33 Energy Audit Report on Tubewells and Sewage Pumping Stations in Sialkot

TA 7321 PAK Punjab Cities Improvement

Investment Program

Government of Punjab Urban Unit

ENERGY AUDIT REPORT ON

TUBEWELLS AND SEWAGE PUMPING STATIONS IN SIALKOT

Draft Final

December 2010

J40252334

GHK Consulting Ltd

Electricity has a direct relation with the cost of accessing water and is therefore our starting

point for making suggestion for optimization of this resource.

With rising energy cost, public sector is also increasing its focus on the amount of energy

expended by rotating equipment accounts for 20% of world electrical demand; energy cost is

the largest element in owning a pump. Improperly sized or poorly performing pumps are

costing municipalities millions of unnecessary rupees. Unscheduled repair and poor

reliability are causing them serious hindrances in the continuation of the pumps operation.

So our motto is, lets not waste even a single watt of energy without benefiting a man.

It is the time of understanding the need of conserving precious resources (both water and

electricity) which are limited and apprehended to be diminished.

Access to safe, affordable and convenient water drastically reduces diseases, improves the

quality of life and strengthens the economy.

In this context the energy audit is being carried out and realization of the recommendations

is expected to turn out in annual savings of energy as well as ensure the availability of clean

water in the smooth way too.

Energy Audit Report of Tubewells, Sewage Pumping Stations Table of Contents

GHK Consulting Limited J40252334

Page i

TABLE OF CONTENTS ACRONYMS & ABBREVIATION ........................................................................................................... ii EXECUTIVE SUMMARY ........................................................................................................................ 1 1.0 INTRODUCTION ......................................................................................................................... 4 2.0 LOCATION .................................................................................................................................. 5 3.0 TERMS OF REFERENCE .......................................................................................................... 7 4.0 METHODOLOGY ........................................................................................................................ 8 5.0 REFERENCE OF ANNEXURE ................................................................................................... 9 6.0 UTILITIES ANALYSIS .............................................................................................................. 10 7.0 NON OPERATIONAL TUBEWELLS........................................................................................ 11 8.0 OPERATIONAL TUBEWELLS AND THEIR CAPACITY ........................................................ 12 9.0 RECOMMENDATION REGARDING DEPLETING WATER LEVEL ....................................... 13 10.0 NON CONTRIBUTING TUBEWELLS ...................................................................................... 14 11.0 PUMPS FOR REHABILITATION ............................................................................................. 15 12.0 ELECTRICITY ANALYSIS ....................................................................................................... 18 12.1 Energy Trend with Depleting Water Level ................................................................................ 18 12.2 Energy Consumption Analysis .................................................................................................. 20 12.3 Power Factor on Site ................................................................................................................ 22 12.4 Important to understand Energy Cost ....................................................................................... 24 13.0 ENERGY MANAGEMENT PLAN ............................................................................................. 26 13.1 ECO 1: Improved Motor Control Panels ................................................................................... 26 13.2 ECO 2: Awareness Raising And Education .............................................................................. 26 13.3 ECO3: Minimizing Voltage Unbalances .................................................................................... 27 13.4 ECO 4: Adequate Maintenance ................................................................................................ 28 13.5 ECO 5: Monitoring .................................................................................................................... 28 13.6 ECO 6: Adequate Design Parameters ...................................................................................... 29 13.7 ECO 7: Preventing Throttling Of Pumps ................................................................................... 30 13.8 ECO 8: Procurement of Right Pumps ....................................................................................... 30 13.9 ECO 09: Proper Distribution System ........................................................................................ 31 13.10 ECO 10: Energy Savings in Electric Motors ............................................................................. 32 14.0 CONCLUSION .......................................................................................................................... 33

TABLES Table 6-1: Number of Pumps Operated by Cantt and TMA ............................................................ 10 Table 6-2: Tube wells Operating Schedule ..................................................................................... 10 Table 7-1: Reason of Non Operational Tube wells ......................................................................... 11 Table 8-1: Design Capacity of Installed Pumps Vs Operational Capacity of Pumps ...................... 12 Table 10-1: TMA Pumps Not Adding in the System .......................................................................... 14 Table 11-1: Pumps Required to be Upgraded/ Refurbished ............................................................. 15 Table 12-1: Present consumption of Electricity ................................................................................. 18 Table 12-2: Position of total Discharge per kW consumed ............................................................... 18 Table 12-3: Next Year Position after 80-90 Ft Water Level............................................................... 19 Table 12-4: Next Year Position of Discharge per kW consumed ...................................................... 19 Table 12-5: Expected performance of the pumps after Implementation of Recommendations. ....... 19 Table 12-6; Position of Discharge per kW consumed after Implementation of Recommendations .. 19 Table 12-7: Extraordinary Energy Consumption ............................................................................... 20 Table 12-8: Power Factor of TMA Pumps ......................................................................................... 22 Table 12-9: Power Factor of PHED Pumps ....................................................................................... 23 Table 12-10: Power Factor of Cantt Pumps ........................................................................................ 24 Table 12-11: Power Factor of Disposal Pumps ................................................................................... 24

FIGURES Figure 2-1: Map of Sialkot Showing Location of Tubewells ................................................................ 6 Figure 7-1: Non Operational Pumps (Graphical Form) ..................................................................... 11 Figure 8-1: Installed Capacity Vs Operational Capacity (Graphical form) ........................................ 12 Figure 11-1: TMA Tube wells Present and Next Year Discharge ....................................................... 16 Figure 11-2: Remaining TMA Tubewells Present and Next Year Discharge ..................................... 16 Figure 11-3: PHED Tube wells Present and Next Year Discharge .................................................... 17 Figure 11-4: Cantt Board Tube wells Present and Next Year Discharge ........................................... 17 Figure 12-1: Future Discharge Trend in Graphical Form .................................................................... 20 Figure 12-2: Energy Saving Potential: ................................................................................................ 21 Figure 12-3: Detail of Power Factor and Expected Annual Penalty ................................................... 24

Energy Audit Report of Tubewells, Sewage Pumping Stations Acronyms & Abbreviations


Page ii

ACRONYMS & ABBREVIATION

ADB Asian Development Bank

GHK GHK Consulting Ltd.

TMA Tehsil Municipal Administration

PHED Public Health Engineering Department

Cantt Cantonment Board Sialkot Best

BEP Best Efficiency Point

DOH Daily Operating Hours

TOR Terms of Reference

PF Power Factor

ECO Energy Conservation Opportunities

KW Kilo Watt

V Voltage

M3 Cubic Meter

Ft Feet

Cusec Cubic Feet Per Second

H Head of Pump

Q Capacity of Pump

Vs Verses

Nr. Number

No. Number

Note: For the calculation of energy cost a flat rate of Rs. 14/kwh is used.

Energy Audit Report of Tubewells, Sewage Pumping Stations Executive Summary


Page 1

EXECUTIVE SUMMARY Energy Audit is a systematic study or survey on the current usage of energy and identifies energy conservation opportunities with the help of proper audit methods and equipments. It provides feasibility or technical solution options for the authorities to decide project implementation. Energy audit conducted in Sialkot is basically on the Tube wells, so during survey our main focus on the rotating equipment which were pumps. Pumps are designed for a specific flow and pressure and attain its maximum efficiency at a specific point i.e. Best Efficiency Point (BEP). If the design point is within the limit of BEP, it gives required output with minimum required energy. On the contrary if pump is operated away from its BEP it will be increasingly inefficient and not only consuming more energy but also suffer mechanical damage or reduced operating life. It is important to select a pump to be operated close to its BEP Figure E.1 shows the selection of the pump to be made in such a way that it should work around best efficiency point, departing from BEP incur high energy consumption and may take pump operation into uncertain condition. During energy audit pumps behavior was studied very precisely to draw some analysis. Main focus was remained on the study of the site loads and matching it with the installed Pumps, measurement of actual energy consumed by each pump at site and the power factor of the motor, calculation of the duty point, assessment of the required motor power, drawing pump performance curves of individual pump in order to make recommendations for modification / repair / replacement of specific components. The energy audit conducted under contract with GHK having reference TA NO 7321-PAK: PREPARATION OF PUNJAB CITIES IMPROVEMENT INVESTMENT PROJECT (PCIIP) with ASIAN DEVELOPMENT BANK (URBAN UNIT AND P & D DEPARTMENT) in the continuation of Survey Report on Tubewells and Sewage Pumping Stations in Sialkot, an industrial city located in the north east of Punjab near the Indian Border in Pakistan. The study has been carried out in the form of individual site surveys with the help of necessary gadgets for measuring the required operating parameters to adopt the strategy of adjusting and optimizing energy requirements per unit of output by reducing the total cost. The survey is to estimate the energy cost of pumping water which is contributing heavily in the overall expenditure of municipal and water authorities. The report is the part of the studies, a pre-investment tool, to enable funding authorities for making a feasibility

Figure E-1: Selection Parameters



Page 2

report of the project and optimum allocation of funds for improvement and rehabilitation of utilities in the city. Table E-1 is giving an overview on the total number of Tubewells and their working schedule Table E-1: Total Number of Tubewells Inspected

