 01 6.0 5.39 37 Nawaz Sharif Disposal 01 2.0 1.47 38 Q Block Disposal 01 4.0 3.04

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39 Sharif Colony Disposal 01 6.0 4.85 40 Zafar Ali Disposal 01 5.0 4.89 41 Mecca Colony-01 01 25.0 5.53 42 Mecca Colony-02 01 8.0 5.88 43 Mecca Colony-03 01 8.0 7.35 Total 19 231.0 143.35

The installed capacity of WASA tube wells of Gulberg Subdivision is 39.31 million m3 per annum whereas actual discharge is 36.14 million m3 per annum, for average 16 hours per day operation and 365 days per year. This actual discharge is about 8% lesser than the installed capacity. The installed capacity of WASA disposal pumps of Gulberg Subdivision is 103.20 million m3 per annum whereas actual discharge is 64.04 million m3 per annum, for average 12 hours per day operation and 365 days per year. This actual discharge is about 38% lesser than the installed capacity. 2.1 Pumping System Efficiency Pumping plant performance can be classified as “Low”, “Fair”, “Good”, or “Excellent” by referring to the following table, which is based upon the results of thousands of pump tests conducted by Pacific Gas & Electric Company, USA. This classification is used to categorize WASA pumps.

Table-3: Typical Overall Pumping System Efficiency Classification

Motor HP Low Fair Good Excellent 3-7.5 <44.0 44-49.9 50-54.9 >54.9

10 <46.0 46-52.9 53-57.9 >57.9 15 <47.1 48-53.9 54-59.9 >59.9

20-25 <48.0 50-56.9 57-60.9 >60.9 30-50 <52.1 52.1-58.9 59-61.9 >61.9 60-75 <56.0 56-60.9 61-65.9 >65.9 100 <57.3 57.3-62.9 63-66.9 >66.9 150 <58.1 58.1-63.4 63.5-68.9 >68.9 200 <59.1 59.1-63.8 63.9-69.4 >69.4 250 <59.1 59.1-63.8 63.9-69.4 >69.4 300 <60 60-64.0 64.1-69.9 >69.9

Source: Pacific Gas & Electric Company, USA The detail of pumping system efficiency and motor loading of each WASA station is given in Table-4. The calculations for the efficiency determination are given in the energy audit report of each pump in Annexure-1.

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

WASA Station Motor Load (%)

Pumping System Efficiency (%)

Pumping System Efficiency Rating

E1 Block 81 70 EXCELLENT B Block 80 69 EXCELLENT C Block 76 80 EXCELLENT E1 Block 81 71 EXCELLENT G Block 91 77 EXCELLENT Gurumanget 70 74 EXCELLENT Henery K Old 57 68 EXCELLENT Jail Road 71 71 EXCELLENT Jinnah Park 62 82 EXCELLENT Mecca Colony Street-22 75 67 EXCELLENT Nawaz Sharif Colony 86 71 EXCELLENT Nisar Press 64 73 EXCELLENT Q Block 83 71 EXCELLENT Qurban Line 79 62 GOOD Ghalib Market 59 66 GOOD Ittehad Colony 67 63 GOOD Mecca Colony Old 47 67 GOOD T Block 71 62 GOOD C II Block 89 62 FAIR FCC 89 59 FAIR P Block 68 54 FAIR Saint Marry 87 56 FAIR K Block 76 54 LOW Khan Colony 102 45 LOW Disposal Pumps Arfa-01 59 81 EXCELLENT Arfa-02 73 82 EXCELLENT Arfa-03 84 75 EXCELLENT Arfa-05 93 69 EXCELLENT G Block-01 84 69 EXCELLENT Nawaz Sharif Disposal 82 81 EXCELLENT Sharif Colony Disposal 66 75 EXCELLENT Zafar Ali Disposal 94 73 EXCELLENT Mecca Colony-02 43 80 EXCELLENT Mecca Colony-01 15 75 EXCELLENT Arfa-04 98 66 GOOD Centre Pont disposal 33 61 GOOD G Block-03 78 67 GOOD Gurumanget-01 44 53 LOW Kalma Chowk-01 44 33 LOW Kalma Chowk-02 80 24 LOW Kalma Chowk-03 64 26 LOW Q Block Disposal 88 46 LOW Mecca Colony-03 107 45 LOW About 75% of the tube wells are under excellent and good category of pumping system efficiency whereas 25% are under fair and low category as illustrated in Fig-1.

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Figure-1: Pumping System Efficiency Category

About 68% of the operational disposal pumps are under excellent and good category whereas 32% are under low category of pumping system efficiency. 2.2 Electricity Consumption Trend The detail of annual water discharge and correspondingly electricity consumption and unit electricity consumption of each WASA station is given in Table-5.

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 C II Block 2,493,680 576,563 0.23 2 E1 Block 1,401,600 286,520 0.20 3 B Block 2,160,800 517,263 0.23 4 C Block 2,493,680 494,952 0.19 5 E1 Block 1,401,600 286,520 0.20 6 FCC 1,261,440 314,115 0.24 7 G Block 2,956,500 663,165 0.22 8 Ghalib Market 1,518,400 382,810 0.25 9 Gurumanget 1,956,400 450,330 0.23

10 Henery K Old 759,200 163,626 0.21 11 Ittehad Colony 1,254,870 266,851 0.21 12 Jail Road 949,000 203,698 0.21 13 Jinnah Park 1,314,000 219,587 0.16 14 K Block 1,182,600 300,538 0.25 15 Khan Colony 1,022,000 316,464 0.30 16 Mecca Colony Street-22 945,350 232,210 0.24 17 Mecca Colony Old 1,460,000 304,721 0.20 18 Nawaz Sharif Colony 2,337,825 522,914 0.22 19 Nisar Press 1,045,360 227,220 0.21 20 P Block 695,325 224,027 0.32

Excellent 54%

Good 21%

Fair 17%

Low 8%

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21 Q Block 2,230,880 537,225 0.24 22 Qurban Line 1,132,960 278,300 0.24 23 Saint Marry 1,103,760 307,657 0.27 24 T Block 1,092,080 250,705 0.22 Total 36,169,310 8,327,981 0.23 Disposal Pumps

