Energy Audit & Energy Efficiency Improvement Program for ...pcgip.urbanunit.gov.pk/docs/energy/Final...
Transcript of Energy Audit & Energy Efficiency Improvement Program for ...pcgip.urbanunit.gov.pk/docs/energy/Final...
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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
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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19
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
Station Wise Investment (M. Rs)
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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20
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
Install PFI control/relay Install/replace motor terminal box /Improve open and loose motor connection
× ×
Improve panel condition × × × × × Improve wiring condition × × × × Replace de-rated capacitors Relocate panel away from bore hole Replace electrical motor Install fan in the panel Replace PFI HRC fuses Replace PFI display meter Correct date & time of electrical meter
Replace/correct electrical meter Replace change over Replace main circuit breaker Mechanical Replace damaged/install new flow meter
× × × × × × × × × × × × × ×
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21
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
Station Wise Investment (M. Rs)
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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22
ANNEXURE-1
Energy Audit Reports
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station 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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 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)
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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
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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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 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
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station 11- E1
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial 21-8-10-10296
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 210 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 59.5 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 9 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(Non-operational)
Panel Condition/Issues Average
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator no
Flow Meter no
Pressure Gauge ok
Bore Hole in Front of Panno
Wiring fair
Housekeeping Fair
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 240 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.06 m/sec
Pressure
i) Pressure at Discharge Side of Pump 9 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 451 452 456
ii) Ampere 98.7 108.1 94.5
iii) Power Factor 0.62
iv) Appearant Power (kVA) 78.7
v) Running Power (kW) 48.8
vi) Reactive Power (kVAr) 61.8
vi) Motor Working on Loading Basis 81.3 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,490 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.4
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 20.79 ft
vi) Discharge Side Frictional Head 10.91 ft
vii) Dynamic Discharge Head (v+vi) 31.70 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 172.74 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 64.43
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,017
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 46.10 hp
xiv) Brake Horsepower (bhp) (OEM Data) 59.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 65.42 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 77.47 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 70.47 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 3,840 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,401,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 286,520 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,724,761 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 526,000 PKR
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Water flow meter is not Installed Install Water flow meter
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 AmmeterAmmeter is not working
Improve wiring conditionWiring is not in safe condition
Voltmeter is not working Install Voltmeter
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1 Pumping Station Information
Picture
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 B-Block
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 Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture 2005
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 122.63 BHP
ix) Speed (n) 1,485 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge (Out of order) Yes No (Installed by Team)
viii) Discharge Pressure 18 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 50kvar(Non-operational)
Panel Condition/Issues poor
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator N/A
Flow Meter N/A
Pressure Gauge yes(Not working)
Bore Hole in Front of Panno
Wiring poor
Housekeeping poor
Motor Terminal open and lose motor connections
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 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 370 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.03 m/sec
Pressure
i) Pressure at Discharge Side of Pump 18 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 41 meter Estimated
ii) Pumping Water Level 45 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 383.8 385.7 386.9
ii) Ampere 169.8 174.8 169.9
iii) Power Factor 0.77
iv) Appearant Power (kVA) 114.4
v) Running Power (kW) 88.1
vi) Reactive Power (kVAr) 73
vi) Motor Working on Loading Basis 80.1 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,485 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) 13.12 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 41.58 ft
vi) Discharge Side Frictional Head 10.20 ft
vii) Dynamic Discharge Head (v+vi) 51.78 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 199.38 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 124.17
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,130
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) 82.03 hp
xiv) Brake Horsepower (bhp) (OEM Data) 122.63 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 118.10 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 66.89 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 69.46 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 5,920 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,160,800 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 517,263 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,724,416 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 69.46%. For pump attached with 150 HP motor, efficiency <69 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 834,000 PKR
Improve housekeepingHousekeeping is poor
Improve wiring conditionWiring is not in safe condition
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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
Open and lose motor connections. Close motor connections in terminal box
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Voltmeter is not working Install Voltmeter
Ammeter is not working Install Ammeter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station C-Block
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
Picture
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture 2012
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 210 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 118.12 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 16 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 50kvar(Non-operational)
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator N/A
Flow Meter N/A
Pressure Gauge ok
Bore Hole in Front of Panno
Wiring good
Housekeeping good
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate not working
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 905 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 16 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 401.5 404.1 398.3
ii) Ampere 158.8 162 164.8
iii) Power Factor 0.75
iv) Appearant Power (kVA) 112.4
v) Running Power (kW) 84.3
vi) Reactive Power (kVAr) 74.3
vi) Motor Working on Loading Basis 76.6 %
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: 95
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 36.96 ft
vi) Discharge Side Frictional Head 13.44 ft
vii) Dynamic Discharge Head (v+vi) 50.40 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 191.44 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 1,222
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 90.89 hp
xiv) Brake Horsepower (bhp) (OEM Data) 118.12 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 113.00 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 76.95 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 80.43 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 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) 494,952 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,434,373 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 833,000 PKR
Install VFDNo VFD installed
Install digital pressure gauge at discahrge pipelinePressure gauge installed at discahrge pipeline but not proper working
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
Leakage at the pump gland Control leakage
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station E-1 Block
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes Not working No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial 21-8-10-10296
iii) Certification Mark
iv) Year of Manufacture 2008
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 210 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 59.5 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 10 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(Non-operational)
Panel Condition/Issues fair
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator Yes(Not working)
Flow Meter N/A
Pressure Gauge ok
Bore Hole in Front of Panno
Wiring fair
Housekeeping Fair
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 240 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.06 m/sec
Pressure
i) Pressure at Discharge Side of Pump 10 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 451 452 456
ii) Ampere 98.7 108.1 94.5
iii) Power Factor 0.62
iv) Appearant Power (kVA) 78.7
v) Running Power (kW) 48.8
vi) Reactive Power (kVAr) 61.8
vi) Motor Working on Loading Basis 81.3 %
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: 88.4
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 23.1 ft
vi) Discharge Side Frictional Head 10.91 ft
vii) Dynamic Discharge Head (v+vi) 34.01 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 175.05 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 64.43
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 979
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 46.71 hp
xiv) Brake Horsepower (bhp) (OEM Data) 59.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 65.42 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 78.51 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 71.41 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.20 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 3,840 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,401,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 286,520 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,724,761 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 71.41%. For pump attached with 80 HP motor, efficiency <66 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 534,000 PKR
Attach chlorinator and make it operationalizeChlorinator is not working
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Water flow meter is not Installed Install Water flow meter
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 AmmeterAmmeter is not working
Control leakageLeakage at the pump gland
Voltmeter is not working Install Voltmeter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station FCC
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes Manual Drum No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture 1998
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 210 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 59.5 BHP
ix) Speed (n) 1,457 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 8 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,457 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues fair
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator yes(manual Drum)
Flow Meter N/A
Pressure Gauge N/A
Bore Hole in Front of Panno
Wiring fair
Housekeeping fair
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate Not working
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter 875 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 216 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.85 m/sec
Pressure
i) Pressure at Discharge Side of Pump 8 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 41 meter Estimated
ii) Pumping Water Level 45 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 383.3 381.8 368.9
ii) Ampere 97.2 93 102.2
iii) Power Factor 0.84
iv) Appearant Power (kVA) 63.7
v) Running Power (kW) 53.5
vi) Reactive Power (kVAr) 34.6
vi) Motor Working on Loading Basis 89.2 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,457 RPM
ii) Speed of Pump Impeller 1,450 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 13.12 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 18.48 ft