Area Installed by Dept Equipment No. of wells Daily Operating

Hrs

Cantt Cantt Tube wells 15 8

TMA Tube wells 74

TMA PHED Tube wells 26 13

TMA Sewage Pump 1

Total 116

E.1 Findings & Suggestions During Survey All the tube wells were visited and the necessary data was collected after installation of flow meter, pressure gauge and power analyzer. The data collected was compared with the data of equipment installed and individual performance curves of each pump were drawn. It is observed that 13 pumps working in TMA are hardly adding 2.99 Cusecs into the system and are not capable to perform any longer so are required to be replaced. Similarly 33 pumps which are adding 36 Cusecs against their installed capacity of 49 Cusecs will only deliver 26 Cusecs next year. These pumps are required to be replaced or refurbished as per their condition after pulling out and inspection. The overall operative capacity of 149.5 Cusecs is only delivering 123.46 Cusec at the moment and will deliver only 102 Cusec next year. The main reason is depleting water table in the area which is at the moment at 70-80 ft and is likely to go down up to 80-90 feet in the coming 1-2 years. The pumps installed with 120, 130 and 140 ft head are not capable to pump out enough water with the depleting water level. The other major factor is installation of high head pumps of 200 and 250 ft in the same areas which are creating resistance in the system especially at off peak hours. These high head pumps are also damaging the borehole at the time of peak hours by producing more water than the designed capacity of boreholes. The measures advised will not only increase the overall discharge to the design level but also ensure the overall energy saving of Rs. 16 Mio per annum with the increased discharge. The output which is currently 4.8 M3/kW and likely to go to 3.94 M3/kW after 1-2 year will come up to 5.94 M3/kW after implementation of measure identified. The overall energy saving is expected to be 30-40%. Apart from the measure about replacement, refurbishment and repair, the measures to be taken against reactive power penalty will be having a saving of another Rs. 18 Mio per annum. Table E-2 presents the short summary of the key Energy Conservation Opportunities (ECOS) along with the measures advised to be taken while the details are later in the report.

E.2 Graphical Representation of Potential Savings

By collecting data of operating parameters and review the conditions with the maintenance staff of all Tubewells, 10 finding associated with energy savings and improvement of value of service or productivity were identified. Against all findings techno-economical solutions are offered. Implementation of given suggestions not only decrease electricity demand but also reduce cost of service and improve operating efficiency. The savings expected are 30 - 40% while the benefits of conserving available resources and global environment protection are additional.



Page 3

Table E-2: Summary of Recommendations on Findings and Potential Saving Estimation

ECO Recommended Measures Findings on Current

Situation Potential Cost

Savings

1 Minimize the reactive power charges No PFI Capacitorsinstalled Up to 12%

2 Training of operators and supervisory Staff Un Trained Operators Up to 3%

3 Minimizing Voltage unbalances Voltage Fluctuation found Up to 2%

4 Preventive maintenance of equipment installed

No Preventive maintenance Up to 4%

5 Monitoring of input and output: Installation of metering devices for Power input and flow and pressure output

No Pressure Gauges and Flow Meters

Up to 10%

6 Proper designing and adjustment of equipment as per site condition and system requirement.

Over and Under Designed Up to 20%

7 Prevent Throttling of Pumps by impeller trimming

Undersized delivery pipes Up to 5%

8 Procurement after necessary testing and qualification

Testing of equipment lacking Up to 10%

9 Proper design of Distribution System Undersized pipes dia and fittings

Not Calculated (not in scope)

10 Appropriate size of motors Motors were big/small than required Up to 1%

Total Potential Annual Saving Up to 30 %

Total Potential Demand Reduction by Installation of Water Meters at Consumer end

No Metering at consumer end 30-40% as per international studies.

Figure E-2 pie chart shows, "Expected Cost Savings" accounts for 30 - 40% of the total consumption, provide a further breakdown and elaboration Figure E-2: Expected Saving Distribution

E.3 Conclusion of Executive Summary

Adopting suggested measures as a routine or developing them as a culture gives life to energy conservation in addition to improve water supply services by reducing losses and increasing efficiency. It will ensure energy savings up to 30-40% which is equivalent to Rs. 30 Mio per annum approximately. It also ensures the optimum output of water against each kW consumed and increases the overall water production by 48 Cusecs. i.e. from 102 cusecs to 150 Cusec.

Reactive Power, 12 , 16%

Training, 3 , 4%

Voltage, 2 , 3%

Maintenenace, 4 , 5%

Monitoring, 10 , 12%

Proper Design, 30 ,

37%

Throttling, 5 , 6%

Procurement, 10 , 12%

Motor Sizing, 1 , 1%

Reactive Power

Training

Voltage

Maintenenace

Monitoring

Proper Design

Throttling

Procurement

Motor Sizing

Energy Audit Report of Tubewells, Sewage Pumping Stations

Section 1 Introduction


Page 4

1.0 INTRODUCTION

In 2009, ADB (Asian Development Bank); Urban Unit and P & D Department, passed the Punjab Cities Improvement Investment Project (PCIIP) which contains funding for rehabilitation of water and sewage infrastructure in Pakistan and the project consultancy awarded to GHK under reference TA. No. 7321 PAK. GHK . GHK promotes sustainable water infrastructure practices, makes recommendations directed to energy efficiency, water efficiency, and green infrastructure so emphasis is being paid on assisting water utilities and local authorities in vulnerability assessments so that they are incorporated into infrastructure planning systems. GHK believes that

Pumping System account for nearly 20% of the worlds electrical energy. In Municipal Utility companies energy cost accounts for 40-60% of overall budget. In bulk water supply pumping stations energy costs account for 70-80% of the total costs.

The rising cost of energy is increasing the graveness of the situation and is growing worst day by day. In Pakistan the electricity distribution companies are increasing the electricity charges at the rate of 2% every month which is alarming indeed. In this situation energy audit is an excellent way to obtain energy savings through Improvements that optimize pumping systems to operate efficiently and effectively. Energy conservation measures are expected to reduce the energy costs up to handsome figure. In addition to this, implementation of energy conservation measures will definitely improve consumer comfort and reduce operations and maintenance costs. All energy audit activities are performed as per TOR (Term of Reference), data of all the necessary parameter collected by applying instruments, afterwards, verified and analyzed Inferences were drawn and energy conservation measures defined by adopting systematic approach for improving efficiency of water pumping operations.


Section 2 Location


Page 5

2.0 LOCATION

Project capturing the energy audit of 115 Wells in Sialkot. The city is about 5000 years old and the population of the Sialkot city (proper) is about 500,000 while Population Density is 1160/km2 From 115 tube wells visited in Sialkot, 74 are under Tehsil Municipal Administration (TMA) while 26 are under Punjab Public & Health Engineering Department (PHED) and 15 are under Cantonment Board. Currently the maintenance of 100 tube wells is the responsibility of TMA while 15 tube wells are coming under responsibility of Sialkot Cantt.

Map of Punjab


Section 2 Location


Page 6

Figure 2-1: Map of Sialkot Showing Location of Tubewells

Source: Adapted from Urban Units base map. Survey undertaken by GHK team who visited each location marked in the map


Section 3 Terms of Reference


Page 7

3.0 TERMS OF REFERENCE

(i) Study of pumps design and their operational characteristics. (ii) Study of the Site Loads and match it with the installed Pumps. (iii) Execution of Field performance tests for determination of Pumping

Machinery performance and measurement of the flow, head and efficiency of the installed machinery.

(iv) Determining the system resistance and calculation of the duty point. (v) Identified expected energy saving on the basis of modifications that will

reduce the energy usage. (vi) Prepared a rank-ordered list of appropriate modifications. (vii) Measurement of actual energy consumed by each pump installed (viii) Comparison of actual energy consumption with the designed energy

requirements of the pump installed (ix) Assessment of the need of motor-power and comparison with the motor

installed. (x) Suggestions after evaluation of overall Water Supply System and

operation of Tubewells. (xi) Preparation of a datasheet to document the analysis process and results.

Drawing of the Pump performance curve at site (xii) Recommendation for modification! Repair/replacement of specific

components. (xiii) Performance objective for modification! Repair/ replacement activity.