25 Arfa-01 10,840,500 485,117 0.04 26 Arfa-02 12,045,000 600,342 0.04 27 Arfa-03 5,840,000 457,229 0.07 28 Arfa-04 7,270,500 322,922 0.04 29 Arfa-05 4,270,500 305,969 0.07 30 Centre Pont disposal 1,798,720 72,804 0.04 31 G Block-01 7,000,700 257,384 0.04 32 G Block-03 8,584,800 447,467 0.05 33 Gurumanget-01 6,645,555 308,794 0.04 34 Kalma Chowk-01 3,504,000 153,241 0.04 35 Kalma Chowk-02 3,363,840 211,367 0.06 36 Kalma Chowk-03 3,212,000 167,332 0.05 37 Nawaz Sharif Disposal 438,000 35,815 0.08 38 Q Block Disposal 1,929,755 122,894 0.06 39 Sharif Colony Disposal 3,613,500 180,543 0.05 40 Zafar Ali Disposal 3,642,700 258,338 0.07 41 Mecca Colony-01 3,093,375 94,675 0.03 42 Mecca Colony-02 3,285,000 105,684 0.03 43 Mecca Colony-03 31,481,250 2,017,163 0.06 Total 121,859,695 6,605,080 0.05 Total annual energy cost of Gulber subdivision is about Rs. 194 million. The unit electricity consumption trend for each WASA station is illustrated in Fig-2. From figure, it is clear that 0.20 kWh/m3 is considered to be optimum figure for water supply pumps. This figure is based on NEC experience of conducting water turbine audits of different industries. WASA audits also reflect the similar figure.

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Figure-2: Unit Electricity Consumption Trend

About 79% of the tube wells consume electricity more than the 0.20 kWh/m3. In case if all the 24 tube wells consume optimum electricity, then annually Rs. 14 million (13%) can be saved. 2.3 Pumping System Efficiency Improvement Potential The 06 tube wells and 06 disposal pumps having system efficiency in the category of FAIR to LOW, as given in Table-4, have the potential of efficiency improvement into the GOOD category. Table-6 gives detail of this efficiency improvement potential.

Table-6: System Energy Efficiency Potential of Tube Wells

WASA Station Existing Pumping Efficiency

(%)

Improved Pumping Efficiency

(%)

Annual

(kWh)

Saving

(Rs)

Impeller

Adjustment /Repair &

Maintenance

Intervention

Motor Replace

Pump Replace

C II Block 62 65 23,226 301,938 × FCC 58 62 17,152 222,976 × K Block 54 62 36,957 480,441 × Khan Colony 45 65 96,388 1,253,048 × P Block 55 65 35,397 460,167 × Saint Marry 56 62 31,210 405,727 × Gurumanget-01 53 64 48,737 633,586 × Kalma Chowk-01

33 61 71,108 924,410 ×

Kalma Chowk-02

24 61 129,773 1,687,047 ×

Kalma Chowk-03

26 61 95,646 1,243,401 ×

Q Block Disposal

46 60 28,800 374,397 ×

Mecca Colony-03

45 61 520,240 6,763,117 ×

Total 1,134,634 14,750,255

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

kWh/m3

Optimum

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2.4 Interventions for the Improvement of WASA Stations Energy audit activity of Gulberg subdivision revealed that there are certain areas of electrical, mechanical and housekeeping which needs improvement. Table-7 presents detail of interventions and investment requirement in each WASA station for better, efficient and safe operation of WASA station. About Rs. 25.16 million are required to improve WASA stations of Gulberg subdivision, Lahore.

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

Intervention WASA Stations CII E1 B

Block C

Block E1

Block FCC G

Block Ghalib Guru. Henery Ittehad Jail

Road Jinnah Park

K Block

Khan

Electrical Install VFD × × × × × × × × × × × × × × × Install hour meter × × × × × × × × × × × × × × × Replace ampere meter × × × × × × × × × Replace volt meter × × × × × × × Replace over current relays Replace over voltage relay Install/maintain PFI plant × × × × × × × × × × × × × Install/connect capacitors at PFI plant

Install PFI control/relay Install/replace motor terminal box /Improve open and loose motor connection

× × × × ×

Improve panel condition × × × × × Improve wiring condition × × × × × Replace de-rated capacitors Relocate panel away from bore hole × Replace electrical motor × Install fan in the panel Replace PFI HRC fuses Replace PFI display meter Correct date & time of electrical meter

Replace/correct electrical meter Replace change over Replace main circuit breaker Mechanical Replace damaged/install new flow meter

× × × × × × × × × × × × × ×

Replace damaged/install new digital × × × × × × × × × × × × × ×

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Intervention WASA Stations CII E1 B

Block C

Block E1

Block FCC G

Block Ghalib Guru. Henery Ittehad Jail

Road Jinnah Park

K Block

Khan

pressure gauge Control gland leakage × × × × × × × × × × × × × × Make operational/install new chlorinator

× × × × × × × × × × × × ×

Maintain ratchet plate × × × × Adjust impeller × × × Repair & maintenance of pump Replace existing pumping system Maintain/install new non return valve

×

Housekeeping Improve general housekeeping × × × × × × Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption

Station Wise Investment (M. Rs)

0.83 0.52 0.83 0.83 0.53 0.55 0.83 0.66 0.83 0.45 0.53 0.53 0.49 0.53 1.15

Annual Saving (M. Rs) 0.30 0.22 0.48 1.20 Payback (Year) 2.76 2.5 1.10 0.95

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Table-7B: Interventions & Investment Required in WASA Stations- Gulberg Subdivision Intervention WASA Stations Mecca

22 Mecca

Old Nawaz Colony

Nisar P Block Q Block

Qurban Line

Saint Mary

T Block

Arfa-01

Arfa-02 Arfa-03 Arfa-04 Arfa-05

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


× ×

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 damaged/install new digital × × × × × × × × × × × × × ×

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Intervention WASA Stations Mecca

22 Mecca

Old Nawaz Colony

Nisar P Block Q Block

Qurban Line

Saint Mary

T Block

Arfa-01

Arfa-02 Arfa-03 Arfa-04 Arfa-05

pressure gauge Control gland leakage × × × × × × × × × Make operational/install new chlorinator

× × × × × × × × ×

Maintain ratchet plate × × Adjust impeller × × Repair & maintenance of pump Replace existing pumping system Maintain/install new non return valve

×

Housekeeping Improve general housekeeping × × × × Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption


0.43 0.89 0.71 0.53 0.57 0.83 0.53 0.55 0.53 0.13 0.13 0.12 0.12 0.12

Annual Saving (M. Rs) 0.46 0.40 Payback (Year) 1.23 1.37

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Table-7C: Interventions & Investment Required in WASA Stations- Gulberg Subdivision Intervention WASA Stations Centre

Point G Block-

01 G Block-

03 Guru-

01 Kalma-

01 Kalma-

02 Kalma-

03 Zafar

Ali Disp

Mecca-01

Mecca-02

Nawaz Disp.