vi) Discharge Side Frictional Head 8.95 ft
vii) Dynamic Discharge Head (v+vi) 27.43 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 175.03 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 72.49
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 929
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 42.04 hp
xiv) Brake Horsepower (bhp) (OEM Data) 59.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 71.72 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 70.65 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 58.61 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 3,456 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,261,440 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 314,115 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,083,499 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 62 %
xxvii) Water Flow after Efficiency Improvement 228 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.24 kWh/m3
xxix) Potential of Energy Reduction 5.46 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 17,152 kWh/yr
xxxi) Annual Financial Saving on Pumping 222,976 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 553,500 PKR
Ratchet plate is not working Make it operational
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Pump needs impeller adjustment to increase water flow rate Adjust impellers
PFI panel is not installed Install PFI panel
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
Ammeter is not working Install Ammeter
Improve housekeepingHousekeeping is poor
Improve wiring conditionWiring is not in safe condition
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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1 Pumping Station Information
Picture
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 G-Block TW
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 18 hrs/ Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 14 B/4 Serial 21-06-10-6239
iii) Certification Mark
iv) Year of Manufacture 2006
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 122.63 BHP
ix) Speed (n) 1,485 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 18 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
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Lag by Lead by
iv) Transformer Rating (kVA) 630(disposal & TW ) 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 30kvar(Non-operational)
Panel Condition/Issues fair
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator no
Flow Meter no
Pressure Gauge no
Bore Hole in Front of Panno
Wiring fair
Housekeeping fair
Motor Terminal ok
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 880 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 450 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.47 m/sec
Pressure
i) Pressure at Discharge Side of Pump 18 psig Estimated
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 41 meter
ii) Pumping Water Level 46 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 364.7 362.4 354.5
ii) Ampere 181.5 182.8 190.7
iii) Power Factor 0.87
iv) Appearant Power (kVA) 115.4
v) Running Power (kW) 100.4
vi) Reactive Power (kVAr) 56.9
vi) Motor Working on Loading Basis 91.3 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,485 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) 41.58 ft
vi) Discharge Side Frictional Head 15.08 ft
vii) Dynamic Discharge Head (v+vi) 56.66 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 207.54 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 120.81
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,209
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) 103.84 hp
xiv) Brake Horsepower (bhp) (OEM Data) 122.63 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 134.58 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 84.68 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 77.16 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 8,100 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,956,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 663,165 kWh/yr
xxv) Annual Energy Expenditure on Pumping 8,621,143 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 77.16%. For pump attached with 150 HP motor, efficiency <69 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 833,500 PKR
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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 AmmeterAmmeter is not working
Install VFDNo VFD installed
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Ghalib Market
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 118.22 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 20 psig
6 Motor Nameplate Data
i) Manufacturer 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(operational)
Panel Condition/Issues Excellent
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator ok
Flow Meter ok
Pressure Gauge ok
Bore Hole in Front of Panno
Wiring good
Housekeeping good
Motor Terminal good
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 260 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.23 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 408.9 405.1 407.5
ii) Ampere 109 114 111.5
iii) Power Factor 0.83
iv) Appearant Power (kVA) 78.5
v) Running Power (kW) 65.2
vi) Reactive Power (kVAr) 43.8
vi) Motor Working on Loading Basis 59.3 %
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:
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 46.2 ft
vi) Discharge Side Frictional Head 12.77 ft
vii) Dynamic Discharge Head (v+vi) 58.97 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 200.01 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 69.80
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 922
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 57.82 hp
xiv) Brake Horsepower (bhp) (OEM Data) 118.22 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 87.40 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 48.91 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 66.16 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 4,160 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,518,400 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 382,810 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,976,525 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 660,000 PKR
No VFD installed Install VFD
Leakage at the pump gland Control leakage
There is analogue pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
Picture
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 Grumanget
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 118.12 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 Not working Yes No
ix) Suction Pressure (Not Valid incase of Tubewells)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Not working Yes No (Installed by Team)
viii) Discharge Pressure 20 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 50kvar(Non-operational)
Panel Condition/Issues very poor
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator no
Flow Meter no
Pressure Gauge yes(not working)
Bore Hole in Front of Panno
Wiring very poor
Housekeeping very poor
Motor Terminal Open and lose motor connections.
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 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 335 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.84 m/sec
Pressure
i) Pressure at Discharge Side of Pump 20 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 41 meter Estimated
ii) Pumping Water Level 46 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 373.8 375.2 380.9
ii) Ampere 151.9 149.5 140.2
iii) Power Factor 0.8
iv) Appearant Power (kVA) 95.9
v) Running Power (kW) 76.7
vi) Reactive Power (kVAr) 57.5
vi) Motor Working on Loading Basis 69.8 %
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: 92.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 46.2 ft
vi) Discharge Side Frictional Head 8.42 ft
vii) Dynamic Discharge Head (v+vi) 54.62 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 205.50 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 89.94
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,026
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 76.54 hp
xiv) Brake Horsepower (bhp) (OEM Data) 118.12 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 102.82 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 64.80 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 74.45 %
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 5,360 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,956,400 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 450,330 kWh/yr
xxv) Annual Energy Expenditure on Pumping 5,854,287 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 74.45%. For pump attached with 150 HP motor, efficiency <69 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 834,000 PKR
Improve housekeepingHousekeeping is poor
Improve wiring conditionWiring is not in safe condition
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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
Voltmeter is not working Install Voltmeter
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
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
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1 Pumping Station Information
Picture
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 Henery K Old
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact M.Shahid Sail
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 13 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial
iii) Certification Mark
iv) Year of Manufacture 2007
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.93 BHP
ix) Speed (n) 1,475 RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) (Not Valid incase of Tubewells)
ii) Enter Length of Suction Pipe (ft) (Not Valid incase of Tubewells)
iii) Enter Fittings on Suction Pipe (Not Valid incase of Tubewells)
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Foot Valve 1
Bends
Strainer 1
iv) Storage Capacity of Suction Source (Aquafier)
v) Working Volume of Source
vi) Suction Lift (from Datum Line)
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure (Not Valid incase of Tubewells)
21-07-10-6749
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No NW
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 12.5kvar
Panel Condition/Issues very poor
Gland Leakage moderate leakage
Non Return Valve not working
Chlorinator not avaialble
Flow Meter no
Pressure Gauge not working
Bore Hole in Front of Panno
Wiring very poor
Housekeeping Not good
Motor Terminal Open and lose motor connections
Foundation/Civil work ok
Ratchet Plate not avaialble
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 160 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.37 m/sec
Pressure
i) Pressure at Discharge Side of Pump 7 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 41 meter
ii) Pumping Water Level 47 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 392.7 390.2
ii) Ampere 62 69 70.2
iii) Power Factor 0.75
iv) Appearant Power (kVA) 45.7
v) Running Power (kW) 34.3
vi) Reactive Power (kVAr) 30.2
vi) Motor Working on Loading Basis 57.1 % +
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,485 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 98
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 19.68 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 16.17 ft
vi) Discharge Side Frictional Head 5.01 ft
vii) Dynamic Discharge Head (v+vi) 21.18 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 175.34 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 35.80
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 818
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) 31.19 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.93 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 45.98 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 49.57 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 67.84 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 13 hrs
xxi) Daily Pump flow 2,080 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 759,200 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 163,626 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,127,140 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 454,000 PKR
Improve housekeepingHousekeeping is poor
Improve wiring conditionWiring is not in safe condition
Chlorinator is not avaialble Attach chlorinator and make it operationalize
No water flow meter. Attach new water flow meter and properly record 24 hour flow reading.
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
Voltmeter is not working Install Voltmeter
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Non return valve not working install new non return valve
Ammeter is not working Install Ammeter
pressure gauge installed but not working Install digital pressure gauge at discahrge pipeline
Open and lose motor connections. Close motor connections in terminal box
MCCB is not available Install MCCB in circuit
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1 Pumping Station Information
Picture
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 Itehad Colony
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 18 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.7 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 6 psig Estimated
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(Non-operational)
Panel Condition/Issues poor
Gland Leakage moderate leakage
Non Return Valve
Chlorinator N/A
Flow Meter N/A
Pressure Gauge N/A
Bore Hole in Front of Panno
Wiring poor
Housekeeping poor
Motor Terminal Open and lose motor connections.