Comprehensive Study Elements Part A Design Parameters 1. Pump Efficiency at Design Flow

and Head 2. Pump Performance Curve 3. Motor Rated Power 4. Motor Efficiency at Design Load 5. Motor Power Factor at Full Load

Part B Pump Behavior at Site

1. Measurement of Discharge 2. Measurement of Static Water Level 3. Measurement of Pumping Water

level 4. Computation of Draw Down 5. Computation of system head 6. Motor Power Factor at Duty Point 7. Measurement of Power inputs (Ampere, and Kw) 8. Measurement of Motor winding and Bearing temperature. 9. Measurement of Hydraulic Efficiency


Section 4 Methodology


Page 8

4.0 METHODOLOGY

This section presents the "Work Plan and Methodology" adopted to handle the entire project and to perform various assignments/activities according to our scope of work as described in Terms of Reference. This has been based on our best understanding of the project and experience on the assignments of similar nature. First the pumps were examined in the idle condition; fittings and free running of the pumps were checked and noted under design parameters in the given format. The Static water level and the incoming power conditions were also verified. After visual inspection the following equipment was installed and readings were taken. 1. Flow Rate with ultrasonic flow meter. 2. Pumping water level with wired gauge inserted in the borehole 3. Head with the pressure gauge installed at the discharge head 4. Motor RPM with tachometer 5. Power Input with Power Analyzer. (Amp, Volts, Power input,

Factor) 6. Temperature with infrared temperature meter (Motor Upper and

Lower Bearings, Winding and Water Temp)

Total 5 reading were taken on the fully opened valve (One reading), partially closed valve (3 readings) and completely closed valve (1 reading) and the pump curve is drawn. The curve drawn on the basis of site data is compared with the performance curve of the pump manufacturer to determine pump performance and proposing the remedial measures. All the tube wells were visited between 8th November 2010 and 30 November 2010 and the data was recorded


Section 5 Reference of Annexure


Page 9

5.0 REFERENCE OF ANNEXURE

Following 3 Annexure is part of the report to provide sufficient data about the pump performance. Annexure 1 Showing all the data of pump performance while operating in system collectively as well as individually. It also contains the power consumption, and power factor as well as the potential savings after implementation of recommendations. Annexure 2, Annexure 3, and Annexure 4 contain example data of TMA, PHED and Cantt pump performance in 3 sheets. 1st sheets shows the Name, type and size of the pump, manufacturer name, pump and motor serial number as well as the site performance comprising of flow rate, head, power absorbed, power factor, efficiency of the pump and head at ground level. The 2nd pages shows the pump performance curve and compare it with the pump manufacturer's curve. Three different curves are provided to show flow rate versus head, pump efficiency and power absorbed. On the 3rd page comparison between pump present performance with the design performance and actually required pump for the site as per present site conditions is made. Energy Audit complete report with individual data of each pump is available on the following web link. http://pciip.ghkpak.com/reports/energy_audit_report.zip (10.7 MB) Annexure 5 contain the pump data of Model Town pumping station, summarize in three sheets as discussed in previous para. Annexure 6 Contains the pump performance curves of the pump manufacturers.


Section 6 Utilities Analysis


Page 10

6.0 UTILITIES ANALYSIS

Tube wells were visited between 8 th November to 2nd December 2010 and the data collected and compiled in order to calculate the total energy consumption and to design the further course of action in the context of rapidly decreasing water level which has got down from 40 Ft to 80 - 90 Ft in just a decade. On the other side the electricity charges increased from Rs. 2 to Rs.14 in the said time which definitely raised the cost of per cubic meter of water up to 12 to 15 times higher. The TMA (Tehsil Municipal Administration) and Cantt (Cantonment Board) are responsible for providing the water and sanitation facilities to the citizens of Sialkot. The No of pumps being operated by the two departments are as under. Table 6-1: Number of Pumps Operated by Cantt and TMA

Area Installed by Dept Equipment No. of wells

Cantt Cantt Tube wells 15

TMA

TMA Tube wells 74

PHED Tube wells 26

TMA Sewage Pump 1

Total: 116

The pumps shown against the PHED are the pumps newly installed in 2008-2010 by PHED (Public Health Engineering Department) for TMA and are now being operated by TMA. Currently the water supply is not being provided 24 hours but intermittently. The supply hours for Cantt operated tube wells are 8 hours per day and for TMA operated tubewells are 13 hours per day. The overall schedule of supply is as under.

Table 6-2: Tube wells Operating Schedule

Daily Operating

Hours 1st Operating Time 2nd Operating Time 3rd Operating Time

Cantt 8 05:00 AM to 08:00 AM 11:00 AM to 02:00 PM 04:00 PM to 6:00 PM

TMA 13 05:00 AM to 10:00 AM 12:00 Noon to 08:00 PM


Section 7 Non Operational Tubewells


Page 11

7.0 NON OPERATIONAL TUBEWELLS Out of 115 Tube wells installed, only 98 are currently operational. 17 Tubewells are non-operational currently because of the following reasons. Table 7-1: Reason of Non Operational Tube wells

Area Reasons (of non operational) Tube Wells Serial Nr Qty

(Non Operational)

CANTT

Not yet commissioned 8 1

Abandoned 12 1

TMA

PHED

Transformer Fault 6 1

Not yet commissioned 20,21,22,23,24,25 6

TMA

Motor Burnt 14 1

Transformer Fault 29,44 2

Bore Collapsed 26, 43 2

MCU Problem 57 1

Pump Problem 68 1

Transformer and Cable 74 1

TMA Total: 15

Grand Total: 17

Figure 7-1 showing the reasons and the number of pumps which are non operational and their further distribution in order to understand major cause Figure 7-1: Non Operational Pumps (Graphical Form)

Not Yet Commissioned,

7

Abandoned, 1 Motor Burnt, 1

Transformer Fault, 3

Bore Collapsed, 2

MCU Problem, 1

Pump Problem, 1

Transformer and Cable, 1


Section 8 Operational Tubewells and Their Capacity


Page 12

8.0 OPERATIONAL TUBEWELLS AND THEIR CAPACITY

The operational 98 pumps are capable of producing 146.5 Cusec instead of giving their design capacity of 174 Cusecs while 1 Sewage disposal pump installed at Model Town Disposal Station is capable of producing 3 Cusec. Mismatch between equipment capacity and requirement leads to in-efficiencies due to part load operations, operation apart from Best Efficiency point, wastages etc. optimization is the energy audit mandate that involves the graceful matching of energy equipment capacity with the end - use needs. When two or more than two pumps are being operated in the same location or nearby but with the different heads, the pressure creates in the main line by high pressure pump may not let the other pump give its flow with low head.

Table 8-1 and Figure 8-1 Showing the designed Capacity of the installed pumps along with operational Capacity in order to make a clear picture of current situation prevailing

Table 8-1: Design Capacity of Installed Pumps Vs Operational Capacity of

Pumps

Area Installed Capacity Operational Capacity

Nrs Cusec Nrs Design Cusecs

WATER SUPPLY

Cantt 15 22 13 20

PHED 26 39 19 28.5

TMA 74 110 66 98

Total: 115 171 98 146.5

SEWAGE

Disposal 1 3 1 3

Grand Total: 116 174 99 149.5

Figure 8-1: Installed Capacity Vs Operational Capacity (Graphical form)

15 13

22 20 26

19

39

28.5

74 66

110

98

1 1 3 3

0

20

40

60

80

100

120

Installed Capacity OperationalCapacity

Installed Capacity OperationalCapacity

NRS Cusec

Cantt

PHED

TMA

Disposal


Section 9 Recommendation Regarding Depleting Water Level


Page 13

9.0 RECOMMENDATION REGARDING DEPLETING WATER LEVEL Keeping in view the above mentioned situation, it is recommended that the tube wells having design head 120, 130, 135 Ft should immediately be replaced with new pumps of 150 Head. When two or more than two pumps are being operated in the same location or nearby but with the different heads, the pressure creates in the main line by high pressure pump may not let the other pump give its flow with low head. One the other hand the installation of very high head pumps in the same system is restricting the low head pumps to give substantial output and it is possible that the low head pump may not produce at all when a high head pump is also operating in the same zone. This phenomenon should be minimized by curtailing and adjusting the head of high head pumps of 200 and 250 Ft in the same zone to 150 Ft Head


Section 10 Non Contributing Tubewells


Page 14

10.0 NON CONTRIBUTING TUBEWELLS

For optimum operation in the municipalities where direct pumping is involved, the pressure head at the ground level should be between 1.5 to 2.5 bar depending on the performance parameters of the utility provider and topography of the area to be served. Furthermore, It has been observed during the survey that pumps with the head varying from 120 to 250 Feet have been installed in the same zone which cannot contribute the required flow as was calculated in the very beginning. Therefore, some of the present tube wells given in the Fig 2.1 with the existing design parameters will not be capable of producing at all when operated in the system while some of the present tube wells will reduce their discharge less than 1 Cusec against the installed discharge of 1.5 Cusec as given Fig 2.2

Table 10-1: TMA Pumps Not Adding in the System

TubeWell No.

Site Name Year of

Installation

Design Discharge

Cusec

Present Discharge at 1.5 Bar

Cusec

Discharge at 1.5 Bar after

Water Level 90 Cusec

2 Naya mayana Pura 1990 1.5 0.78 0.00

3 Muzafar Pur (Grave Yard) 2003 1.5 0.00 0.00

36 RangpuraSaheenPura 1996 1.5 0.74 0.00

46 Haider Park 2004 1.5 0.00 0.00

50 Babey Bairey mohallah Khamaran

1991 1.5 0.00 0.00

61 Shahab Pura near Darbar 2001 1.5 0.78 0.00

62 Shah Monga WaIl 1993 1.5 0.69 0.00

64 Haji pura Bin No 1 1982 1.5 0.00 0.00

66 Kacha Shahab road Marianwala 1993 1.5 0.00 0.00

67 Ghos pura tanky 1993 1.5 0.00 0.00

69 Fatheh Garh graveyard 1988 1.5 0.00 0.00

70 FathehGarhomertown 2004 1 0.00 0.00

71 Fatheh Garh agency chowk 1993 1.5 0.00 0.00

Total: 19 2.99 0.00

10.1 Recommendation for Non-Contributing Tubewells

Pumps Installed at following TMA sites are not capable to add any flow when the system head exceeds 1.5 Bar. It is advised that these pumps should be replaced immediately. Till the replacement, it is advisable not to operate at Off Peak Hours


Section 11 Pumps for Rehabilitation


Page 15

11.0 PUMPS FOR REHABILITATION

Following pumps are required to be rehabilitated in order to obtain the designed productivity in the perspective of depleting water level expected during very next year. Corrective action for rehabilitation is mentioned in the relevant annexure. Table 11-1: Pumps Required to be Upgraded/ Refurbished

Sr. No.