Q Block Disp

Sharif Disp

Mecca-03

Electrical Install VFD Install hour meter × × × × × × × × × × × × × × Replace ampere meter × × × × × × × × × × Replace volt meter × × × × × × × × × × Replace over current relays Replace over voltage relay Install/maintain PFI plant × × × × × × × × × × × × × × Install/connect capacitors at PFI plant


× ×

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


× × × × × × × × × × × × × ×

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Intervention WASA Stations Centre

Point G Block-

01 G Block-

03 Guru-

01 Kalma-

01 Kalma-

02 Kalma-

03 Zafar

Ali Disp

Mecca-01

Mecca-02

Nawaz Disp.

Q Block Disp

Sharif Disp

Mecca-03

Replace damaged/install new digital pressure gauge

× × × × × × × × × × × × × ×

Control gland leakage Make operational/install new chlorinator

Maintain ratchet plate Adjust impeller × × × × Repair & maintenance of pump × × Replace existing pumping system × × Maintain/install new non return valve

Housekeeping Improve general housekeeping Install shades on motor & pump Rain protection of motor & pump Fix panel properly Proper support of discharge pipeline Maintain monthly record of fuel consumption


0.15 0.39 0.14 0.28 0.29 3.2 3.2 0.15 0.18 0.14 0.22 0.25 0.15 0.14

Annual Saving (M. Rs) 0.63 0.92 1.7 1.2 0.37 6.7 Payback (Year) 0.44 0.31 1.88 2.6 0.67 0.02 Total Investment of Subdivision (M.Rs) = 25.16

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ANNEXURE-1

Energy Audit Reports

1 Pumping Station Information

1 Fresh Water Supply

2 Wastewater Disposal

3 Waste Water Treatment Plant

4 Water Treatment Plant

Name of Engineer

WASA Staff Name

i) Name of Pumping Station 1- C-II

ii) Name of Subdivision GULBERG , Lahore

iii) Operator Name & Contact NA

iv) Total Number of Pumps Installed 1

v) Total Number of Pumps in Operation 1

vi) Year of Starting Operation

vii) Types of Pumps

Standard Deep Well Water Turbine Pumps Qty 1

Submersible Deep Well Water Turbine Pumps Qty

Centrifugal Pump Qty

vi) Operational Scheme of Pumps Qty

Independent 1

Series

Parallel

vii) Any Header / Tank / Reservoir

Yes No

viii) Any Record Keeping

Time Flow Pressure

Level Quality of Water Power Consumption

Maintenance Record Electricity Bill Fuel Consumption Data

viii) Daily Operational Time 16 hrs/day

ix) Annual Working Days 365 days

x) Source of Power

Energy Report of WASA Pumps

Primary LESCO Secondary

xi) In Case of Secondary Power Source Fuel Data Details

xii) Operational Hours of Secondary Power Source hrs/day

xiii) Availability of Chlorinator

Yes No

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

i) Type of Pump Deep Well

Submersible

Overhung

Between Bearing

ii) Mounting / Erection

Horizontal Vertical

Foundation

iii) Concrete Bolted Bolted

iv) Lubrication Type

Oil Water

v) Cooling Type

Water Cooled Air Cooled

vi) Number of Stages

Single Multi 4

vii) Pump and Motor Assembly

Direct Coupled Belt / Gear

viii) Source of Suction

Ground Water Aquafier Overhead Tank Underground Tank

Pressurized Source

ix) Pump Discharge Destination

Overhead Tank Drain On Ground Reservoir

Fresh Water Supply Network

Pump Operational Scheme

On / OFF Proportional

x) Pump Flow Control

Throttle VFD Controlled

xi) Any Retrofits ?

Impeller Detail

Casing / Volute Detail

Line Shaft (DW) Detail

Column Sett. (DW) Detail

Motor Replacement Detail

Motor Rewinding Detail

xii) Self Priming

Yes No NA (not applicable)

xiii) Non Clogging (In case of wastewater)

Yes No

xiv) Flowmeter Available

Yes No

xv) Flowmeter Working

Working Properly Malfunctioning (Damaged)

3 Pump Nameplate Data

i) Make / Brand KSB Pumps Country Pakistan

ii) Model B. 1 B/4 Serial 21-11-10-12267

iii) Certification Mark

iv) Year of Manufacture 2011

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

vi) Head (H) 210 ft

vii) Discharge Pressure (P) Psig

viii) Power / HP / BHP 124.6 BHP

ix) Speed (n) 1,450 RPM

x) Maximum Pressure (Pmax)

xi) Maxiumum Allowable Temperature

5 Piping System

Suction Side

Select Pipe Material of Construction MS Pipe

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

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

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

Fitting Type 1 Qty Type 2 Qty Type 3 Qty

Valves Foot Valve 1

Bends

Strainer 1

iv) Storage Capacity of Suction Source (Aquafier)

v) Working Volume of Source

vi) Suction Lift (from Datum Line)

viii) Availbility of Pressure Gauge Yes No

ix) Suction Pressure (Not Valid incase of Tubewells)

Discharge Side

Pipe Material of Construction MS Pipe

i) Diameter of Discharge Pipe 10 inch

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

iii) Fittings on Discharge Pipe


Valves Control 1 Check 1

Bends Elbow 1

Strainer

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

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

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

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

viii) Discharge Pressure 8 psig Estimated

6 Motor Nameplate Data

i) Manufacturer Siemens

ii) Rated kW / hp 150 hp 112.5 kW

iii) Voltage Range (Volts) 380 Volts

iv) Current (Ampere) 215

v) Power Factor (Cos ɸ) 0.85

Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed 1,488 RPM

vii) Reference Frequency 50 C/S

viii) Insulation Class F

ix) Motor Frame Size 315 S

x)

7 Electrical System Observations

i) Electrical Meter Reference Number

ii) Meter Reading

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 50kvar(Non-operational)

Panel Condition/Issues good

Gland Leakage moderate leakage

Non Return Valve

Chlorinator no

Flow Meter no

Pressure Gauge no

Bore Hole in Front of Panno

Wiring good

Housekeeping good

Motor Terminal good

Foundation/Civil work ok

Ratchet Plate

Field Measurements

8 Flow Measurement

i) Flow Measurement Location

Discharge Pipe Suction Pipe

ii) Pipe Material of Construction MS Pipe

iii) Paint on Pipe Yes No

iv) Pipe Diameter 10 inches (on which flowmeter is clamped)

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

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

viii) Flow Measurement 427 m3/hr (Through Transit Time Ultrasonic Flowmeter)