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 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 191 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.64 m/sec
Pressure
i) Pressure at Discharge Side of Pump 6 psig Estimated
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 393 395.3 392.5
ii) Ampere 78.7 80.4 84.9
iii) Power Factor 0.73
iv) Appearant Power (kVA) 55.4
v) Running Power (kW) 40.4
vi) Reactive Power (kVAr) 55.4
vi) Motor Working on Loading Basis 67.4 %
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: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 13.86 ft
vi) Discharge Side Frictional Head 6.96 ft
vii) Dynamic Discharge Head (v+vi) 20.82 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 161.86 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 51.28
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 927
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) 34.37 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.7 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 54.16 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 54.82 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 63.47 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 3,438 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,254,870 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 266,851 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,469,066 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 534,000 PKR
Voltmeter is not working Install Voltmeter
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
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
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
Improve housekeepingHousekeeping is poor
Improve wiring conditionWiring is not in safe condition
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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1 Pumping Station Information
Picture
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 Jail Road TW
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 13 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.7 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 6 psig Estimated
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 50kvar
Panel Condition/Issues poor
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator N/A
Flow Meter N/A
Pressure Gauge N/A
Bore Hole in Front of Panno
Wiring poor
Housekeeping poor
Motor Terminal Open and lose motor connections
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 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 200 m3/hr (Through Transit Time Ultrasonic Flowmeter) Estimated
Velocity in Pipe 1.71 m/sec
Pressure
i) Pressure at Discharge Side of Pump 6 psig Estimated
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 44 meter Estimated
ii) Pumping Water Level 49 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 379.3 378.9 374.6
ii) Ampere 82.5 79.6 86
iii) Power Factor 0.79
iv) Appearant Power (kVA) 54
v) Running Power (kW) 42.7
vi) Reactive Power (kVAr) 33.1
vi) Motor Working on Loading Basis 71.1 %
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: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 13.86 ft
vi) Discharge Side Frictional Head 7.84 ft
vii) Dynamic Discharge Head (v+vi) 21.70 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 182.42 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 53.70
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 867
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) 40.57 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.7 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 57.24 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 64.70 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 70.87 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 13 hrs
xxi) Daily Pump flow 2,600 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 949,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 203,698 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,648,073 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 534,000 PKR
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Voltmeter is not working Install Voltmeter
Ammeter is not working Install Ammeter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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
Improve housekeepingHousekeeping is poor
Close motor connections in terminal box.Open and lose motor connections
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Jinah Park
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial
iii) Certification Mark
iv) Year of Manufacture 2012
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.7 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 18kvar(operational)
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator N/A
Flow Meter N/A
Pressure Gauge N/A
Bore Hole in Front of Panno
Wiring good
Housekeeping good
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate Not working
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 225 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.93 m/sec
Pressure
i) Pressure at Discharge Side of Pump 6 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 391.8 391.9 389.6
ii) Ampere 60.8 62.6 64.9
iii) Power Factor 0.88
iv) Appearant Power (kVA) 42.5
v) Running Power (kW) 37.4
vi) Reactive Power (kVAr) 20.2
vi) Motor Working on Loading Basis 62.3 %
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: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 13.86 ft
vi) Discharge Side Frictional Head 9.61 ft
vii) Dynamic Discharge Head (v+vi) 23.47 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 164.51 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 60.41
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 994
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 41.15 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.7 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 50.13 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 65.64 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 82.09 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.17 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 3,600 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,314,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 219,587 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,854,633 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 82.09%. For pump attached with 80 HP motor, efficiency <66 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 493,000 PKR
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Control leakageLeakage at the pump gland
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
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1 Pumping Station Information
Picture
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 K-Block
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 18 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture 2006
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.93 BHP
ix) Speed (n) 1,475 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Not working Yes No (Installed by Team)
viii) Discharge Pressure 8 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(Non-operational)
Panel Condition/Issues good
Gland Leakage moderate leakage
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
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 180 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.54 m/sec
Pressure
i) Pressure at Discharge Side of Pump 8 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 364.6 360.1 360.5
ii) Ampere 85.2 88.1 86.3
iii) Power Factor 0.84
iv) Appearant Power (kVA) 54.2
v) Running Power (kW) 45.5
vi) Reactive Power (kVAr) 29.4
vi) Motor Working on Loading Basis 75.8 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,475 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 18.48 ft
vi) Discharge Side Frictional Head 6.19 ft
vii) Dynamic Discharge Head (v+vi) 24.67 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 165.71 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 48.33
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 899
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 33.16 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.93 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 60.99 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 52.70 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 54.38 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 18 hrs
xxi) Daily Pump flow 3,240 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,182,600 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 300,538 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,906,992 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 62 %
xxvii) Water Flow after Efficiency Improvement 205 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.22 kWh/m3
xxix) Potential of Energy Reduction 12.30 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 36,957 kWh/yr
xxxi) Annual Financial Saving on Pumping 480,441 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 533,000 PKR
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
Pump needs impeller adjustment to increase water flow rate Adjust impellers
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 pipelinePressure gauge installed at discahrge pipeline but not working
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Khan Colony
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 14 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial
iii) Certification Mark
iv) Year of Manufacture 1994
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 210 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 59.67 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator not working
Flow Meter not working
Pressure Gauge not working
Bore Hole in Front of Panno
Wiring good
Housekeeping Not good
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate not working
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 200 m3/hr (Through Transit Time Ultrasonic Flowmeter) Estimated
Velocity in Pipe 1.71 m/sec
Pressure
i) Pressure at Discharge Side of Pump 4 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 38 meter
ii) Pumping Water Level 46 meter
Electric Measurements
i) Voltage 395.3 391 391.2
ii) Ampere 103.5 110 1052.8
iii) Power Factor 0.86
iv) Appearant Power (kVA) 71.6
v) Running Power (kW) 61.6
vi) Reactive Power (kVAr) 36.5
vi) Motor Working on Loading Basis 102.6 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,477 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.2
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 26.24 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) 9.24 ft
vi) Discharge Side Frictional Head 7.73 ft
vii) Dynamic Discharge Head (v+vi) 16.97 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 167.85 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 33.56
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 940
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 37.33 hp
xiv) Brake Horsepower (bhp) (OEM Data) 59.67 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 82.57 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 62.55 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 45.20 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.31 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 14 hrs
xxi) Daily Pump flow 2,800 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,022,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 316,464 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,114,029 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 288 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.22 kWh/m3
xxix) Potential of Energy Reduction 30.46 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 96,388 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,253,048 PKR/Yr
11 Summary of Findings
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. .
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 1,158,000 PKR
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Pump is inefficient Electric motor needs to be replaced
PFI panel not installed installed PFI panel
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
water flow meter is not avaialble Attach new water flow meter and properly record 24 hour flow reading.
Improve housekeepingHousekeeping is poor
change motor from 80 hp to 150hpMotor is overloaded
Chlorinator is not avaialble Attach chlorinator.
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1 Pumping Station Information
Picture
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 Macca Colony Street No.22
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact Asif
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 14 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial
iii) Certification Mark
iv) Year of Manufacture 2006
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.9 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar
Panel Condition/Issues Average
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator NA
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of Panno
Wiring fair
Housekeeping Not good
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 185 m3/hr (Through Transit Time Ultrasonic Flowmeter) Estimated
Velocity in Pipe 1.58 m/sec
Pressure
i) Pressure at Discharge Side of Pump 15 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 41 meter
ii) Pumping Water Level 48 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 382.5 368.1 384.5
ii) Ampere 83.9 76.6 76.4
iii) Power Factor 0.86
iv) Appearant Power (kVA) 52.5
v) Running Power (kW) 45.2
vi) Reactive Power (kVAr) 26.8
vi) Motor Working on Loading Basis 75.3 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,482 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 88.9
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 22.96 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 34.65 ft
vi) Discharge Side Frictional Head 6.69 ft
vii) Dynamic Discharge Head (v+vi) 41.34 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 198.78 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 35.48
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 799
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) 40.89 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.9 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 60.59 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 65.01 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 67.49 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 14 hrs
xxi) Daily Pump flow 2,590 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 945,350 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 232,210 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,018,736 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 67.49%. For pump attached with 80 HP motor, efficiency <65.9 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 434,000 PKR
Improve housekeepingHousekeeping is poor
Chlorinator is not avaialble Attach chlorinator and make it operationalize
water flow meter is not avaialble Attach new water flow meter and properly record 24 hour flow reading.
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
Voltmeter is not working Install Voltmeter
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Ammeter is not working Install Ammeter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Makkah Colony(old)
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 118.22 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 10 psig 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator no
Flow Meter no
Pressure Gauge no
Bore Hole in Front of Panno
Wiring good
Housekeeping good
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 250 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.37 m/sec
Pressure
i) Pressure at Discharge Side of Pump 10 psig Estimated
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 365 366.5 360
ii) Ampere 93.9 101.3 114
iii) Power Factor 0.8
iv) Appearant Power (kVA) 64.9
v) Running Power (kW) 51.9
vi) Reactive Power (kVAr) 38.9
vi) Motor Working on Loading Basis 47.2 %
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: 90
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 23.1 ft
vi) Discharge Side Frictional Head 4.67 ft
vii) Dynamic Discharge Head (v+vi) 27.77 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 168.81 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 67.12
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,027
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 46.92 hp
xiv) Brake Horsepower (bhp) (OEM Data) 118.22 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 69.57 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 39.69 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 67.45 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.21 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 4,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,460,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 304,721 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,961,375 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 893,000 PKR
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
PFI panel not installed install PFI panel
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
Leakage at the pump gland Control leakage
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Nawaz Sharif Colony
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact Haroon Rapheel
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 15 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Picture
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 4
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
Not operational
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 14 B/4 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 122.6 BHP
ix) Speed (n) 1,485 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 50kvar
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve
Chlorinator not working
Flow Meter NA
Pressure Gauge NA
Bore Hole in Front of Panel
Wiring good
Housekeeping Not good
Motor Terminal ok
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 16 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 399 396.1 393.1
ii) Ampere 167.4 166 180
iii) Power Factor 0.81
iv) Appearant Power (kVA) 117.3
v) Running Power (kW) 95
vi) Reactive Power (kVAr) 68.8
vi) Motor Working on Loading Basis 86.3 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,487 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 93.7
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 36.96 ft
vi) Discharge Side Frictional Head 13.44 ft
vii) Dynamic Discharge Head (v+vi) 50.40 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 191.44 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 1,253
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 90.89 hp
xiv) Brake Horsepower (bhp) (OEM Data) 122.6 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 127.35 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 74.14 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 71.37 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 6,405 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,337,825 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 522,914 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,797,880 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 71.37%. For pump attached with 150 HP motor, efficiency <68.9 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 713,500 PKR
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
water flow meter is not avaialble Attach new water flow meter and properly record 24 hour flow reading.