Tubewell Name Design

Discharge Cusec

Design Head

Ft

Present Discharge at 1.5 Bar

Cusec

Discharge at 1.5 Bar after Water Level

90Cusec

TMA

1 Kotli behram 1.50 140 0.88 0.78

2 Khagara Darbar (Kashmir Road) 1.50 120 0.88 0.78

3 Model Town Tanky 1.50 140 1.08 0.88

4 Model town capital road 1.50 130 0.98 0.78

5 Mubarik pura 1.50 150 1.27 0.98

6 Noor pura Hakeem Khadim Ali road 1.50 130 1.47 0.98

7 Nasir road 1.50 130 1.27 0.98

8 Roadas Road Makki Masjid 1.50 120 0.88 0.74

9 Pak pura 1.50 120 1.23 0.78

10 PremNagarAbetroad 1.50 120 1.47 0.98

11 Poran Nagar Gali No 3 1.50 135 1.27 0.98

12 Muhammad Pura Tanky 1.50 135 1.23 0.78

13 Anwar Club 1.50 120 0.88 0.78

14 Shah Saidan school 1.50 120 1.08 0.88

15 Taj Pura 1.50 130 0.88 0.88

16 Daraarayan 1.50 130 0.88 0.78

17 College Road 1.50 130 1.32 0.78

18 Raja road 1.50 130 1.08 0.88

19 Islam pura near mosque 1.50 130 1.18 0.98

20 ZafarAbad 1.50 130 0.98 0.88

21 Rang pura New Pir Bashir 1.50 120 1.13 0.98

22 Rangpora Ban Pura 1.50 160 1.08 0.49

23 Rangpora Barian Lambian Pura 1.50 130 1.47 0.98

24 Rangpora Awanan Pura 1.50 130 1.08 0.69

25 Islaam Abad 1.50 130 1.08 0.88

26 Tiba Kakey Zaian Qabrastan 1.50 130 1.08 0.88

27 Habib pura Aman Abad 1.50 135 0.98 0.83

28 Habib pura Chugain 1.50 130 1.18 0.93

29 Chah gondlan 1.50 130 0.69 0.59

30 Shahab Pura Tanky 1.50 130 1.08 0.78

31 Haji pura Mai sabran 1.50 140 1.08 0.69

32 Kotli Loharan East 1.00 120 0.69 0.49

TMA Total: 47.5 34.76 26.5

PHED

1 Ahahta Water Works No 1 1.50 200 0.98 0.69

2 Ahahta Water Works No 4 1.50 200 0.98 0.49

PHED Total: 3.00 1.96 1.18

CANTT

3 Fire Brigade Station Ward No. 5, Sadar

2.00 150 1.37 0.83

Total: 52.50 38.21 28.51




Page 16

Fig 11-1, 11-2, 11-3 and 11.4 are showing the prominent decrease of water availability expected during next year due to depleted ground water level Figure 11-1: TMA Tube wells Present and Next Year Discharge

Figure 11-2: Remaining TMA Tubewells Present and Next Year Discharge

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 27 28 30 31 32 33 34 35 36

Flow at 1.5 Bar 2Flow at 1.5 Bar after Water Level 90 2Present AverageNext Year Average

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

37 38 39 40 41 42 45 46 47 48 49 50 51 52 53 54 55 56 58 59 60 61 62 63 64 65 66 67 69 70 71 72

Flow at 1.5 Bar 2 Flow at 1.5 Bar after Water Level 90 2

Present Average Next Year Average




Page 17

Figure 11-3: PHED Tube wells Present and Next Year Discharge

Figure 11-4: Cantt Board Tube wells Present and Next Year Discharge

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 26



0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

2.20

1 2 3 4 5 6 7 8 9 10 11 13 14 15




Section 12 Electricity Analysis


Page 18

12.0 ELECTRICITY ANALYSIS

During Survey Power Factor (ratio of the actual power consumed by the equipment to the power supplied to the equipment) measured, Motor rating and Motor Control Units (MCU5) were also analyzed to make the clear picture of electricity consumption behavior. In our studies, we are also providing the current power factor of the individual site to find out the energy saving potential.

Table 12-1 & Table 12-2 represents the present capability against working hours and the total outflow that is 152,360 M3 with an average input of 4.8 M3/KW Table 12-1: Present consumption of Electricity

Pump in Operation

Area Operational

Capacity

Actual Power Input

Actual Present Discharge

at 1.5 Bar

Present Consumption per

cusec

Nrs Design Cusecs

kW Cusec kW

Cantt 13 20 398 22.25 17.88 PHED 19 28.5 613.60 29.97 20.47 TMA 66 98 1,566.40 68.24 22.96 Disposal 1 3 16.50 03.00 05.50 Grand Total: 99 149.5 2,594.64 123.46

Table 12-2: Position of total Discharge per kW consumed

Area DOH Output M3 Input KW M3/KW

Cantt 8 18,156 3,184 5.70

PHED 13 39,740 7,977 4.98

TMA 13 90,486 20,363 4.44

Disposal 13 3,978 215 18.55

Grand Total: 152,360 31,738 4.80

12.1 Energy Trend with Depleting Water Level

The water level in the area is depleting rapidly and at some places it is already more than 80 Ft which is a real alarming situation. Although, last monsoon heavy rainfall affected the conditions positively but it will not be the same for a long time and we are afraid that the water level in the area is expected to reach at 80-90 Ft in the coming summer. Then the overall condition will be as under. Table 12-3 & Table 12-4 says that with the above mentioned impact and working hours the total discharge will be 18% reduced to 125,046 M3 with an average input of 3.94 M3/ KW




Page 19

Table 12-3: Next Year Position after 80-90 Ft Water Level

Pump in Operation

Area Operational

Capacity

Expected Power Input

Expected discharge in 1-2 Years at 1.5 Bar

Estimated Consumption per

cusec

Nrs Design Cusecs

kW Cusec kW

Cantt 13 20 398 20.09 18.45 PHED 19 28.5 613.60 26.46 23.19 TMA 66 98 1,566.40 52.48 29.85 Disposal 1 3 16.50 3.00 5.50 Grand Total 99 149.5 2,621.64 103.51

Table 12-4: Next Year Position of Discharge per kW consumed

Area DOH Output M3 Input KW M

3/KW

Cantt 8 16,393 3,184 5.15

PHED 13 35,086 7,977 4.40

TMA 13 69,588 20,363 3.42

Disposal 13 3,978 215 18.55

Grand Total 125,046 31,739 3.94

12.1.1 Recommendation regarding Electricity

Losses due to voltage fluctuations, poor power factor, throttling of pumps, in-efficient motors or inadequate motor sizes can be curbed by improving power factor with the help of capacitors, trimming of impellers where heads are high and installation of correctly sized motors (individual recommendations are in the relevant annexure and detail is in the Energy management plan)

12.1.2 Energy Behavior after implementation of recommendations

By equalizing the pumps behavior the overall reduction in the electr icity can be achieved which also optimize the output from the individual pump while operating in the system. The more conservation can be achieved by load management that is switching off the pumps when they are not needed after analyzing the required pressure with the help of pressure gauges at all sites. Table 12-5: Expected performance of the pumps after Implementation of

Recommendations.

Pump in Operation

Area Operational

Capacity

Power input required

after Adjustment

Output Flow in 1- 2 Years at 1.8 Bar

Estimated Consumption

per cusec

Nrs Design Cusecs kW Cusec kW

Cantt 13 20 349.18 20.0 17.46 PHED 19 28.5 497.58 28.5 17.46 TMA 66 98 1,710.99 98.0 17.46 Disposal 1 3 11.97 3.0 3.99 Grand Total 99 149.5 2,587.18 149.5

Table 12-6; Position of Discharge per kW consumed after Implementation of

Recommendations

DOH M3 KW M3/KW

Cantt 8 17,136 2,933 5.84

PHED 13 37,791 6,469 5.84

TMA 13 129,948 22,243 5.84

Disposal 13 3,978 156 25.56

Grand Total: 188,853 31,800 5.94




Page 20

Only the advised modification, of replacing low head pumps and decreasing the pressure of high head pumps, will reduce the 33% energy consumption per M3 and the system will be capable to produce 5.94 M3/kW instead of 3.94 M3/ kW. Figure 12-1 shows the discharge trend of operational pumps with Vs without implementation of recommendations Figure 12-1: Future Discharge Trend in Graphical Form

12.2 Energy Consumption Analysis

As per site observations and measurement, energy consumption is found high in the following pumps due to specific reasons in which more prominent encountered was inappropriate designing and low efficiency.