Velocity in Pipe 2.34 m/sec

Pressure

i) Pressure at Discharge Side of Pump 8 psig Estimated

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

iii) Water Shutoff Head

Levels

i) Static Water Level 38 meter Estimated

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

Electric Measurements

i) Voltage 395 395 391

ii) Ampere 159 168.2 164.3

iii) Power Factor 0.88

iv) Appearant Power (kVA) 111.6

v) Running Power (kW) 98.2

vi) Reactive Power (kVAr) 53

vi) Motor Working on Loading Basis 89.3 %

Oversize Undersize Properly Sized

Speed

i) Speed of Motor 1,488 RPM

ii) Speed of Pump Impeller 1,450 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) 18.48 ft

vi) Discharge Side Frictional Head 13.44 ft

vii) Dynamic Discharge Head (v+vi) 31.92 ft

viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 172.96 ft

ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 114.64

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) 82.12 hp

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

xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 131.64 hp

xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 65.90 %

xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 62.38 %

xviii) Existing Specific Pumping Energy (En(pumping01)) 0.23 kWh/m3

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

xx) Daily Operational Time of Pump 16 hrs

xxi) Daily Pump flow 6,832 m3/day

xxii) Annual working days 365 days

xxiii) Annual Pump flow 2,493,680 m3/yr

xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 576,563 kWh/yr

xxv) Annual Energy Expenditure on Pumping 7,495,319 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 0.22 kWh/m3

xxix) Potential of Energy Reduction 4.03 %

xxx) Reduced Annual Energy Consumption at Improved Efficiency 23,226 kWh/yr

xxxi) Annual Financial Saving on Pumping 301,938 PKR/Yr

11 Summary of Findings

Pumping system efficiency is 62.38%. For pump attached with 150 HP motor, efficiency between 58 - 64 is considered to be FAIR (> 68.9 is

excellent). This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 62.38% to 65% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 301,938 per year.

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 833,000 PKR

Control leakageLeakage at the pump gland

Pump needs impeller adjustment to increase water flow rate Adjust impellers

Malfunctioning of PFI plantIt is recommened to change the control circuity of the pannel which includes HRC fuses, current transformer, magnetic contactors and control terminals

Install VFDNo VFD installed

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

Chlorinator is not avaialble Attach chlorinator and make it operationalize

Water flow meter is not Installed Install Water flow meter






Name of Engineer

WASA Staff Name

i) Name of Pumping Station 11- E1






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 210 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer





viii) Discharge Pressure 9 psig



ii) Rated kW / hp 80 hp 60 kW




Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency




ix) Motor Frame Size 250 M

x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues Average


Non Return Valve ok

Chlorinator no

Flow Meter no

Pressure Gauge ok


Wiring fair

Housekeeping Fair

Motor Terminal ok


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure

i) Pressure at Discharge Side of Pump 9 psig



Levels




i) Voltage 451 452 456

ii) Ampere 98.7 108.1 94.5




vi) Reactive Power (kVAr) 61.8



Speed



Noise Level

Noise Level (db(A)) Avg. Max: 88.4

Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 70.47%. For pump attached with 80 HP motor, efficiency <66 is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




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

No VFD installed Install VFD



Install AmmeterAmmeter is not working

Improve wiring conditionWiring is not in safe condition

Voltmeter is not working Install Voltmeter


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station B-Block






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure



viii) Daily Operational Time 16 hrs/day Estimated


x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer




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








Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues poor


Non Return Valve ok

Chlorinator N/A

Flow Meter N/A

Pressure Gauge yes(Not working)


Wiring poor

Housekeeping poor

Motor Terminal open and lose motor connections


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 383.8 385.7 386.9

ii) Ampere 169.8 174.8 169.9




vi) Reactive Power (kVAr) 73



Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10

































i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Improve housekeepingHousekeeping is poor





Open and lose motor connections. Close motor connections in terminal box





Ammeter is not working Install Ammeter

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






Name of Engineer

WASA Staff Name

i) Name of Pumping Station C-Block






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model B. 14 B/4 Serial




vi) Head (H) 210 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve ok

Chlorinator N/A

Flow Meter N/A

Pressure Gauge ok


Wiring good

Housekeeping good

Motor Terminal ok


Ratchet Plate not working

Field Measurements

8 Flow Measurement






v) Pipe Perimeter 905 mm (on which flowmeter is clamped)




Pressure




Levels




i) Voltage 401.5 404.1 398.3

ii) Ampere 158.8 162 164.8







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 80.43%. For pump attached with 150 HP motor, efficiency >69% is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Install digital pressure gauge at discahrge pipelinePressure gauge installed at discahrge pipeline but not proper working





Leakage at the pump gland Control leakage






Name of Engineer

WASA Staff Name

i) Name of Pumping Station E-1 Block






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes Not working No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 210 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues fair


Non Return Valve ok

Chlorinator Yes(Not working)

Flow Meter N/A

Pressure Gauge ok


Wiring fair

Housekeeping Fair

Motor Terminal ok


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 451 452 456

ii) Ampere 98.7 108.1 94.5







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10












impeller rpm necessary to produce 1gpm/ft head 979





















i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Attach chlorinator and make it operationalizeChlorinator is not working













Name of Engineer

WASA Staff Name

i) Name of Pumping Station FCC






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes Manual Drum No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 210 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant Not installed



Non Return Valve ok

Chlorinator yes(manual Drum)

Flow Meter N/A

Pressure Gauge N/A


Wiring fair

Housekeeping fair

Motor Terminal ok


Ratchet Plate Not working

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 383.3 381.8 368.9

ii) Ampere 97.2 93 102.2







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 58.61%. For pump attached with 80 HP motor, efficiency between 56 - 61 is considered to be FAIR (> 65.9 is

excellent). This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 58.61% to 65% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 222,976 per year. The motor is operating at 89.2% load.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Ratchet plate is not working Make it operational





PFI panel is not installed Install PFI panel








Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station G-Block TW

ii) Name of Subdivision Gulberg , Lahore





vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure



viii) Daily Operational Time 18 hrs/ Estimated


x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by

iv) Transformer Rating (kVA) 630(disposal & TW ) Condition OK

Pump O & M Cost











Non Return Valve ok

Chlorinator no

Flow Meter no

Pressure Gauge no


Wiring fair

Housekeeping fair

Motor Terminal ok


Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels

i) Static Water Level 41 meter



i) Voltage 364.7 362.4 354.5

ii) Ampere 181.5 182.8 190.7







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10

































i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)
















Name of Engineer

WASA Staff Name

i) Name of Pumping Station Ghalib Market






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial


iv) Year of Manufacture


vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25kvar(operational)

Panel Condition/Issues Excellent


Non Return Valve ok

Chlorinator ok

Flow Meter ok

Pressure Gauge ok


Wiring good

Housekeeping good

Motor Terminal good


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 408.9 405.1 407.5

ii) Ampere 109 114 111.5







Speed



Noise Level

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

Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 66%. For pump attached with 150 HP motor, efficiency between 63 - 67% is considered to be GOOD (> 68.9 is

excellent). This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





There is analogue pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Grumanget






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1




viii) Availbility of Pressure Gauge Not working Yes No


Discharge Side







Bends Elbow 1

Strainer




vii) Availbility of Pressure Gauge Not working Yes No (Installed by Team)








Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues very poor


Non Return Valve ok

Chlorinator no

Flow Meter no

Pressure Gauge yes(not working)


Wiring very poor

Housekeeping very poor

Motor Terminal Open and lose motor connections.