Improve housekeepingHousekeeping is poor
Install AmmeterAmmeter is not working
Chlorinator is not avaialble Attach chlorinator and make it operationalize
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Nisar Press
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.7 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 10 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(Non-Operational)
Panel Condition/Issues poor
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator N/A
Flow Meter N/A
Pressure Gauge N/A
Bore Hole in Front of Panno
Wiring poor
Housekeeping poor
Motor Terminal Open and lose motor connections
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 179 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.53 m/sec
Pressure
i) Pressure at Discharge Side of Pump 10 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 44 meter Estimated
ii) Pumping Water Level 49 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 396.6 393.2 394.3
ii) Ampere 74.9 76.7 74.9
iii) Power Factor 0.75
iv) Appearant Power (kVA) 51.6
v) Running Power (kW) 38.7
vi) Reactive Power (kVAr) 34.1
vi) Motor Working on Loading Basis 64.4 %
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: 88
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 23.1 ft
vi) Discharge Side Frictional Head 6.30 ft
vii) Dynamic Discharge Head (v+vi) 29.40 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 190.12 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 48.06
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 795
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 37.84 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.7 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 51.88 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 60.35 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 72.94 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.22 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 2,864 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,045,360 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 227,220 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,953,858 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 534,000 PKR
Improve housekeepingHousekeeping is poor
Close motor connections in terminal boxOpen and lose motor connections
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Voltmeter is not working Install Voltmeter
Ammeter is not working Install Ammeter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station P-Block
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 15 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
Not operational
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial
iii) Certification Mark
iv) Year of Manufacture 2006
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 215 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 61.84 BHP
ix) Speed (n) 1,475 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve not working
Chlorinator not working
Flow Meter no
Pressure Gauge yes
Bore Hole in Front of Panno
Wiring good
Housekeeping Not good
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate not working
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 127 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.09 m/sec
Pressure
i) Pressure at Discharge Side of Pump 22 psig Estimated (Flactuation)
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 40 meter Estimated
ii) Pumping Water Level 48 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 418.3 416 419
ii) Ampere 79 76 76.3
iii) Power Factor 0.73
iv) Appearant Power (kVA) 55.7
v) Running Power (kW) 40.7
vi) Reactive Power (kVAr) 38.1
vi) Motor Working on Loading Basis 67.8 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,483 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 96.8
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 26.24 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 50.82 ft
vi) Discharge Side Frictional Head 3.20 ft
vii) Dynamic Discharge Head (v+vi) 54.02 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 211.46 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 21.31
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 632
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 29.86 hp
xiv) Brake Horsepower (bhp) (OEM Data) 61.84 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 54.56 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 48.28 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 54.73 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.32 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 1,905 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 695,325 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 224,027 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,912,355 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 65 %
xxvii) Water Flow after Efficiency Improvement 151 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.27 kWh/m3
xxix) Potential of Energy Reduction 15.80 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 35,397 kWh/yr
xxxi) Annual Financial Saving on Pumping 460,167 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 574,000 PKR
Improve housekeepingHousekeeping is poor
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.
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
Voltmeter is not working Install Voltmeter
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
No VFD installed Install VFD
Pump needs impeller adjustment to increase water flow rate Adjust impellers
Ammeter is not working Install Ammeter
Pressure guage available but fluctuating Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Q-Block
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes Not working 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
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) 210 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 118.59 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 10 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 15 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112.5 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 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
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(Non-operational)
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator yes(Not working)
Flow Meter yes(Not working)
Pressure Gauge no
Bore Hole in Front of Panno
Wiring good
Housekeeping good
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate ok
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 382 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 2.09 m/sec
Pressure
i) Pressure at Discharge Side of Pump 15 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 44 meter Estimated
ii) Pumping Water Level 49 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 378.9 374.2 374
ii) Ampere 164.8 173.4 164.8
iii) Power Factor 0.84
iv) Appearant Power (kVA) 109
v) Running Power (kW) 91.5
vi) Reactive Power (kVAr) 59.1
vi) Motor Working on Loading Basis 83.2 %
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: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 34.65 ft
vi) Discharge Side Frictional Head 11.03 ft
vii) Dynamic Discharge Head (v+vi) 45.68 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 206.40 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 102.56
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 1,092
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 87.67 hp
xiv) Brake Horsepower (bhp) (OEM Data) 118.59 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 122.65 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 73.92 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 71.47 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.24 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 6,112 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 2,230,880 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 537,225 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,983,928 PKR/Yr
11 Summary of Findings
Pumping system efficiency is 71.47%. For pump attached with 150 HP motor, efficiency <69 is considered to be EXCELLENT. This pumping system requires no intervention.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 833,000 PKR
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
Leakage at the pump gland Control leakage
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
Install VFDNo VFD installed
Install digital pressure gauge at discahrge pipelineThere is no pressure gauge installed at discahrge pipeline
Chlorinator is not working Attach new chlorinator.
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Qurban line
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 62.7 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 6 psig Estimated
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 25kvar(Non-operational)
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve
Chlorinator N/A
Flow Meter N/A
Pressure Gauge N/A
Bore Hole in Front of Panno
Wiring good
Housekeeping good
Motor Terminal ok
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 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 194 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.66 m/sec
Pressure
i) Pressure at Discharge Side of Pump 6 psig Estimated
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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iii) Water Shutoff Head
Levels
i) Static Water Level 44 meter Estimated
ii) Pumping Water Level 49 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 376.1 375.5 378.6
ii) Ampere 88.2 89.8 84.6
iii) Power Factor 0.83
iv) Appearant Power (kVA) 57
v) Running Power (kW) 47.4
vi) Reactive Power (kVAr) 31.8
vi) Motor Working on Loading Basis 78.9 %
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: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 13.86 ft
vi) Discharge Side Frictional Head 7.38 ft
vii) Dynamic Discharge Head (v+vi) 21.24 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 181.96 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 52.08
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 855
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 39.25 hp
xiv) Brake Horsepower (bhp) (OEM Data) 62.7 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 63.54 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 62.60 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 61.77 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.25 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 3,104 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,132,960 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 278,300 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,617,903 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 533,500 PKR
Install VFDNo VFD installed
Install VoltmeterVoltmeter is not working
Chlorinator is not avaialble Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
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
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Saint Marry
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes Not woring No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr Not Conform
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 59.5 BHP
ix) Speed (n) 1,480 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 8 psig Estimated
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 S
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues Excellent
Gland Leakage moderate leakage
Non Return Valve
Chlorinator yes(Non-operational)
Flow Meter N/A
Pressure Gauge N/A
Bore Hole in Front of Panno
Wiring good
Housekeeping good
Motor Terminal ok
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 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter 725 mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 189 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.62 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)
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iii) Water Shutoff Head
Levels
i) Static Water Level 44 meter Estimated
ii) Pumping Water Level 49 meter (estimated due to gland leakage and catching of wire by suction)
Electric Measurements
i) Voltage 369.1 365.8 373.8
ii) Ampere 101.2 97.8 86.8
iii) Power Factor 0.86
iv) Appearant Power (kVA) 60.9
v) Running Power (kW) 52.4
vi) Reactive Power (kVAr) 31.1
vi) Motor Working on Loading Basis 87.33 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,480 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 7.01 ft
vii) Dynamic Discharge Head (v+vi) 25.49 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 186.21 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 50.74
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 847
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 39.13 hp
xiv) Brake Horsepower (bhp) (OEM Data) 59.5 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 70.24 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 65.77 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 55.71 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.28 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 3,024 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,103,760 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 307,657 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,999,539 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 62 %
xxvii) Water Flow after Efficiency Improvement 210 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.25 kWh/m3
xxix) Potential of Energy Reduction 10.14 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 31,210 kWh/yr
xxxi) Annual Financial Saving on Pumping 405,727 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 553,000 PKR
Control leakageLeakage at the pump gland
Install VFDNo VFD installed
Chlorinator is not working Attach chlorinator and make it operationalize
Water flow meter is not Installed Install Water flow meter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
Install Pfi panelPFI panel not installed
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
Pump needs impeller adjustment to increase water flow rate Adjust impellers
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station T-Block
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
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