Table 12-7: Extraordinary Energy Consumption

Tube Well No.

Tube well Name Year of

Installation

Energy Cost Difference

with a Suitable pump Rs. '000

Reason

TMA

3 Muzafar Pur (Grave Yard) 2003 194 low design head / In Efficient

9 Mubarik pura 1998 225 Degraded / In Efficient

11 Nasir road 1992 421 low design head / Worn out

12 Roadas Road Makki Masjid 1991 143 low design head / Worn out

15 Prem Nagar Abet road 1986 291 low design head / Worn out

19 Anwar Club 1999 317 low design head / Worn out

22 Daraarayan 1972 175 low design head/Worn out

30 Islam pura near mosque 1997 248 low design head / Worn out

34 Ahmad Pura Naya 2008 184 low design head / In Efficient

35 Rang pura New Pir Bashir 1995 208 low design head / Worn out

37 Rangpora Ban Pura 1995 114 Degraded / In Efficient

42 Haji Pura near Kothi school 2003 548 High design head

45 Islaam Abad 2005 118 low design head / In Efficient

52 Habib pura Aman Abad 2003 410 low design head

53 Habib pura Chugain 1997 279 low design head / Worn out

54 Amam Sahib Number 2 1995 237 low design head / Worn out

55 Chah gondlan 1997 412 low design head / Worn out

58 Saraie Bahabrian No 1 2003 435 High design head / In Efficient

64 Haji pura Bin No 1 1982 464 low design head / Worn out

69 Fatheh Garh graveyard 1988 128 low design head / Worn out

70 Fatheh Garh omer town 2004 288 High design head / In Efficient

72 Kotli Loha ran East 354 low design head / Worn out

Total TMA: 6,193

0

20

40

60

80

100

120

140

160

Present Next Year After Implementation

Discharge of Water from Operational Pumps

Disposal

TMA

PHED

Cantt




Page 21

PHED

1 Islamia Park 2009 340 High design head / In Efficient

2 Ahahta Water Works No 1 2009 119 High design head / In Efficient

3 Ahahta Water Works No 4 2009 199 High design head / In Efficient

5 Shabudin Park 2009 703 High design head / In Efficient

7 Haji pura bin no 2 2009 613 High design head / In Efficient

8 Muzafar Pur defence road 2009 381 High design head / In Efficient

9 Roaras road Burna sports 2009 286 In Efficient / In Efficient

10 Namiana pura Qabrastan 2009 518 High design head / In Efficient

11 Raamtalli 2009 311 High design head / In Efficient

12 Shah China 2009 567 High design head / In Efficient

13 Behar Colony 2009 371 High design head / In Efficient

14 Fatheh Garh Dara arayan tanky 2009 664 High design head / In Efficient

15 Shjah Abad No 3 2009 803 High design head / In Efficient

16 Rangpura lanky 2009 319 High design head / In Efficient

17 Chahtar Khanan 2009 241 High design head / In Efficient

18 Tehseel Bazar 2009 418 High design head / In Efficient

19 Ghod pur road 2009 385 High design head / In Efficient

Total PHED: 7,238

CANTT

1 Fire Brigade Station 1980 168 Degraded / Worn out

3 Near Jamia Masjid 1990 216 Worn out / In Efficient

4 Mirza Abdur Rauf Road 1983 206 Degraded / Worn out

5 Mohallah Qasab road 1993 317 Worn out / In Efficient

6 Iqbal Colony Ghazi Pur Road 1983 257 Degraded / Worn out

7 Pakistan Chowk - 1994 404 Worn out / In Efficient

9 Regement Bazar - 1994 236 Worn out / In Efficient

11 Askari Coloney No.1 - 1996 360 High design head / In Efficient

13 Tariq Road Ward No.7 - 2007 349 High design head / In Efficient

14 Qasim road near Church - 2007 227 Worn out / In Efficient

Total Cantt: 2,740

Disposal Station

1 Model Town Disposal Station 218 Worn out / In Efficient

12.2.1 Recommendations against Extra Energy Consumption Tubewells.

Following pumps are consuming extraordinary excess energy amounting Rs. 16

Mio. Per annum, and are required to be adjusted / refurbished / redesigned / and

replaced as recommended in the individual datasheet of the respective pump in

Annex

Figure 12-2: Energy Saving Potential:

TMA, 6193

PHED, 7238

Cantt Board, 2740

Disposal, 218

TMA

PHED

Cantt Board

Disposal




Page 22

12.3 Power Factor on Site Power factor correction saves money, reduces power bills by minimizing losses in conductors in return lessen loading on transformers which improve voltage drops too. PF below 0.9 is considered low and indicates the potential for savings. When PF is .085 or below, as is the case looking hereunder, losses are significant. If PF is less than 0.95 or specified limit over the billing period, generally penalty of the difference of power factor from 1 is charged in the bill amount, because it is mandatory to maintain PF to the specified limit. Improving PF above the specified limit is useful for conservation of electricity.

Table 12-8: Power Factor of TMA Pumps

Tube

Well

No.

Area Tube well Name Power

Factor

Expected

Annual Penalty

in Rs'OOO

1 TMA Mohallah Cheela Pura 0.84 191

2 TMA Naya mayana Pura Near Kothi Mian Saeed 0.84 191

3 TMA Muzafar Pur (Grave Yard) 0.84 191

4 TMA Kotli behram 0.93 35

5 TMA Khagara Darbar (Kashmir Road) 0.93 35

6 TMA Model Town Tanky 0.83 209

7 TMA Model Town Muradia road 0.78 296

8 TMA Model town capital road 0.75 348

9 TMA Mubarik pura 0.91 70

10 TMA Noor pura Hakeem Khadim Ali road 0.82 226

11 TMA Nasir road 0.81 244

12 TMA Roadas Road Makki Masjid 0.6 609

13 TMA Pak pura 0.91 70

15 TMA Prem Nagar Abet road 0.88 122

16 TMA Poran Nagar Gali No 3 0.88 122

17 TMA MuhammadPuraTanky 0.84 191

18 TMA Nishat park paris road 0.91 70

19 TMA Anwar Club 0.81 244

20 TMA Shah Saidan school 0.81 244

21 TMA Taj Pura 0.87 139

22 TMA Dara arayan 0.76 331

23 TMA Green Town Street 0.83 209

24 TMA Bara-e- Qilla Darbar pir muradia 0.83 209

25 TMA College Road 0.94 17

27 TMA Raja road 0.82 226

28 TMA Maha Raja road 0.8 261

30 TMA Islam pura near mosque 0.86 157

31 TMA Shah Khaki Wali 0.85 174

32 TMA ZafarAbad 0.82 226

33 TMA Amanat Pura 0.87 139

34 TMA Ahmad Pura Naya 0.78 296

35 TMA Rang pura New Pir Bashir 0.86 157

36 TMA RangpuraSaheenPura 0.74 365

37 TMA Rangpora Ban Pura 0.75 348

38 TMA Rangpora Barian Lambian Pura 0.91 70

39 TMA Rangpora Awanan Pura 0.81 244




Page 23

Tube

Well

No.


Factor

Expected

Annual Penalty

in Rs'OOO

40 TMA Neqa pora Kocha Shaikan 0.88 122

41 TMA Neqa pora shah deena 0.88 122

42 TMA Haji Pura near Kothi school 0.92 52

45 TMA lslaam Abad 0.84 191

46 TMA Haider Park 0.82 226

47 TMA Tiba Kakey Zaian Qabrastan 0.87 139

48 TMA Kashmiri Mohallah 0.92 52

49 TMA BabeyBairey 0.71 418

50 TMA Babey Bairey mohallah Khamaran 0.66 505

51 TMA Babey Bairey Alshamas street 0.8 261

52 TMA Habib pura Aman Abad 0.89 104

53 TMA Habib pura Chugain 0.83 209

54 TMA Amam Sahib Number 2 0.79 278

55 TMA Chah gond lan 0.85 174

56 TMA Shawala Park no 1 0.84 191

58 TMA Saraie Bahabrian No 1 0.89 104

59 TMA Saraie Bahabrian near Ahmadia school 0.89 104

60 TMA ShahabPuralanky 0.82 226

61 TMA Shahab Pura near Darbar 0.88 122

62 TMA Shah Monga Wali 0.79 278

63 TMA Factory Area 0.8 261

64 TMA Haji pura Bin No 1 0.82 226

65 TMA Haji pura Mai sabran 0.87 139

66 TMA Kacha Shahab road Marian wala 0.99 0

67 TMA Ghos pura tanky 0.89 104

69 TMA Fatheh Garh graveyard 0.84 191

70 TMA FathehGarhomertown 0.78 197

71 TMA Fatheh Garh agency chowk 0.78 296

72 TMA Kotli Loharan East 0.63 371

73 TMA Kotli Loharan West 0.71 418

Total TMA: 13,355

Table 12-9: Power Factor of PHED Pumps

Tube

Well No.