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 373.8 375.2 380.9

ii) Ampere 151.9 149.5 140.2







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10

































i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)
















Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Henery K Old


iii) Operator Name & Contact M.Shahid Sail




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






21-07-10-6749

Discharge Side







Bends Elbow 1

Strainer




vii) Availbility of Pressure Gauge Yes No NW

viii) Discharge Pressure psig







Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 12.5kvar

Panel Condition/Issues very poor


Non Return Valve not working

Chlorinator not avaialble

Flow Meter no

Pressure Gauge not working


Wiring very poor

Housekeeping Not good

Motor Terminal Open and lose motor connections


Ratchet Plate not avaialble

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 392.7 390.2

ii) Ampere 62 69 70.2





vi) Motor Working on Loading Basis 57.1 % +


Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10


























xxiii) Annual Pump flow 759,200 m3/yr




Pumping system efficiency is 67.84%. For pump attached with 80 HP motor, efficiency <65.9 is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)






No water flow meter. Attach new water flow meter and properly record 24 hour flow reading.






Non return valve not working install new non return valve


pressure gauge installed but not working Install digital pressure gauge at discahrge pipeline


MCCB is not available Install MCCB in circuit


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Itehad Colony






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve

Chlorinator N/A

Flow Meter N/A

Pressure Gauge N/A


Wiring poor

Housekeeping poor

Motor Terminal Open and lose motor connections.


Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 393 395.3 392.5

ii) Ampere 78.7 80.4 84.9







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 63.47%. For pump attached with 80 HP motor, efficiency between 61-66 is considered to be GOOD. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)
















Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Jail Road TW






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50kvar



Non Return Valve ok

Chlorinator N/A

Flow Meter N/A

Pressure Gauge N/A


Wiring poor

Housekeeping poor



Ratchet Plate

Field Measurements

8 Flow Measurement








viii) Flow Measurement 200 m3/hr (Through Transit Time Ultrasonic Flowmeter) Estimated


Pressure




Levels




i) Voltage 379.3 378.9 374.6

ii) Ampere 82.5 79.6 86


iv) Appearant Power (kVA) 54





Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 70.87% For pump attached with 80 HP motor, efficiency <66 is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)









Malfunctioning of PFI plantIt is recommened to change the control circuity of the pannel which includes HRC fuses, current transformer, magnetic contactors and control terminals for


Close motor connections in terminal box.Open and lose motor connections








Name of Engineer

WASA Staff Name

i) Name of Pumping Station Jinah Park






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 18kvar(operational)



Non Return Valve ok

Chlorinator N/A

Flow Meter N/A

Pressure Gauge N/A


Wiring good

Housekeeping good

Motor Terminal ok


Ratchet Plate Not working

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 391.8 391.9 389.6

ii) Ampere 60.8 62.6 64.9







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10

































i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)










Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station K-Block






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer




vii) Availbility of Pressure Gauge Not working Yes No (Installed by Team)








Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve ok

Chlorinator no

Flow Meter no

Pressure Gauge no

Bore Hole in Front of PanYes

Wiring good

Housekeeping good

Motor Terminal ok


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 364.6 360.1 360.5

ii) Ampere 85.2 88.1 86.3







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 54.38%. For pump attached with 80 HP motor, efficiency <56% is considered to be LOW (> 65.9 is excellent). This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 54.38% to 62% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 480,441 per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)








Install digital pressure gauge at discahrge pipelinePressure gauge installed at discahrge pipeline but not working








Name of Engineer

WASA Staff Name

i) Name of Pumping Station Khan Colony






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 210 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve ok

Chlorinator not working

Flow Meter not working

Pressure Gauge not working


Wiring good


Motor Terminal ok



Field Measurements

8 Flow Measurement










Pressure




Levels


ii) Pumping Water Level 46 meter


i) Voltage 395.3 391 391.2

ii) Ampere 103.5 110 1052.8







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10


































xxxi) Annual Financial Saving on Pumping 1,253,048 PKR/Yr


Pumping system efficiency is 45%. For pump attached with 80 HP motor, efficiency <56.0 is considered to be Low (> 65.9 is excellent). This pumping system requires to replace electric motor. It is estimated that this intervention would increase pumping efficiency from 45% to 65% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 1,253,048 per year. .



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)


12 Estimated Investment for Improvement Plan 1,158,000 PKR




Pump is inefficient Electric motor needs to be replaced

PFI panel not installed installed PFI panel


water flow meter is not avaialble Attach new water flow meter and properly record 24 hour flow reading.


change motor from 80 hp to 150hpMotor is overloaded

Chlorinator is not avaialble Attach chlorinator.


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Macca Colony Street No.22


iii) Operator Name & Contact Asif




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25kvar



Non Return Valve ok

Chlorinator NA

Flow Meter NA

Pressure Gauge NA


Wiring fair


Motor Terminal ok


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 382.5 368.1 384.5

ii) Ampere 83.9 76.6 76.4







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10

































i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)


















Name of Engineer

WASA Staff Name

i) Name of Pumping Station Makkah Colony(old)






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve ok

Chlorinator no

Flow Meter no

Pressure Gauge no


Wiring good

Housekeeping good

Motor Terminal ok


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 365 366.5 360

ii) Ampere 93.9 101.3 114







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 67.45%. For pump attached with 150 HP motor, efficiency between 63-69% is considered to be GOOD. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)







PFI panel not installed install PFI panel








Name of Engineer

WASA Staff Name

i) Name of Pumping Station Nawaz Sharif Colony


iii) Operator Name & Contact Haroon Rapheel




vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail




Not operational



xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 50kvar



Non Return Valve


Flow Meter NA

Pressure Gauge NA

Bore Hole in Front of Panel

Wiring good


Motor Terminal ok


Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 399 396.1 393.1

ii) Ampere 167.4 166 180



v) Running Power (kW) 95




Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10

































i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)
















Name of Engineer

WASA Staff Name

i) Name of Pumping Station Nisar Press






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25kvar(Non-Operational)



Non Return Valve ok

Chlorinator N/A

Flow Meter N/A

Pressure Gauge N/A


Wiring poor

Housekeeping poor



Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 396.6 393.2 394.3

ii) Ampere 74.9 76.7 74.9







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 72.94%. For pump attached with 80 HP motor, efficiency <66% is considered to be EXCELLENT. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Close motor connections in terminal boxOpen and lose motor connections















Name of Engineer

WASA Staff Name

i) Name of Pumping Station P-Block






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail




Not operational



xii) Self Priming



Yes No


Yes No









vi) Head (H) 215 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 25kvar



Non Return Valve not working


Flow Meter no

Pressure Gauge yes


Wiring good


Motor Terminal ok



Field Measurements

8 Flow Measurement










Pressure

i) Pressure at Discharge Side of Pump 22 psig Estimated (Flactuation)



Levels




i) Voltage 418.3 416 419

ii) Ampere 79 76 76.3







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 55%. For pump attached with 80 HP motor, efficiency of 55% is considered to be LOW. This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 55% to 65% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 460,167 per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Install new non return valveNon return valve not working

Chlorinator is not working Attach chlorinator and make it operationalize

water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.