xiii) Availability of Chlorinator
Yes Not Working No
2 Pump Basic Information (Pump Ref # CITY_FWPS/WWDS_Pump #)
i) Type of Pump Deep Well
Submersible
Overhung
Between Bearing
ii) Mounting / Erection
Horizontal Vertical
Foundation
iii) Concrete Bolted Bolted
iv) Lubrication Type
Oil Water
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi 5
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Ground Water Aquafier Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Fresh Water Supply Network
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Pumps Country Pakistan
ii) Model B. 12 B/5 Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) 220 ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP 63.33 BHP
ix) Speed (n) 1,482 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)
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe 8 inch
ii) Length of Discharge Pipe (Not known as directly connected to network underground)
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Control 1 Check 1
Bends Elbow 1
Strainer
iv) Storage Capacity of Discharge Destination (Not known as directly connected to network underground))
v) Working Volume of Discharge Destination (Not known as directly connected to network underground))
vi) Discharge Elevation (from Datum Line) (In case of no gauge)
vii) Availbility of Pressure Gauge Yes No (Installed by Team)
viii) Discharge Pressure 10 psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range (Volts) 380 Volts
iv) Current (Ampere) 115
v) Power Factor (Cos ɸ) 0.85
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed 1,488 RPM
vii) Reference Frequency 50 C/S
viii) Insulation Class F
ix) Motor Frame Size 250 M
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 12.5kvar(Non-operational)
Panel Condition/Issues good
Gland Leakage moderate leakage
Non Return Valve ok
Chlorinator yes(Not working)
Flow Meter no
Pressure Gauge no
Bore Hole in Front of Panno
Wiring fair
Housekeeping Fair
Motor Terminal ok
Foundation/Civil work ok
Ratchet Plate no
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches (on which flowmeter is clamped)
v) Pipe Perimeter mm (on which flowmeter is clamped)
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 187 m3/hr (Through Transit Time Ultrasonic Flowmeter)
Velocity in Pipe 1.60 m/sec
Pressure
i) Pressure at Discharge Side of Pump 10 psig
ii) Pressure at Suction Side of Pump (Not Valid incase of Tubewells)
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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 379.2 376.8 377.7
ii) Ampere 81 87.2 86.4
iii) Power Factor 0.77
iv) Appearant Power (kVA) 55.5
v) Running Power (kW) 42.7
vi) Reactive Power (kVAr) 35.4
vi) Motor Working on Loading Basis 71.2 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 1,488 RPM
ii) Speed of Pump Impeller 1,482 RPM
Noise Level
Noise Level (db(A)) Avg. Max: 87.5
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
Calculations
10
i) Drawdown of Pump (Pumping water level - Static Water Level) 16.4 ft
ii) Static Suction Head (Only for WW Pump) ft
iii) Suction Side Frictional Head (Only for WW Pump) ft
iv) Dynamic Suction Head (ii+iii) (Only for WW Pump) ft
v) Discharge Head (Pressure Gauge) 23.1 ft
vi) Discharge Side Frictional Head 6.67 ft
vii) Dynamic Discharge Head (v+vi) 29.77 ft
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viii) Total Dynamic Head of Pump (TDH) (vii + Pumping Water Level) 170.81 ft
ix) Specific Capacity of Pump (Water Turbine) gpm/ft of drawdown 50.20
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 900
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) 35.52 hp
xiv) Brake Horsepower (bhp) (OEM Data) 63.33 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 57.24 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 56.08 %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 62.05 %
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 2,992 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,092,080 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 250,705 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,259,166 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 533,500 PKR
Install AmmeterAmmeter is not working
Install VFDNo VFD installed
Chlorinator is not not working Attach new chlorinator
Attached water flow meter is not working Attach new water flow meter .
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
Control leakageLeakage at the pump gland
Provide proper support at the discahrge pipelineThere is no proper support for discahrge pipeline
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Arfa IT Tower Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 5
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 5
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 25 Cusec 2,550 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 32
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 30 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 34 ft
Suction Side Elevation 15 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 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)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 35kvar
Panel Condition/Issues Average
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
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,485 m3/hr 24.75 m3/min
Velocity in Pipe 3.18 m/sec
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 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller 760 RPM
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Noise Level
Noise Level (db(A)) Avg. Max: 94
Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
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
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viii) Total Dynamic Head of Pump (TDH) 43.64 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 3,619
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 72.05 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 88.61 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 81.32 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 29,700 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 10,840,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 485,117 kWh/yr
xxv) Annual Energy Expenditure on Pumping 6,306,525 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 126,000 PKR
Over voltage relay is defective Replave over voltage relay
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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
Install AmmeterAmmeter 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
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Arfa IT Tower Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 5
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 5
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 25 Cusec 2,550 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 32
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 34 ft
Suction Side Elevation 15 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 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)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 35kvar
Panel Condition/Issues poor
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring poor
Housekeeping
Motor Terminal poor
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,650 m3/hr 27.5 m3/min Estimated
Velocity in Pipe 3.53 m/sec
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 388.2 386 386
Ampere 164 170 155
kW 81.8 Power Factor 0.75
vi) Motor Working on Loading Basis 73 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller 743 RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 15 ft
v) Static Discahrge Head 34 ft
vi) Frictional Head (Suction and Discahrge) 30.40 ft
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viii) Total Dynamic Head of Pump (TDH) 49.40 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 3,399
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 90.63 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 109.65 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 82.65 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 33,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 12,045,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 600,342 kWh/yr
xxv) Annual Energy Expenditure on Pumping 7,804,444 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 126,000 PKR
Voltmeter is not working
Install AmmeterAmmeter is not working
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
Install Voltmeter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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
Over voltage relay is defective Replace over voltage relay
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Arfa IT Tower Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 5
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 5
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 03
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 10 Cusec 1,020 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 10
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 10
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 25 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 100 hp 75 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 35kvar
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not Available
Pressure Gauge not Available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches
v) Pipe Perimeter 798 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 800 m3/hr 13.333 m3/min
Velocity in Pipe 4.39 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 16 meter
Electric Measurements Volt 388.4 393 390
Ampere 86.66 92.66 90.53
kW 62.3 Power Factor 0.75
vi) Motor Working on Loading Basis 84 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 25 ft
vi) Frictional Head (Suction and Discahrge) 47.58 ft
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viii) Total Dynamic Head of Pump (TDH) 70.58 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 62.78 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 83.51 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 75.17 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 16,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 5,840,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 457,229 kWh/yr
xxv) Annual Energy Expenditure on Pumping 5,943,971 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 125,000 PKR
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
PFI control is defective
Install digital pressure gauge at discahrge pipelineThere is no pressure gauge installed at discahrge pipeline
Over voltage relay is defective Replace overvoltage relay
Replace PFI control
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Arfa IT Tower Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 5
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 5
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 04
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 6 Cusec 612 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 10
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 10
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 36 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
Estimated
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 35kvar
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches
v) Pipe Perimeter 798 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 585 m3/hr 9.75 m3/min
Velocity in Pipe 3.21 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 16 meter
Electric Measurements Volt 393.9 395 391.5
Ampere 81.2 80 81
kW 44 Power Factor 0.8
vi) Motor Working on Loading Basis 98 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 36 ft
vi) Frictional Head (Suction and Discahrge) 25.51 ft
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viii) Total Dynamic Head of Pump (TDH) 59.51 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 38.71 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 58.98 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 65.62 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 11,700 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,270,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 322,922 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,197,989 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 125,000 PKR
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Arfa IT Tower Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 5
v) Total Number of Pumps in Operation 5
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 5
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Picture
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 05
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 6 Cusec 612 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 10
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 10
ii) Length of Discharge Pipe (ft) 50
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 36 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant 35kvar
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 10 inches
v) Pipe Perimeter 798 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 585 m3/hr 9.75 m3/min
Velocity in Pipe 3.21 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 16 meter
Electric Measurements Volt 404 406 404.3
Ampere 78 80 76.7
kW 41.69 Power Factor 0.76
vi) Motor Working on Loading Basis 93 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 36 ft
vi) Frictional Head (Suction and Discahrge) 25.51 ft
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viii) Total Dynamic Head of Pump (TDH) 59.51 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 38.71 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 55.88 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 69.26 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 11,700 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 4,270,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 305,969 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,977,595 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 125,000 PKR
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
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1 Pumping Station Information
Picture
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 Center Point Disposal Station pump 2