Area Tube well Name Power Factor

Expected Annual Penalty

in Rs'OOO

1 PHED Islamia Park 0.84 191

2 PHED Ahahta Water Works No 1 0.86 157

3 PHED Ahahta Water Works No 4 0.81 244

4 PHED Muhammad Pura Kanga Bebian 0.84 191

5 PHED Shabudin Park 0.89 104

7 PHED Haji pura bin no 2 0.79 278

8 PHED Muzafar Pur defence road 0.82 226 9 PHED Roarasroad Burnasports 0.83 209

10 PHED Namiana pura Qabrastan 0.81 244

11 PHED Raamtalli 0.78 296

12 PHED Shah China 0.79 278

13 PHED Behar Colony 0.82 226

14 PHED Fatheh Garh Dara arayan tanky 0.84 191

15 PHED Shjah Abad No 3 0.84 191

16 PHED Rangpura lanky 0.85 174

17 PHED Chahtar Khanan 0.93 35

18 PHED Tehseel Bazar 0.86 157

19 PHED Ghod pur road 0.85 174

26 PHED Bohri Muhallah 0.85 174

Total PHED: 3,740




Page 24

Table 12-10: Power Factor of Cantt Pumps

Sr # Area Tube well Name Power Factor


in Rs'OOO

1 Cantt Fire Brigade Station Ward No. 5, Sadar 0.89 86

2 Cantt Jinnah High School Ward No. 5, Sadar - 0.83 128

3 Cantt Near Jamia Masjid Ward No.5, Sadar - 0.93 21

4 Cantt Mirza Abdur Rauf Road Ward No.4, Sadar - 0.93 29

5 Cantt Mohallah Qasab road Ward No.6, Sadar- 0.88 75

6 Cantt lqbal Colony Ghazi Pur Road Ward No.6, Sadar 0.73 314

7 Cantt Pakistan Chowk - 0.82 139 9 Cantt Regement Bazar near Cantonment Area - 0.9 54

10 Cantt Lalkurti Bazar - 0.96 0

11 Cantt Askari Coloney No.1 - 0.83 86

13 Cantt lar iq Road Ward No.7 - 0.82 93

14 Cantt QasimroadnearChurchNo.12- 0.77 193

15 Cantt Fazal-e-Qadir Road - 0.76 203

Total Cantt 1,420

Table 12-11: Power Factor of Disposal Pumps

Sr. No.


Factor


in Rs'OOO

1 Disposal Model Town Disposal Station 0.72 183

Figure 12-3: Detail of Power Factor and Expected Annual Penalty

12.3.1 Recommendation for Improving Power Factor:

To improve power factor, Capacitors of relevant sizes are advised. Capacitors supply,

for free, the reactive energy required by inductive load. Capacitors size can easily be

calculated by applying mathematical formulas

12.4 Important to understand Energy Cost

Understanding energy cost is imperative for awareness purpose but it cannot be translated in the form of calculating numbers from the electricity bills.

TMA, 13355

PHED, 3740

Cantt, 1420

Disposal, 183

TMA

PHED

Cantt

Disposal




Page 25

Energy efficiency savings can therefore be realized even with increased flows (for example, a municipal water utility being able to provide water service for poor urban inhabitants or expand the hours during which water is available), reduction of non operating hours or regular water availability through the system thus total energy consumption may increase but service will also increase and get better. The pressure on water and energy resources is growing rapidly due to a increased demand of potable water, unplanned growth of cities and on the other hand inefficiencies prevailing throughout the municipal water utilities. It is also possible that despite, reducing energy consumption of particular unit, overall energy consumption may increase, but service will also be increased and improved in many folds by giving benefit to all inhabitants of the city. Keeping in view the potential demand for affordable, clean water in the context of sustainable rehabilitation of infrastructure, the advised recommendations will assume that any increase in water delivered is simply meeting that enhanced demand. The increased demand would have needed new tube wells for meeting basic service requirement, but after implementing the advised proposals if the demand of more tube wells is not realized, it is also the form of saving investment and energy as well. Therefore, energy savings in municipal utilities can never always be interpreted in the form of reducing electricity bills but can be gauged by the satisfaction of the end user and reduction for the requirement of new water schemes by making old tube wells more productive. This assertion is based on a thorough review of the design of the pumps, their behavior, fieldwork with municipalities, measuring necessary parameter with the help of gadgets and then making inferences on that screened data in the background of utilities infrastructure


Section 13 Energy Management Plan


Page 26

13.0 ENERGY MANAGEMENT PLAN

On the basis of factual data collected during site survey in the context of site condition some inferences are drawn which are leading us towards some recommendations for energy management going to be proved the strong ground for taking some measures in order to conserve the resources.

13.1 ECO 1: Improved Motor Control Panels

Flow of electricity should be inspected for its continuous flow to make all wells operative along with the power factor improvement. Power factor is the ratio of working power to apparent power. It measures how effectively electrical power is being used. Electrical equipments require the formation of a magnetic field to operate transformer applications. It contribute to the total power consumed but does not put in to the total power. A high power factor ensures efficient utilization of electrical power, while a low power factor indicates poor utilization of electrical power. Inductive loads like transformers, electric motors, and lighting may cause a low power factor. PF is thus a general measure of efficiency for electrical equipments. The PF ratio is commonly expressed in percentage, PF of 0.95, means that only 5% of the power drawn is reactive and thus not useful. Although it is quite common, a PF below 0.9 is considered low and indicates the potential for savings. When PF is 0.85 or below, as is the cases in Pakistan like other developing countries, losses are significant. If PF is less than 0.95 or specified limit over the billing period, generally penalty of the difference of power factor from 1 is charged in the bill amount, because it is mandatory to maintain PF to the specified limit. Improving PF above the specified limit is useful for conservation of electricity. Thus PF can be improved without casting any adverse effect on motors but would decrease the electricity consumption .

13.1.1 Recommendations:

Capacitors bring the PF to a higher level would increase the ratio of useful power to total power and would yield substantial improvements in overall electrical efficiency. PF improvement will eliminate the penalty and reduce the electricity bill of TMA, PHED and Cantt Board Tube wells upto 12% which will cause the saving of approx. Rs. 18 Mio per annum

13.2 ECO 2: Awareness Raising And Education

Awareness and training programs can provide considerable potential for energy savings. Staff should be given trainings as practical tools to promote energy literacy and encouraging action for learning right way of operating installed machines as per site conditions and requirement.




Page 27

Awareness raising and education for the best practices of utility operations is as important to the municipal utility sector as the investment at the initial time is counting essential. Operator behaviour can have a significant effect on the effectiveness of energy efficiency measures. During the off peak hours when the demand reduces, the system pressure increases. This aspect can easily be monitored by installing pressure gauges on the delivery pipe. Simply turning off equipment when it is not substantially adding into the system at the time of already high existing pressure in the system especially at off-peak hours can provide an easy way of saving both energy and money.


The operators should be instructed for switching off their respective pumps when the system pressure increases from a certain limit. This limit can be given after studying the area topography. Generally it should be 1.5 to 2 Bar. If the system pressure is already 1.5 to 2 Bar then there is no need to switch on another pump. Switching off the pumps, when there is no system requirement, will help in saving up to 5%. The workshops or training sessions can be conducted by the department or at the premises of equipment manufacturer just with the investment of t ime and should be considered a pre-requisite at the induction time of the operating staff.

13.3 ECO3: Minimizing Voltage Unbalances

A voltage unbalance degrades the performance and shortens the life of three-phase motors. A voltage unbalance causes a current unbalance, which will result in torque pulsations, increased vibration and mechanical stress, increased losses, and motor overheating, which can reduce the life of a motor's winding insulation. Voltage unbalances may be caused by faulty operation of power factor correction equipment, an unbalanced transformer bank, or an open circuit. A rule of thumb is that the voltage unbalance at the motor terminals should not exceed 1% although even a 1% unbalance will reduce motor efficiency at part load operation. A 2.5% unbalance will reduce motor efficiency at full load operation. The voltage unbalance in the Sialkot lies between 2% to 5%.


By regularly monitoring the voltages at the motor terminal and through regular thermo graphic inspections of motors, voltage unbalances may be identified. It is




Page 28

also recommended to verify that single-phase loads are uniformly distributed and to install ground fault indicators as required

13.4 ECO 4: Adequate Maintenance

Inadequate maintenance causes pumps to wear out quickly which lowers pump system efficiency and increases power requirement and in turn energy cost. Better maintenance will reduce these problems and save energy. A simple maintenance program to ensure that all components of the equipment are operating well at peak performance can result in substantial savings. On average the possible energy savings are estimated at 10% with an average payback time of 1-2 Months. Proper maintenance of Deepwell Turbine pumps includes the following, Replacement of worn impellers. Column Shafts Bearing inspection and

repair. Inspection and replacement of Gland

packing. Pump/motor alignment check. The largest opportunity is usually to avoid throttling losses. Motor Bearing lubrication replacement, once annually or semi annually. Any pump optimization project provides an opportunity to update operation and maintenance practices. Vibration analysis can determine if problems are developing in the pump or motor bearings. Vibration and various electrical test methods can evaluate the motor stator and rotor health. Where oil lubrication is used, oil analysis can indicate bearing condition. Routine maintenance, such as valve overhauls, heat exchanger cleaning, and mechanical joint repair, can further improve system efficiencies

13.5 ECO 5: Monitoring Monitoring in conjunction with operations and maintenance can be used to detect problemsand determine solutions to create a more efficient system. Monitoring can determine clearances that need to be adjusted, indicate blockage, impeller damage, inadequate suction, operation outside preferences, clogged pumps or pipes, or worn out pumps.