Pressure guage available but fluctuating Install digital pressure gauge at discahrge pipeline






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Q-Block






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes Not working No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 4





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 210 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve ok

Chlorinator yes(Not working)

Flow Meter yes(Not working)

Pressure Gauge no


Wiring good

Housekeeping good

Motor Terminal ok


Ratchet Plate ok

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 378.9 374.2 374

ii) Ampere 164.8 173.4 164.8







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10

































i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





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

Malfunctioning of PFI plant

It is recommened to change the control circuity of the pannel which includes HRC fuses, current transformer, magnetic contactors and control terminals for the control circuit.Also reactive power factor regulator relay for auto



Chlorinator is not working Attach new chlorinator.






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Qurban line






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost











Non Return Valve

Chlorinator N/A

Flow Meter N/A

Pressure Gauge N/A


Wiring good

Housekeeping good

Motor Terminal ok


Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 376.1 375.5 378.6

ii) Ampere 88.2 89.8 84.6







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 61.77%. For pump attached with 80 HP motor, efficiency between 61-66% is considered to be GOOD. This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Install VoltmeterVoltmeter is not working












Name of Engineer

WASA Staff Name

i) Name of Pumping Station Saint Marry






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes Not woring No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial



v) Flowrate (Q) 2 Cusec 204 m3/hr Not Conform

vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues Excellent


Non Return Valve

Chlorinator yes(Non-operational)

Flow Meter N/A

Pressure Gauge N/A


Wiring good

Housekeeping good

Motor Terminal ok


Ratchet Plate

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 369.1 365.8 373.8

ii) Ampere 101.2 97.8 86.8







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10




































Pumping system efficiency is 56%. For pump attached with 80 HP motor, efficiency of 56% is considered to be FAIR. This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 55.71% to 62% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 405,727 per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





Chlorinator is not working Attach chlorinator and make it operationalize



Install Pfi panelPFI panel not installed








Name of Engineer

WASA Staff Name

i) Name of Pumping Station T-Block






vii) Types of Pumps





Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power






Yes Not Working No



Submersible

Overhung

Between Bearing


Horizontal Vertical

Foundation



Oil Water

v) Cooling Type



Single Multi 5





Pressurized Source








xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No









vi) Head (H) 220 ft






5 Piping System

Suction Side






Valves Foot Valve 1

Bends

Strainer 1






Discharge Side







Bends Elbow 1

Strainer












Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency





x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 12.5kvar(Non-operational)



Non Return Valve ok

Chlorinator yes(Not working)

Flow Meter no

Pressure Gauge no


Wiring fair

Housekeeping Fair

Motor Terminal ok


Ratchet Plate no

Field Measurements

8 Flow Measurement










Pressure




Levels




i) Voltage 379.2 376.8 377.7

ii) Ampere 81 87.2 86.4







Speed



Noise Level


Thermal Imaging



Electric Panels

Calculations

10






























Pumping system efficiency is 62.05%. For pump attached with 80 HP motor, efficiency between 61-66 % is considered to be GOOD (> 66 is

excellent). This pumping system requires no intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





Chlorinator is not not working Attach new chlorinator

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










Name of Engineer

WASA Staff Name

i) Name of Pumping Station Arfa IT Tower Disposal Station






vii) Types of Pumps

Standard Deep Well Water Turbine Pumps Qty


Centrifugal Pump Qty 2

Submersible Disposal Pump Qty 3


Independent 5

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power





2 Pump Basic Information Pump # 01


Horizontal Vertical Submersible

Foundation


iv)

v) Cooling Type



Single Multi




Wet Well Overhead Tank Underground Tank

Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No




i) Make / Brand KSB Country Pakistan

ii) Model Serial



v) Flowrate (Q) 25 Cusec 2,550 m3/hr

vi) Head (H) ft


viii) Power / HP / BHP BHP

ix) Speed (n) RPM



5 Piping System

Suction Side


i) Enter Diameter of Suction Pipe (In) 16

ii) Enter Length of Suction Pipe (ft) 32

iii) Enter Fittings on Suction Pipe


Valves Flow control 1

Bends

Strainer 1


ix) Suction Pressure

Discharge Side


i) Diameter of Discharge Pipe (in) 16

ii) Length of Discharge Pipe (ft) 30 Estimated



Valves Non return 1 1

Bends 1

Strainer

vi) Discharge Elevation (from Datum Line) 34 ft

Suction Side Elevation 15 ft

vii) Availbility of Pressure Gauge Yes No





iii) Voltage Range Volts

iv) Current Amperes

v) Power Factor (Cos ɸ)

Standard

Ambient Temp oC

Year of Manufacturing

Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM

vii) Reference Frequency 50 Hz

viii) Insulation Class

ix) Motor Frame Size

x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 35kvar


Gland Leakage

Non Return Valve

Flow Meter not available

Pressure Gauge not available

Wiring fair

Housekeeping

Motor Terminal ok

Foundation/Civil work

Field Measurements

8 Flow Measurement





iv) Pipe Diameter 16 inches

v) Pipe Perimeter 1,276 mm


viii) Flow Measurement 1,485 m3/hr 24.75 m3/min


Pressure

i) Pressure at Discharge Side of Pump psig

ii) Pressure at Suction Side of Pump

ii) Total Length (Suction+Discahrge Pipe) 19 meter

Electric Measurements Volt 418 415 413

Ampere 131 139 135.8

kW 66.1 Power Factor 0.68

vi) Motor Working on Loading Basis 59 %


Speed

i) Speed of Motor 0 RPM

ii) Speed of Pump Impeller 760 RPM

Noise Level


Thermal Imaging



Electric Panels

10 Calculations

ii) Static Suction Head (Only for WW Pump) 15 ft

v) Static Discahrge Head 34 ft

vi) Frictional Head (Suction and Discahrge) 24.64 ft

viii) Total Dynamic Head of Pump (TDH) 43.64 ft










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











Pumping system efficiency is 81.32%. For pump attached with 180 HP motor, efficiency above 69% is considered to be EXCELLENT. This pumping system does not require any ntervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Over voltage relay is defective Replave over voltage relay