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 2
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 2
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 6 Cusec 612 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 8
ii) Enter Length of Suction Pipe (ft) 24
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 8
ii) Length of Discharge Pipe (ft) 30 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 24.6 ft
Suction Side Elevation 12.5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 50 hp 37 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues poor
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring poor
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches
v) Pipe Perimeter 638 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 308 m3/hr 5.1333 m3/min 350
Velocity in Pipe 2.64 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 16 meter
Electric Measurements Volt 420 415 415
Ampere 31 32 34
kW 12.4 Power Factor 0.53
vi) Motor Working on Loading Basis 33 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 12.5 ft
v) Static Discahrge Head 24.6 ft
vi) Frictional Head (Suction and Discahrge) 17.64 ft
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viii) Total Dynamic Head of Pump (TDH) 29.74 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 10.18 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 16.62 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 61.27 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 4,928 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,798,720 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 72,804 kWh/yr
xxv) Annual Energy Expenditure on Pumping 946,456 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 146,000 PKR
Defective A and V meter
Install digital pressure gauge at discahrge pipelineThere is no pressure gauge installed at discahrge pipeline
Voltmeter is not working Install Voltmeter
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
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1 Pumping Station Information
Picture
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 G-Block Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 6
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 6
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 14 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 25 Cusec 2,550 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 15
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 17 ft
Suction Side Elevation 7.5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,370 m3/hr 22.833 m3/min
Velocity in Pipe 2.93 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 14 meter
Electric Measurements Volt 363 361 365
Ampere 100 89 86
kW 50.1 Power Factor 0.87
vi) Motor Working on Loading Basis 84 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 7.5 ft
v) Static Discahrge Head 17 ft
vi) Frictional Head (Suction and Discahrge) 20.75 ft
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viii) Total Dynamic Head of Pump (TDH) 30.25 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 46.08 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 67.16 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 68.62 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 14 hrs
xxi) Daily Pump flow 19,180 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 7,000,700 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 257,384 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,345,988 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 385,000 PKR
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
PFI panel not installed PFI of 150 KVAR is recommended for disposal station
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station G-Block Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 6
v) Total Number of Pumps in Operation 2
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 6
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 14 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 03
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 25 Cusec 2,550 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 12.6
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 18 ft
Suction Side Elevation 7.5 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 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)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 630 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,680 m3/hr 28 m3/min Estimated
Velocity in Pipe 3.60 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 13 meter
Electric Measurements Volt 371 372 366
Ampere 165 170 176
kW 87.1 Power Factor 0.8
vi) Motor Working on Loading Basis 78 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 7.5 ft
v) Static Discahrge Head 18 ft
vi) Frictional Head (Suction and Discahrge) 31.13 ft
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viii) Total Dynamic Head of Pump (TDH) 41.63 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 77.76 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 116.76 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 66.60 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 14 hrs
xxi) Daily Pump flow 23,520 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 8,584,800 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 447,467 kWh/yr
xxv) Annual Energy Expenditure on Pumping 5,817,077 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 135,000 PKR
PFI panel not installed Install PFI panel of 150 KVAR
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
Picture
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 Grumangat Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 1
Submersible Disposal Pump Qty 2
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 17 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 25 Cusec 2,550 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16
ii) Length of Discharge Pipe (ft) 30 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 33 ft
Suction Side Elevation 16 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 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)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 400 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 1,071 m3/hr 17.85 m3/min
Velocity in Pipe 2.29 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 17 meter
Electric Measurements Volt 381.1 379.6 376.1
Ampere 118.3 129.6 123.8
kW 49.5 Power Factor 0.61
vi) Motor Working on Loading Basis 44 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 16 ft
v) Static Discahrge Head 33 ft
vi) Frictional Head (Suction and Discahrge) 12.80 ft
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viii) Total Dynamic Head of Pump (TDH) 29.80 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 35.48 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 66.35 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 53.48 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 17 hrs
xxi) Daily Pump flow 18,207 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 6,645,555 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 308,794 kWh/yr
xxv) Annual Energy Expenditure on Pumping 4,014,327 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 64 %
xxvii) Water Flow after Efficiency Improvement 1,272 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.04 kWh/m3
xxix) Potential of Energy Reduction 15.78 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 48,737 kWh/yr
xxxi) Annual Financial Saving on Pumping 633,586 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 285,000 PKR
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
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kalma Chowk Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 8 Cusec 816 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 15
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 15
ii) Length of Discharge Pipe (ft) 34 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 14 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 80 hp 60 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
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 15 inches
v) Pipe Perimeter 1,196 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 600 m3/hr 10 m3/min Estimated
Velocity in Pipe 1.46 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 11 meter
Electric Measurements Volt 409 404 404.8
Ampere 47 49.6 48.3
kW 26.1 Power Factor 0.77
vi) Motor Working on Loading Basis 44 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 14 ft
vi) Frictional Head (Suction and Discahrge) 5.15 ft
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viii) Total Dynamic Head of Pump (TDH) 17.15 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 11.44 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 34.99 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 32.69 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.04 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 9,600 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,504,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 153,241 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,992,137 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 61 %
xxvii) Water Flow after Efficiency Improvement 1,119 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.02 kWh/m3
xxix) Potential of Energy Reduction 46.40 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 71,108 kWh/yr
xxxi) Annual Financial Saving on Pumping 924,410 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 286,000 PKR
PFI panel not installed PFI of 50 KVAR is recommended
Voltmeter is not working
Install AmmeterAmmeter is not working
Attached water flow meter is not working Attach new water flow meter and properly record 24 hour flow reading.
Install Voltmeter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kalma Chowk Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Picture
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 6 Cusec 612 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 15
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 15
ii) Length of Discharge Pipe (ft) 34
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 15 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
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 15 inches
v) Pipe Perimeter 1,196 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 576 m3/hr 9.6 m3/min
Velocity in Pipe 1.40 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 11 meter
Electric Measurements Volt 394 392 396
Ampere 73.6 69 65.8
kW 36 Power Factor 0.76
vi) Motor Working on Loading Basis 80 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 15 ft
vi) Frictional Head (Suction and Discahrge) 4.74 ft
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viii) Total Dynamic Head of Pump (TDH) 17.74 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 11.36 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 48.26 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 23.55 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 9,216 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,363,840 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 211,367 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,747,775 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 61 %
xxvii) Water Flow after Efficiency Improvement 1,492 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.02 kWh/m3
xxix) Potential of Energy Reduction 61.40 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 129,773 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,687,047 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 3,186,000 PKR
Attached water flow meter is not working Attach new water flow meter and properly record 24 hour flow reading.
PFI panel not installed Install PFI panel of 50 KVAR
Ammeter is not working
Install digital pressure gauge at discahrge pipelineThere is no pressure gauge installed at discahrge pipeline
Voltmeter is not working Install Voltmeter
Install Ammeter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Kalma Chowk Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 3
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 16 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Picture
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 03
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 6 Cusec 612 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 15
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 15
ii) Length of Discharge Pipe (ft) 34
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 14 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
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 15 inches
v) Pipe Perimeter 1,196 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 550 m3/hr 9.1667 m3/min Estimated
Velocity in Pipe 1.34 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 11 meter
Electric Measurements Volt 430 427 426
Ampere 48 49 51
kW 28.5 Power Factor 0.78
vi) Motor Working on Loading Basis 64 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 14 ft
vi) Frictional Head (Suction and Discahrge) 4.33 ft
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viii) Total Dynamic Head of Pump (TDH) 16.33 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 9.98 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 38.20 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 26.13 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 16 hrs
xxi) Daily Pump flow 8,800 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,212,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 167,332 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,175,322 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 61 %
xxvii) Water Flow after Efficiency Improvement 1,284 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.02 kWh/m3
xxix) Potential of Energy Reduction 57.16 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 95,646 kWh/yr
xxxi) Annual Financial Saving on Pumping 1,243,401 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 3,136,000 PKR
Voltmeter is not working
Install AmmeterAmmeter is not working
Attached water flow meter is not working Attach new water flow meter and properly record 24 hour flow reading.