Page 29

Monitoring should include: Wear monitoring Vibration analyses Pressure and flow monitoring Current or power monitoring Differential head and temperature rise Distribution system inspection for

contaminant build-up 13.5.1 Recommendations

Recommended necessary gadget to be installed on each site includes. 1) Pressure Gauges in the quantity of 2 Nos with Ball Valve to cut off. One

between discharge head and Sluice Valve and one after sluice Valve 2) Flow Meter in the quantity of 1 No on line 3) Ampere Meter in the quantity of 1 No with Selector Switch. 4) Volt Meter in the quantity of 1 No with Selector Switch. 5) Water Level Sensor in the quantity of1 No. along with dry Running Protection

Device

13.6 ECO 6: Adequate Design Parameters

Defining correct design parameters is the essence of least energy cost. These parameters include the duty point that is flow rate and head, column setting, diameters of the column pipes, minimum required efficiency of the pump and motor and the correct size of the motor. For optimum operation in the municipalities where direct pumping is involved, the pressure head at the ground level should be between 1.5 to 2.5 bar depending on the performance parameters of the utility provider and topography of the area to be served. It has been observed during the survey that pumps with the head varying from 120 to 250 Feet have been installed in the same zone which cannot contribute the required flow as was calculated in the very beginning.


It is recommended that pumps of same head should be installed in a system. With the depleting water level in the area it is observed that current pumping water level is 70-80 ft which is expected to be going further down so leads to starvation. So it is strongly recommended to increase the column length of all the Tube wells installed in the Sialkot to enable them keep operative in future.




Page 30

It is further recommended that the housing length of the new drilled Tube wells should also be increased from 120 Ft to 150 Ft for new boreholes. Following design parameters are also being recommended for Pumps to be installed. Capacity ------ 1.5 Cusecs Head ----------- 150 Ft Column Setting 110 Ft Motor Rating - 4OHP These advised specifications are applicable for all sites except elevated areas

13.7 ECO 7: Preventing Throttling Of Pumps

During operation, should motor gets overloaded, normally field officer resorts to throttling of pump to avoid overloading of motor. Due to throttling, operating point is shifted which though prevented overloading of the motor, but the discharge is also reduced resulting in operation for more number of pumping hours to meet the same demand and therefore, results in increase in energy consumption. The operation is also generally at low efficiency and consequently cause increased energy cost. Hence, such throttled operation should be avoided. Trimming of the impeller's diameter or reduction of pump speed will shift the operating point which in turn reduces the amount of energy imparted to the pumped fluid; as a result, the pump's flow rate and pressure both decreases. A smaller or trimmed impeller can thus be used efficiently in applications in which the current impeller is consuming extra energy. If the impeller is trimmed by the relationship given in reliable books on pumps can serve the same purpose and can prevent the overloading of motor with the less power requirement corresponding to throttled operation. In the Sialkot City Cantt Area tube wells are being throttled by installing relatively smaller diameter delivery pipes. In all the cases, 6 inch diameter pipe line has been used for 1.5 and 2 Cusec pumps which is adding unnecessary resistance to flow and which should be avoided .

13.8 ECO 8: Procurement of Right Pumps Pump efficiency may degrade 10% to 25% in its lifetime. Industry experts however point out that this degrading performance is not necessarily due to the aging of the pump but can also be caused by variation in the site parameters which may have caused a mismatch between the pump capacity and its site requirement. Nevertheless, it can sometimes be more effective to buy a new suitable pump instead of keep on operating a wrongly selected pump.




Page 31

A number of pumps are available for specific pressure head and flow rate capacity requirements. Choosing the right pump often saves both in operating costs and in capital costs. Better understanding of site parameters and operating conditions can leads towards the better definition of design parameters and eventually procurement of right product. A pump may be incorrectly sized for current needs if it operates under throttled conditions, has high re-circulated flow rate, or has a flow rate that varies more than 30% from its best efficiency point flow rate. Where peak loads can be reduced, pump size can also be reduced. A smaller motor will however not always result in energy savings, as these depend on the load of the motor. Only if the larger motor operates at a low efficiency, replacement may result in energy savings. Pump loads may be reduced with alternative pump configurations and improved operations and management practices. When pumps are dramatically oversized, speed can be reduced with gear or belt drives or a slower speed motor. This practice, however, is not common. Paybacks for implementing these solutions are less than one year. Oversized and throttled pumps that produce excess pressure are excellent candidates for impeller replacement or "trimming," to save energy and reduce costs. Correcting for pump over sizing can save 15% to 25% of electricity consumption for pumping equipment. Oversized multistage pumps with high pressure can also be corrected by reduction of stages of keeping one or 2 stages blind (without impellers). Undersized pumps are even more inefficient than the oversized pumps. The pumps with low pressure output are not capable of delivering in the system. Undersized pumps can be corrected by changing of impellers where possible or increase of speed, or replacement of pumps with other suitable pumps. In the Sialkot area all the pumps installed with 120, 130, 135, 140 Ft head are required to be replaced with the pumps of 150 Ft Head.3. All the pumps installed with 200 and 250 Ft head are required to be adjusted for 150 Ft head.

13.9 ECO 09: Proper Distribution System

Pipes and fittings (Valves, reducers, bends) must be sized correctly for optimal performance and for less friction loss in the system. Inadequate pipe sizing can cause pressure losses, increase leaks and increase generating costs Proper Distribution system not only enhance the reliability of the system abut also reduces annual energy consumption by 10-15%. Study of Distributions system is not part of our project.




Page 32

13.10 ECO 10: Energy Savings in Electric Motors Electric motors installed to operate the pumping machinery represent a significant opportunity for financial savings from energy consumption. One motor is count more efficient than other when it uses less energy to produce the same rated output. It is all due to construction using high quality materials and advance manufacturing techniques and therefore, results in less vibration, noise and heat. Special emphasis should be laid at the time of selection of motors, below areas offer potential savings. 1) Correctly sized motors 2) Energy efficiency of the motors 3) Regular maintenance


These regulatory measures offer the potential for long-term savings, although are unlikely to result in wide scale energy reductions in the short term as they are mostly subjected to future purchases, which may be made five to ten years in the future. 1) In Pakistan the motors being used are following EFF3 class as a practice or

EFF2 class rarely these can be replaced with the EFF1 class motors (EFF1 constructed with better quality material)

2) Motors should be serviced periodically to ensure that: Components are greased properly. Operating at peak performance as recommended by the manufacturer. Identify areas of wear or damage before the performance of the motor is

degraded Electric motors failure relates to the fault in the stator wire, in this situation

rewinding usually repairs the motors but degrades their efficiency and productivity.


Section 14 Conclusion


Page 33

14.0 CONCLUSION

As water and electricity both are considered two critical resources for sustainable economical growth and needed to be conserved, especially when municipalities waste these resources unnecessarily at the same time when several are deprived of. Energy audit can provide a viable advantage on operating expenses and enhance the life of the equipment as well. The overall energy consumption of a water supply system is a vital portion of operating authorities' budgets. For water systems owned and operated by the local municipalities, taxpayers bear the burden of unnecessary operating expenses. To focus on real energy savings within the utility, it is important to understand the pumping system network. Knowing the true system requirements at peak and non-peak loads and understanding the benefits of efficiency for the pump and motor play key roles in minimizing energy consumption. If we ensure power factor is improved, motors and motor controls are replaced with efficient ones or newly installed where required, more efficient and properly sized pumps are procured, maintenance is carried out in more efficient, holistic , proactive approach, monitoring is being done for pressure, leakages, line losses, system deterioration and operators are given trainings for correct operation methodology. The savings are confirmed and can be used by municipalities to improve and expand their services.