Malfunctioning of PFI plantIt is recommened to change the control circuity of the pannel which includes HRC fuses, current transformer, magnetic contactors and control terminals for the

Voltmeter is not working


water flow meter is not AvailableIt is recommened to change the control circuity of the pannel which includes HRC fuses, current transformer, magnetic contactors and control terminals for the

Install Voltmeter






Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 5

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No




i) Make / Brand Country Pakistan

ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side



ii) Length of Discharge Pipe (ft) 30




Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 35kvar


Gland Leakage

Non Return Valve



Wiring poor

Housekeeping

Motor Terminal poor


Field Measurements

8 Flow Measurement








viii) Flow Measurement 1,650 m3/hr 27.5 m3/min Estimated


Pressure




Electric Measurements Volt 388.2 386 386

Ampere 164 170 155




Speed


ii) Speed of Pump Impeller 743 RPM

Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 82.65%. For pump attached with 150 HP motor, efficiency above 68.9% is considered to be EXCELLENT. This pumping system does not require any ntervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)






Install Voltmeter



Over voltage relay is defective Replace over voltage relay






Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 5

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 35kvar


Gland Leakage

Non Return Valve

Flow Meter not Available

Pressure Gauge not Available

Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement






v) Pipe Perimeter 798 mm


viii) Flow Measurement 800 m3/hr 13.333 m3/min


Pressure





Ampere 86.66 92.66 90.53




Speed


ii) Speed of Pump Impeller RPM

Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 75.17%. For pump attached with 100 HP motor, efficiency above 66.9% is considered to be EXCELLENT. This pumping system does not require any ntervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




PFI control is defective


Over voltage relay is defective Replace overvoltage relay

Replace PFI control







Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 5

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Estimated

Lag by Lead by


Pump O & M Cost








PFI Plant 35kvar


Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure




Electric Measurements Volt 393.9 395 391.5

Ampere 81.2 80 81

kW 44 Power Factor 0.8



Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 65.62%. For pump attached with 60 HP motor, efficiency above 61% is considered to be Good. This pumping system does not require any intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)











Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 5

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost








PFI Plant 35kvar


Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure




Electric Measurements Volt 404 406 404.3

Ampere 78 80 76.7




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 69.26%. For pump attached with 60 HP motor, efficiency above 66% is considered to be EXCELLENT. This pumping system does not require any ntervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)







Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Center Point Disposal Station pump 2






vii) Types of Pumps




Submersible Disposal Pump Qty


Independent 2

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer

vi) Discharge Elevation (from Datum Line) 24.6 ft

Suction Side Elevation 12.5 ft







iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring poor

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement








viii) Flow Measurement 308 m3/hr 5.1333 m3/min 350


Pressure





Ampere 31 32 34




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

ii) Static Suction Head (Only for WW Pump) 12.5 ft

v) Static Discahrge Head 24.6 ft





















xxv) Annual Energy Expenditure on Pumping 946,456 PKR/Yr


Pumping system efficiency is 61%. For pump attached with 50 HP motor, efficiency of 61% is considered to be GOOD. This pumping system does not require any ntervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Defective A and V meter



Install A and V meter

water flow meter is not available

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

PFI of 25 KVAR is recommended

Over voltage relay is defective Replace over voltage relay


Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station G-Block Disposal Station






vii) Types of Pumps






Independent 6

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure





Ampere 100 89 86




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 68%. For pump attached with 80 HP motor, efficiency above 66% is considered to be EXCELLENT. This pumping system does not require any ntervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





PFI panel not installed PFI of 150 KVAR is recommended for disposal station






Name of Engineer

WASA Staff Name

i) Name of Pumping Station G-Block Disposal Station






vii) Types of Pumps






Independent 6

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side



ii) Enter Length of Suction Pipe (ft) 12.6




Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement








viii) Flow Measurement 1,680 m3/hr 28 m3/min Estimated


Pressure





Ampere 165 170 176




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 67%. For pump attached with 150 HP motor, efficiency of 67% is considered to be GOOD. This pumping system does not require any intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



PFI panel not installed Install PFI panel of 150 KVAR




Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Grumangat Disposal Station






vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure




Electric Measurements Volt 381.1 379.6 376.1

Ampere 118.3 129.6 123.8




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























xxvii) Water Flow after Efficiency Improvement 1,272 m3/hr






Pumping system efficiency is 53.48%. For pump attached with 150 HP motor, efficiency of 53% is considered to be LOW (> 68.9 is excellent). This pumping system requires impeller adjustment . It is estimated that this impeller adjustment would increase pumping efficiency from 53.48% to 64% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 633,586 per year.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Pumping system requires impeller adjustment

No pressure gauge is not available Install digital pressure gauge

Adjust impellers

No PFI plant installed PFI of 100 KVAR is recommended

water flow meter is not available Install water flow meter






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Kalma Chowk Disposal Station






vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement








viii) Flow Measurement 600 m3/hr 10 m3/min Estimated


Pressure




Electric Measurements Volt 409 404 404.8

Ampere 47 49.6 48.3




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations































Pumping system efficiency is 32%. For pump attached with 80 HP motor, efficiency of 32% is considered to be LOW. This pumping system needs impeller adjustment and repair and maintenance.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



PFI panel not installed PFI of 50 KVAR is recommended



Attached water flow meter is not working Attach new water flow meter and properly record 24 hour flow reading.

Install Voltmeter







Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure





Ampere 73.6 69 65.8

kW 36 Power Factor 0.76



Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations































Pumping system efficiency is 24%. For pump attached with 80 HP motor, efficiency of 24% is considered to be LOW. This pumping system needs to be replaced.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





Ammeter is not working



Install Ammeter






Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement








viii) Flow Measurement 550 m3/hr 9.1667 m3/min Estimated


Pressure





Ampere 48 49 51




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations































Pumping system efficiency is 26%. For pump attached with 80 HP motor, efficiency of 26% is considered to be LOW. This pumping system needs to be replaced.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)






Install Voltmeter




Picture





Name of Engineer

WASA Staff Name

i) Name of Pumping Station Nawaz Sharif Mini Disposal Station






vii) Types of Pumps






Independent 2

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure





Ampere 19.6 19.1 21.3




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations























xxv) Annual Energy Expenditure on Pumping 465,595 PKR/Yr


Pumping system efficiency is 80.63%. For pump attached with 20 HP motor, efficiency above 60.9% is considered to be EXCELLENT. This pumping system does not require any intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