Install Voltmeter
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
PFI panel not installed Install PFI panel of 50 KVAR
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1 Pumping Station Information
Picture
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 Nawaz Sharif Mini Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 2
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty
Submersible Disposal Pump Qty 2
vi) Operational Scheme of Pumps Qty
Independent 2
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 8 hrs/day
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 2 Cusec 204 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 4
ii) Enter Length of Suction Pipe (ft) 2
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 4
ii) Length of Discharge Pipe (ft) 20 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 15 ft
Suction Side Elevation 2 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 20 hp 15 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 50 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 4 inches
v) Pipe Perimeter 319 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 150 m3/hr 2.5 m3/min Estimated
Velocity in Pipe 5.14 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 7 meter
Electric Measurements Volt 423 420 418
Ampere 19.6 19.1 21.3
kW 12.2 Power Factor 0.84
vi) Motor Working on Loading Basis 82 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 2 ft
v) Static Discahrge Head 15 ft
vi) Frictional Head (Suction and Discahrge) 66.06 ft
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viii) Total Dynamic Head of Pump (TDH) 79.06 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 13.19 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 16.35 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 80.63 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.08 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 8 hrs
xxi) Daily Pump flow 1,200 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 438,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 35,815 kWh/yr
xxv) Annual Energy Expenditure on Pumping 465,595 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 216,000 PKR
Voltmeter is not working
Install AmmeterAmmeter is not working
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
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
PFI panel not installed Install PFI panel of 12.5 KVAR
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Q-Block Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 2
Submersible Disposal Pump Qty 1
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 17 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 4 Cusec 408 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 8
ii) Enter Length of Suction Pipe (ft) 38
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 8
ii) Length of Discharge Pipe (ft) 20
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 42 ft
Suction Side Elevation 25 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 30 hp 22 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues poor
Gland Leakage
Non Return Valve
Flow Meter not Available
Pressure Gauge not Available
Wiring poor
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches
v) Pipe Perimeter 638 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 311 m3/hr 5.1833 m3/min
Velocity in Pipe 2.66 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 399.6 401.3 396.2
Ampere 49.5 52.5 45.6
kW 19.7 Power Factor 0.58
vi) Motor Working on Loading Basis 88 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 25 ft
v) Static Discahrge Head 42 ft
vi) Frictional Head (Suction and Discahrge) 18.08 ft
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viii) Total Dynamic Head of Pump (TDH) 35.08 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 12.13 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 26.41 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 45.94 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 17 hrs
xxi) Daily Pump flow 5,287 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 1,929,755 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 122,894 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,597,621 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 60 %
xxvii) Water Flow after Efficiency Improvement 406 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 23.43 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 28,800 kWh/yr
xxxi) Annual Financial Saving on Pumping 374,397 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v) Install new Ammeter
vi)Install new Voltmeter
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 245,000 PKR
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
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Sharif Colony Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact Shabbir Ahmad
iv) Total Number of Pumps Installed 2
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 1
Submersible Disposal Pump Qty 1
vi) Operational Scheme of Pumps Qty
Independent 1
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 6 Cusec 612 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 9
ii) Enter Length of Suction Pipe (ft) 28
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 9
ii) Length of Discharge Pipe (ft) 30
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 33 ft
Suction Side Elevation 16 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 50 hp 37 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues excellent
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
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 9 inches
v) Pipe Perimeter 718 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 495 m3/hr 8.25 m3/min Estimated
Velocity in Pipe 3.35 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 18 meter
Electric Measurements Volt 385 386 380
Ampere 52 44 54
kW 24.6 Power Factor 0.74
vi) Motor Working on Loading Basis 66 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 16 ft
v) Static Discahrge Head 33 ft
vi) Frictional Head (Suction and Discahrge) 28.23 ft
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viii) Total Dynamic Head of Pump (TDH) 45.23 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 24.89 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 32.98 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 75.49 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.05 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 9,900 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,613,500 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 180,543 kWh/yr
xxv) Annual Energy Expenditure on Pumping 2,347,058 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 145,000 PKR
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
There is no pressure gauge installed at discahrge pipeline Install digital pressure gauge at discahrge pipeline
PFI panel not installed Install PFI panel OF 25 Kvar
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Zafar Ali Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 2
v) Total Number of Pumps in Operation 1
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 1
Submersible Disposal Pump Qty 1
vi) Operational Scheme of Pumps Qty
Independent 2
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 20 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Picture
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 5 Cusec 510 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP Estimated
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 8
ii) Enter Length of Suction Pipe (ft) 24
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 8
ii) Length of Discharge Pipe (ft) 30 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 28 ft
Suction Side Elevation 12 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 50 hp 37 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 100 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues poor
Gland Leakage
Non Return Valve
Flow Meter not available
Pressure Gauge not available
Wiring poor
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 8 inches
v) Pipe Perimeter 638 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 499 m3/hr 8.3167 m3/min
Velocity in Pipe 4.27 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 16 meter
Electric Measurements Volt 368 370 368
Ampere 57 63 68
kW 35.2 Power Factor 0.88
vi) Motor Working on Loading Basis 94 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 12 ft
v) Static Discahrge Head 28 ft
vi) Frictional Head (Suction and Discahrge) 46.05 ft
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viii) Total Dynamic Head of Pump (TDH) 62.05 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 34.43 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 47.18 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 72.96 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.07 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 20 hrs
xxi) Daily Pump flow 9,980 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,642,700 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 258,338 kWh/yr
xxv) Annual Energy Expenditure on Pumping 3,358,391 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 145,500 PKR
There is no pressure gauge installed at discahrge pipeline
Over voltage relay is defective Replace overvoltage relay
Install digital pressure gauge at discahrge pipeline
water flow meter is not available Attach new water flow meter and properly record 24 hour flow reading.
PFI panel not installed Install PFI panel of 25 KVAR
Install VoltmeterVoltmeter is not working
Ammeter is not working Install Ammeter
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Macca Colony Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 01
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 25 Cusec 2,550 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 16 Estimated
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 16 Estimated
ii) Length of Discharge Pipe (ft) 30 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 40 ft
Suction Side Elevation 16 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 150 hp 112 kW
iii) Voltage Range 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)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues poor
Gland Leakage
Non Return Valve
Flow Meter not Installed
Pressure Gauge not Installed
Wiring poor
Housekeeping
Motor Terminal poor
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 16 inches
v) Pipe Perimeter 1,276 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 565 m3/hr 9.4167 m3/min
Velocity in Pipe 1.21 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 17 meter
Electric Measurements Volt 388.2 389.7 391.3
Ampere 38.9 41.3 37.4
kW 17.2 Power Factor 0.66
vi) Motor Working on Loading Basis 15 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 16 ft
v) Static Discahrge Head 40 ft
vi) Frictional Head (Suction and Discahrge) 3.58 ft
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viii) Total Dynamic Head of Pump (TDH) 27.58 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 17.32 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 23.06 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 75.13 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.03 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 8,475 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,093,375 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 94,675 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,230,774 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 186,000 PKR
There is no pressure gauge installed at discahrge pipeline
Install A and V meter Defective A and V meter
Over voltage relay is defective Install overvoltage relay
Install digital pressure gauge at discahrge pipeline
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.
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Macca Colony Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 15 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 02
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 8 Cusec 816 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14
ii) Length of Discharge Pipe (ft) 30 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 40 ft
Suction Side Elevation 16 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues good
Gland Leakage
Non Return Valve
Flow Meter not Installed
Pressure Gauge not Installed
Wiring good
Housekeeping
Motor Terminal ok
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 600 m3/hr 10 m3/min
Velocity in Pipe 1.68 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 17 meter
Electric Measurements Volt 398.8 393 398
Ampere 39 38 39.7
kW 19.2 Power Factor 0.72
vi) Motor Working on Loading Basis 43 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 16 ft
v) Static Discahrge Head 40 ft
vi) Frictional Head (Suction and Discahrge) 6.91 ft
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viii) Total Dynamic Head of Pump (TDH) 30.91 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 20.62 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 25.74 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 80.12 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.03 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 15 hrs
xxi) Daily Pump flow 9,000 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 3,285,000 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 105,684 kWh/yr
xxv) Annual Energy Expenditure on Pumping 1,373,887 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 136,000 PKR
There is no pressure gauge installed at discahrge pipeline
Install A and V meter Defective A and V meter
Over voltage relay is defective Install overvoltage relay
Install digital pressure gauge at discahrge pipeline
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.