Annexure 1 Summary of Site Data


Page 34

ANNEXURE 1: SUMMARY OF SITE DATA

Sr

#

Are

a

Tu

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Nam

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Inst

alla

tio

n

Re-

bo

re

Hea

d (

Ft)

Cap

acit

y (

Cu

sec)

Po

wer

Inp

ut

(kW

)

Des

ign

inp

ut

(kW

)

Ap

par

ent

Rem

arks

Act

ual

hea

d

Act

ual

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2

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8 -2

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and

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150

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2

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ut

req

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150

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um

p

En

erg

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ost

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fere

nce

wit

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Su

itab

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um

p

Mo

tor(

HP

)

Man

ufa

ctu

rer

Bo

re D

epth

(F

t)

Ho

usi

ng

Len

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(F

t)

Str

ain

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eng

th (

Ft)

Blin

d P

ipe

Len

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(F

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Pre

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mp

s

1 TMA Mohallah Cheela Pura Muzafar Pur 1988 2002 170 1.5 23.5 30.44 Pump Under performing 38.72 127 150 1.47 1.4 47 140 1.37 110 1.08 153 1.50 26.19 (180) 40 KSB 550 120 128 200 Working 2 TMA Naya mayana Pura Near Kothi Mian Saeed Muzafar Pur 1990 2002 130 1.5 19.1 23.28 Pump Under performing 34.92 115 120 1.18 1 33 80 0.78 0 0.00 153 1.50 26.19 (132) 40 KSB 450 120 128 200 Working 3 TMA Muzafar Pur (Grave Yard) Muzafar Pur 2003

130 1.5 24 23.28 Seems ok 29.31 96 120 1.18 0.6 20 0 0.00 0 0.00 153 1.50 26.19 194 40 KSB 450 120 120 210 Working

4 TMA Kotli behram Kotli Behram 1982 - 140 1.5 22.6 25.07 Pump Under performing 33.45 110 160 1.57 1 33 90 0.88 80 0.78 153 1.50 26.19 (354) 40 KSB 400 120 120 160 Working 5 TMA Khagara Darbar (Kashmir Road) Kotli Behram 1988 - 120 1.5 22.8 21.49 Seems ok 34.96 115 150 1.47 1 33 90 0.88 80 0.78 153 1.50 26.19 (227) 40 KSB 400 120 120 158 Working 6 TMA Model Town Tanky Model Town 1991 2002 140 1.5 23 25.07 Seems ok 34.46 113 150 1.47 1.1 37 110 1.08 90 0.88 153 1.50 26.19 (213) 40 KSB 450 120 120 208 Working 7 TMA Model Town Muradia road Model Town 1992 2001 140 1.5 21.3 25.07 Pump Under performing 38.51 126 120 1.18 1.8 60 135 1.32 120 1.18 153 1.50 26.19 14 40 KSB 400 120 120 160 Working 8 TMA Model town capital road Model Town

2000 130 1.5 16.9 23.28 Pump Under performing 34.3 113 110 1.08 1 33 100 0.98 80 0.78 153 1.50 26.19 (165) 40 KSB 500 120 128 250 Working

9 TMA Mubarik pura Model Town 1998 2004 150 1.5 27.9 26.86 Seems ok 34.96 115 140 1.37 1.3 44 130 1.27 100 0.98 153 1.50 26.19 225 40 KSB 500 120 128 250 Working 10 TMA Noor pura Hakeem Khadim Ali road Model Town 2003

130 1.5 22.3 23.28 Seems ok 38.02 125 140 1.37 1.6 54 150 1.47 100 0.98 153 1.50 26.19 (147) 40 KSB 500 120 128 250 Working

11 TMA Nasir road Model Town 1992 - 130 1.5 18.1 23.28 Pump Under performing 43.67 143 100 0.98 1.8 60 130 1.27 100 0.98 153 1.50 26.19 421 40 KSB 450 120 120 208 Working 12 TMA Roadas Road Makki Masjid Model Town 1991 - 120 1.5 24 21.49 Consuming excess power 38.47 126 90 0.88 1.5 50 90 0.88 75 0.74 153 1.50 26.19 143 40 KSB 390 120 120 148 Working 13 TMA Pak pura Water Works 2003


14 TMA Water works workshop Water Works 1997 -

1.5

- Out of Order

50 KSB 400 120 120 160 Not Working Motor Burnt

15 TMA Prem Nagar Abet road Water Works 1986 2004 120 1.5 28.9 21.49 Consuming excess power 38.02 125 140 1.37 1.6 54 150 1.47 100 0.98 153 1.50 26.19 291 40 KSB 500 120 128 250 Working 16 TMA Poran Nagar Gali No 3 Muhammad Pura 2002


17 TMA Muhammad Pura Tanky Muhammad Pura 2002

135 1.5 25.4 24.17 Seems ok 40.08 131 160 1.57 1.5 50 125 1.23 80 0.78 153 1.50 26.19 (168) 40 KSB 500 120 128 250 Working 18 TMA Nishat park paris road Muhammad Pura 1998 - 130 1.5 24 23.28 Seems ok 38.52 126 135 1.32 1.5 50 135 1.32 125 1.23 153 1.50 26.19 16 40 KSB 450 120 120 208 Working 19 TMA Anwar Club Muhammad Pura 1999 - 120 1.5 17.3 21.49 Pump Under performing 42.03 138 70 0.69 2 67 90 0.88 80 0.78 153 1.50 26.19 317 40 KSB 450 120 120 208 Working 20 TMA Shah Saidan school Shah Saidan 2001 - 120 1.5 20.2 21.49 Seems ok 36.96 121 110 1.08 1.5 50 110 1.08 90 0.88 153 1.50 26.19 55 40 KSB 400 120 120 158 Working 21 TMA Taj Pura Shah Saidan 2003

130 1.5 17.2 23.28 Pump Under performing 35.41 116 100 0.98 1.2 40 90 0.88 90 0.88 153 1.50 26.19 (31) 40 KSB 500 120 128 250 Working

22 TMA Dara arayan Shah Saidan 1972 1995 130 1.5 20.3 23.28 Pump Under performing 40.5 133 100 0.98 1.4 47 90 0.88 80 0.78 153 1.50 26.19 175 40 KSB 400 128 120 150 Working 23 TMA Green Town Street Shah Saidan 1980 2004 135 1.5 24.8 24.17 Seems ok 40.06 131 150 1.47 1.5 50 150 1.47 120 1.18 153 1.50 26.19 (95) 40 KSB 400 120 120 158 Working 24 TMA Bara-e- Qilla Darbar pir muradia Kaream Pura 2003

160 1.5 30.4 28.65 Seems ok 48.82 160 155 1.52 1.3 44 130 1.27 100 0.98 153 1.50 26.19 103 50 KSB 450 128 120 200 Working

25 TMA College Road Kaream Pura 2003

130 1.5 23.3 23.28 Seems ok 40.65 133 135 1.32 1.5 50 135 1.32 80 0.78 153 1.50 26.19 (35) 40 KSB 450 120 120 208 Working 26 TMA Bano Bazar Kaream Pura 1995

130 1.5

Out of Order

0.00

40 KSB 400 128 120 150 Not Working Bore Collapsed

27 TMA Raja road Kaream Pura 1996

130 1.5 21.7 23.28 Seems ok 37.99 125 130 1.27 1.3 44 110 1.08 90 0.88 153 1.50 26.19 (73) 40 KSB 400 120 120 158 Working 28 TMA Maha Raja road Kaream Pura 1998


29 TMA Chowk Rang pura Ahmad Pura 2002

130 1.5

Out of Order

0.00

40 KSB 450 128 120 200 Not Working Transformer Fault

30 TMA Islam pura near mosque Ahmad Pura 1997

130 1.5 21.4 23.28 Seems ok 41.84 137 100 0.98 1.8 60 120 1.18 100 0.98 153 1.50 26.19 248 40 KSB 400 128 120 150 Working 31 TMA Shah Khaki Wali Ahmad Pura 2003

130 1.5 28.6 23.28 Consuming excess power 35.59 117 160 1.57 1 33 130 1.27 120 1.18 153 1.50 26.19 44 40 KSB 500 128 120 250 Working

32 TMA Zafar Abad Ahmad Pura 2002

130 1.5 21.2 23.28 Seems ok 38.59 127 120 1.18 1.3 44 100 0.98 90 0.88 153 1.50 26.19 7 40 KSB 450 120 120 208 Working 33 TMA Amanat Pura Ahmad Pura 2008

135 1.5 27.1 24.17 Consuming excess power 41.19 135 155 1.52 1.55 52 155 1.52 120 1.18 153 1.50 26.19 1 40 KSB 500 120 120 258 Working

34 TMA Ahmad Pura Naya Ahmad Pura 2008

135 1.5 30.3 24.17 Consuming excess power 41.12 135 150 1.47 160 5358 140 1.37 120 1.18 153 1.50 26.19 184 40 KSB 500 128 120 250 Working 35 TMA Rang pura New Pir Bashir Hearan 1995

120 1.5 28.8 21.49 Consuming excess power 36.58 120 145 1.42 1.1 37 115 1.13 100 0.98 153 1.50 26.19 208 40 KSB 450 128 120 200 Working

36 TMA Rangpura Saheen Pura Hearan 1996

120 1.5 16.5 21.49 Pump Under performing 30.32 99 110 1.08 0.7 23 75 0.74 0 0.00 153 1.50 26.19 (191) 40 KSB 450 128 120 200 Working 37 TMA Rangpora Ban Pura Hearan 1995

160 1.5 22.8 28.65 Pump Under performing 40.56 133 120 1.18 1.4 47 110 1.08 50 0.49 153 1.50 26.19 114 40 KSB 450 120 120 208 Working

38 TMA Rangpora Barian Lambian Pura Hearan 1981

130 1.5 28.4 23.28 Consuming excess power 37.55 123 170 1.67 1.4 47 150 1.47 100 0.98 153 1.50 26.19 (83) 40 KSB 390 120 120 148 Working


Annexure 1 Summary of Site Data


Page 35

Sr

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33 Energy Audit Report on Tubewells and Sewage Pumping Stations in Sialkot

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