Attached water flow meter is not workingAttach new water flow meter and properly record 24 hour flow reading. In case of variation in the water flow, the resaons should be investigated and

Install Voltmeter


PFI panel not installed Install PFI panel of 12.5 KVAR






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Q-Block Disposal Station






vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve

Flow Meter not Available

Pressure Gauge not Available

Wiring poor

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure





Ampere 49.5 52.5 45.6




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations































Pumping system efficiency is 45.94%. For pump attached with 30 HP motor, efficiency <52.1 is considered to be low (> 61.9 is excellent). This pumping system requires impeller adjustment and repair and maintenance . It is estimated that this impeller adjustment would increase pumping efficiency from 45.94% to 59% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 3523,664 per year. The motor is operating at 88% load. This load will be increased in case of improved flow and thus efficiency of motor will also be improved.



i)

ii)

iii)

iv)

v) Install new Ammeter

vi)Install new Voltmeter

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



Voltmeter not working

Pump needs impeller adjustment to increase water flow rate Adjust impellers & also need maintenance

water flow meter is not available Install water flow meter

Ammeter not working

No pressure gauge is not available Install digital pressure gauge

No PFI plant installed Install PFI plant 25 KVAR






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Sharif Colony Disposal Station


iii) Operator Name & Contact Shabbir Ahmad




vii) Types of Pumps






Independent 1

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost









Panel Condition/Issues excellent

Gland Leakage

Non Return Valve



Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure





Ampere 52 44 54




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 75.49%. For pump attached with 50HP motor, efficiency above 61.9% is considered to be EXCELLENT. This pumping system does not require any intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)





PFI panel not installed Install PFI panel OF 25 Kvar






Name of Engineer

WASA Staff Name

i) Name of Pumping Station Zafar Ali Disposal Station






vii) Types of Pumps






Independent 2

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power

Picture








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft


viii) Power / HP / BHP BHP Estimated

ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve



Wiring poor

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement










Pressure





Ampere 57 63 68




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 72.96%. For pump attached with 50 HP motor, efficiency above 61.9% is considered to be EXCELLENT. This pumping system does not require any intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)



There is no pressure gauge installed at discahrge pipeline

Over voltage relay is defective Replace overvoltage relay

Install digital pressure gauge at discahrge pipeline



Install VoltmeterVoltmeter is not working







Name of Engineer

WASA Staff Name

i) Name of Pumping Station Macca Colony Disposal Station






vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side


i) Enter Diameter of Suction Pipe (In) 16 Estimated





Bends

Strainer 1



Discharge Side


i) Diameter of Discharge Pipe (in) 16 Estimated





Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve

Flow Meter not Installed

Pressure Gauge not Installed

Wiring poor

Housekeeping

Motor Terminal poor


Field Measurements

8 Flow Measurement










Pressure





Ampere 38.9 41.3 37.4




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 75.13%. For pump attached with 80 HP motor, efficiency above 66% is considered to be EXCELLENT. This pumping system does not require any intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)




Install A and V meter Defective A and V meter

Over voltage relay is defective Install overvoltage relay


water flow meter is not installed Attach new water flow meter and properly record 24 hour flow reading.

PFI panel not installed PFI of 50 KVAR is recommended for disposal station.






Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side







Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve

Flow Meter not Installed

Pressure Gauge not Installed

Wiring good

Housekeeping

Motor Terminal ok


Field Measurements

8 Flow Measurement








viii) Flow Measurement 600 m3/hr 10 m3/min


Pressure





Ampere 39 38 39.7




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations

























Pumping system efficiency is 84.12%. For pump attached with 60 HP motor, efficiency above 66% is considered to be EXCELLENT. This pumping system does not require any intervention.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)














Name of Engineer

WASA Staff Name







vii) Types of Pumps






Independent 3

Series

Parallel


Yes No


Time Flow Pressure





x) Source of Power








Foundation


iv)

v) Cooling Type



Single Multi





Pressurized Source



Pit





xi) Any Retrofits ?

Impeller Detail






xii) Self Priming



Yes No


Yes No





ii) Model Serial




vi) Head (H) ft



ix) Speed (n) RPM



5 Piping System

Suction Side







Bends

Strainer 1



Discharge Side


i) Diameter of Discharge Pipe (in) 14 Estimated





Bends 1

Strainer









iv) Current Amperes


Standard

Ambient Temp oC


Efficiency Class

IE3 Eff 1

IE2 Eff 2

IE1 Eff 3

Standard Efficiency

vi) Motor Speed RPM




x)



ii) Meter Reading


Correct FALSE

Lag by Lead by


Pump O & M Cost










Gland Leakage

Non Return Valve

Flow Meter Not installed

Pressure Gauge Not installed

Wiring poor

Housekeeping

Motor Terminal poor


Field Measurements

8 Flow Measurement










Pressure





Ampere 112 113 117




Speed



Noise Level


Thermal Imaging



Electric Panels

10 Calculations






















xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 2,017,163 kWh/yr









Pumping system efficiency is 45.27%. For pump attached with 60 HP motor, efficiency <56% is considered to be LOW (> 65.9% is excellent). This pumping system requires impeller adjustment. It is estimated that this impeller adjustment would increase pumping efficiency from 45.27% to 61% which is in the range of GOOD efficiency. This efficiency improvement will save about Rs. 6,763,117 per year. The motor is operating at 107% load. This load will be increased in case of improved flow and thus efficiency of motor will also be improved.



i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)









ANNEXURE-2

Selected Pictures

No Motor cover at C III

Defective A meter at Ittehad Colony

Defective PFI display at Ittehad Colony Faulty PFI panel at jail Road

Defective A an V meter at Jail Road Defective PFI at Qurban lines

Open motor connections at Qurban lines

Open terminal box at Jinnah Park

Poor electric wiring at G block Open motor connection at B block New

No PFI and poor wiring at FCC Colony Electric meter without cover at Saint Marry

View of pump at Saint Mary Gland leakage at Q block

No Motor cover at T Block

Poor Electric wiring at Gurumangat

Open and loose motor connections at H Block No meter cover at H Block

Poor electric wiring at makkah Colony St. 22 Open and loose motor connections at Khan

Colony

Poor electric wiring at Arfa Tower disposal

Poor house keeping and open connections at G block disposal

Poor wiring at Makkah Colony disposal Open motor connections at Zafar Ali Road disposal

Documents

Energy Audit & Energy Efficiency Improvement Program for ...pcgip.urbanunit.gov.pk/docs/energy/Final Report Gulberg-Gulberg... · Energy Audit & Energy Efficiency Improvement gram