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1 Pumping Station Information
1 Fresh Water Supply
2 Wastewater Disposal
3 Waste Water Treatment Plant
4 Water Treatment Plant
Name of Engineer
WASA Staff Name
i) Name of Pumping Station Macca Colony Disposal Station
ii) Name of Subdivision GULBERG , Lahore
iii) Operator Name & Contact NA
iv) Total Number of Pumps Installed 3
v) Total Number of Pumps in Operation 3
vi) Year of Starting Operation
vii) Types of Pumps
Standard Deep Well Water Turbine Pumps Qty
Submersible Deep Well Water Turbine Pumps Qty
Centrifugal Pump Qty 3
Submersible Disposal Pump Qty
vi) Operational Scheme of Pumps Qty
Independent 3
Series
Parallel
vii) Any Header / Tank / Reservoir
Yes No
viii) Any Record Keeping
Time Flow Pressure
Level Quality of Water Power Consumption
Maintenance Record Electricity Bill Fuel Consumption Data
viii) Daily Operational Time 115 hrs/day Estimated
ix) Annual Working Days 365 days
x) Source of Power
Energy Report of WASA Pumps
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Primary LESCO Secondary
xi) In Case of Secondary Power Source Fuel Data Details
xii) Operational Hours of Secondary Power Source hrs/day
2 Pump Basic Information Pump # 03
ii) Mounting / Erection
Horizontal Vertical Submersible
Foundation
iii) Concrete Bolted Bolted
iv)
v) Cooling Type
Water Cooled Air Cooled
vi) Number of Stages
Single Multi
vii) Pump and Motor Assembly
Direct Coupled Belt / Gear
viii) Source of Suction
Wet Well Overhead Tank Underground Tank
Pressurized Source
ix) Pump Discharge Destination
Overhead Tank Drain On Ground Reservoir
Pit
Pump Operational Scheme
On / OFF Proportional
x) Pump Flow Control
Throttle VFD Controlled
xi) Any Retrofits ?
Impeller Detail
Casing / Volute Detail
Line Shaft (DW) Detail
Column Sett. (DW) Detail
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Motor Replacement Detail
Motor Rewinding Detail
xii) Self Priming
Yes No NA (not applicable)
xiii) Non Clogging (In case of wastewater)
Yes No
xiv) Flowmeter Available
Yes No
xv) Flowmeter Working
Working Properly Malfunctioning (Damaged)
3 Pump Nameplate Data
i) Make / Brand KSB Country Pakistan
ii) Model Serial
iii) Certification Mark
iv) Year of Manufacture
v) Flowrate (Q) 8 Cusec 816 m3/hr
vi) Head (H) ft
vii) Discharge Pressure (P) Psig
viii) Power / HP / BHP BHP
ix) Speed (n) RPM
x) Maximum Pressure (Pmax)
xi) Maxiumum Allowable Temperature
5 Piping System
Suction Side
Select Pipe Material of Construction MS Pipe
i) Enter Diameter of Suction Pipe (In) 14
ii) Enter Length of Suction Pipe (ft) 27
iii) Enter Fittings on Suction Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Flow control 1
Bends
Strainer 1
viii) Availbility of Pressure Gauge Yes No
ix) Suction Pressure
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Discharge Side
Pipe Material of Construction MS Pipe
i) Diameter of Discharge Pipe (in) 14 Estimated
ii) Length of Discharge Pipe (ft) 30 Estimated
iii) Fittings on Discharge Pipe
Fitting Type 1 Qty Type 2 Qty Type 3 Qty
Valves Non return 1 1
Bends 1
Strainer
vi) Discharge Elevation (from Datum Line) 40 ft
Suction Side Elevation 16 ft
vii) Availbility of Pressure Gauge Yes No
viii) Discharge Pressure psig
6 Motor Nameplate Data
i) Manufacturer Siemens
ii) Rated kW / hp 60 hp 45 kW
iii) Voltage Range Volts
iv) Current Amperes
v) Power Factor (Cos ɸ)
Standard
Ambient Temp oC
Year of Manufacturing
Efficiency Class
IE3 Eff 1
IE2 Eff 2
IE1 Eff 3
Standard Efficiency
vi) Motor Speed RPM
vii) Reference Frequency 50 Hz
viii) Insulation Class
ix) Motor Frame Size
x)
7 Electrical System Observations
i) Electrical Meter Reference Number
ii) Meter Reading
iii) Meter Time and Date
Correct FALSE
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Lag by Lead by
iv) Transformer Rating (kVA) 200 Condition OK
Pump O & M Cost
v) Motor Starting Method
Direct Online Star (Wye) - Delta
Autotransformer Starter Soft Starter
Variable Frequency Drives
v) Electrical Protections Available
Earthing / Grounding Fuses or Miniature Circuit Breaker (MCB)
Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB)
PFI Plant Not installed
Panel Condition/Issues poor
Gland Leakage
Non Return Valve
Flow Meter Not installed
Pressure Gauge Not installed
Wiring poor
Housekeeping
Motor Terminal poor
Foundation/Civil work
Field Measurements
8 Flow Measurement
i) Flow Measurement Location
Discharge Pipe Suction Pipe
ii) Pipe Material of Construction MS Pipe
iii) Paint on Pipe Yes No
iv) Pipe Diameter 14 inches
v) Pipe Perimeter 1,117 mm
vi) Type of Clamping (V/N/Z) V
viii) Flow Measurement 750 m3/hr 12.5 m3/min
Velocity in Pipe 2.10 m/sec
Pressure
i) Pressure at Discharge Side of Pump psig
ii) Pressure at Suction Side of Pump
ii) Total Length (Suction+Discahrge Pipe) 17 meter
Electric Measurements Volt 369 367 365
Ampere 112 113 117
kW 47.8 Power Factor 0.66
vi) Motor Working on Loading Basis 107 %
Oversize Undersize Properly Sized
Speed
i) Speed of Motor 0 RPM
ii) Speed of Pump Impeller RPM
Noise Level
Noise Level (db(A)) Avg. Max:
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Thermal Imaging
i) Motor Motor Pump Coupling
Pump Volute Casing Pump Bearings
Electric Panels
10 Calculations
ii) Static Suction Head (Only for WW Pump) 16 ft
v) Static Discahrge Head 40 ft
vi) Frictional Head (Suction and Discahrge) 10.78 ft
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viii) Total Dynamic Head of Pump (TDH) 34.78 ft
x) Specific Speed of Pump
Ns = RPM x GPM0.5 / H0.75
impeller rpm necessary to produce 1gpm/ft head 0
500-10,000, standard, 2,000-3,000 high efficiency
xi) Difference of Pump Curve flow and Measured Flow at the TDH m3/hr
xii) Deviation of actual flow from the pump curve flow %
xiii) Water Horsepower (whp) (TDH x Actual Measured Flow) 29.01 hp
xiv) Brake Horsepower (bhp) (OEM Data) 0.00 hp
xv) Electrical Horsepower(ehp) (Electrical Measurement at Motor input) 64.08 hp
xvi) Efficiency of Individual Pump (ηpump) (whp/bhp) x 100 #DIV/0! %
xvii) Efficiency of Pumping System (ηsystem)Existing (whp/ehp) x 100 45.27 %
xviii) Existing Specific Pumping Energy (En(pumping01)) 0.06 kWh/m3
xix) Avg. Cost of Energy (Based on Grid and Backup) 13 PKR/kWh
xx) Daily Operational Time of Pump 115 hrs
xxi) Daily Pump flow 86,250 m3/day
xxii) Annual working days 365 days
xxiii) Annual Pump flow 31,481,250 m3/yr
xxiv) Annual Energy Consumption of Pump (En(pumping01) x Annual Pump Flow) 2,017,163 kWh/yr
xxv) Annual Energy Expenditure on Pumping 26,223,122 PKR/Yr
xxvi) Pumping System Efficiency after Improvement 61 %
xxvii) Water Flow after Efficiency Improvement 1,011 m3/hr
xxviii) Specific Energy Consumption at New Efficiency 0.05 kWh/m3
xxix) Potential of Energy Reduction 25.79 %
xxx) Reduced Annual Energy Consumption at Improved Efficiency 520,240 kWh/yr
xxxi) Annual Financial Saving on Pumping 6,763,117 PKR/Yr
11 Summary of Findings
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.
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Issues & Recommendations
12 ISSUES RECOMMENDATIONS
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
Financial Analysis / Indicators
12 Estimated Investment for Improvement Plan 136,000 PKR
There is no pressure gauge installed at discahrge pipeline
Install A and V meter Defective A and V meter
Over voltage relay is defective Install overvoltage relay
Install digital pressure gauge at discahrge pipeline
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.
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ANNEXURE-2
Selected Pictures
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No Motor cover at C III
Defective A meter at Ittehad Colony
Defective PFI display at Ittehad Colony Faulty PFI panel at jail Road
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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
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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
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View of pump at Saint Mary Gland leakage at Q block
No Motor cover at T Block
Poor Electric wiring at Gurumangat
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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
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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