ENERGY MANAGEMENT SERVICES (ENERGY AUDIT) · capacity in renewable energy by 2022, which includes...
Transcript of ENERGY MANAGEMENT SERVICES (ENERGY AUDIT) · capacity in renewable energy by 2022, which includes...
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ENERGY MANAGEMENT SERVICES
(ENERGY AUDIT)
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ABOUT POWER SECTOR
In May 2018, India ranked 4th in the Asia Pacific region out of 25
nations on an index that measures their overall power. India is 3rd
largest producer and 3rd largest consumer of electricity in the
world. India has 5th largest installed capacity in the world.
Total installed capacity of power stations in India stood at
346.05 Gigawatt (GW) as of October 2018.
The government targets capacity addition of around 100 GW under
the 13th Five-Year Plan (2017-22)
Between April 2000 and June 2018, the industry attracted US$
14.18 billion in Foreign Direct Investment (FDI), accounting for 3.64
per cent of total FDI inflows in India. In FY17 it was 1.11 bn US$,
FY18-1.62 bn US$ and in FY19 till June ‘18 it was bn 0.97 US$.
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ROADMAP AHEAD
The Government of India has released its roadmap to achieve 175 GW
capacity in renewable energy by 2022, which includes 100 GW of solar
power and 60 GW of wind power.
The Union Government of India is preparing a 'rent a roof' policy for
supporting its target of generating 40 gigawatts (GW) of power through
solar rooftop projects by 2022.
Coal-based power generation capacity in India, which currently stands at
196.10*GW (*Up to October 2018) is expected to reach 243.86 GW by
2022.
Gas based power capacity measures about 24.94 GW as on October
2018, expecting an addition of 0.41 GW by 2022.
India could become the world's first country to use LEDs for all lighting
needs by 2019, thereby saving Rs 40,000 crore (US$ 6.23 billion) on an
annual basis.
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WHY ENERGY EFFICIENCY & CONSERVATION ?
OBJECTIVE:
The Objective of Energy Management is to achieve & maintain
optimum Energy procurement & utilization, throughout the
organization &
To minimize Energy costs / waste without affecting
production & quality
To minimize Environmental effects.
Energy Audit is the first step in identifying opportunities to Reduce
Energy Expense & Carbon Footprint.
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WHY ENERGY EFFICIENCY & CONSERVATION ?
DEFINITION:
As per the Energy Conservation Act,
Energy Audit is defined as
“The verification, monitoring and analysis of use of energy including
submission of Technical report containing Recommendations for
improving Energy Efficiency with cost benefit analysis and an
Action Plan to reduce Energy consumption".
Types of Energy Audit:
Preliminary Audit
Detailed Audit
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WHY ENERGY EFFICIENCY & CONSERVATION ?
Detailed Energy Auditing is carried out in three phases: Phase I, II
and III.
Phase I - Pre Audit Phase
Phase II - Audit Phase
Phase III - Post Audit Phase
Bureau of Energy Efficiency (BEE) has defined star rating for
Energy Efficiency (3-Star/4-Star/5-Star) to reduce Energy loss,
which in turns reduce energy consumption & reduces Energy bill.
For Residential Equipments like CFL replaced by LED Lights,
Chokes replaced by Electronic Ballasts, AC or Refrigerators now
available with Star Ratings defined by BEE, which are of Higher
Efficiency to reduce Energy Bills.
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ENERGY AUDIT – WATER DISTRIBUTION
All Mechanical Joints like welded joints, valves, etc. from where
leakages possible are considered for area of improvement for
Energy Conservation.
To Reduce these losses, periodic Maintenance to be carried out
to ensure minimum possible leakages in Joints of Pipe Lines.
All Electrical Connections where Loose Connections or Loose
Contacts, there Resistance will be High, which in turn consume
more Power, which shall be considered as area to be focused
considering Energy Conservation.
HT/LT Capacitors not in working condition reduces PF, which in
turn increases Energy Bill & Heavy Penalty on not maintaining
the PF.
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ENERGY AUDIT – WATER DISTRIBUTION
To Reduce these Electrical Losses, periodic maintenance to
be carried out to ensure there shall be no loose Electrical
Connections & all Capacitors shall be in Working Condition.
Thermography of Electrical Connections in 66kV Sub station
shall be done every year to ensure there is no leakage, also
Outdoor Electrical Connections especially Joints shall be
Cleaned properly to reduce Contact Resistance & increase
Efficiency.
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WHY ENERGY EFFICIENCY & CONSERVATION ?
Identification of Energy Conservation Opportunities:
1. Fuel substitution:
Identify the appropriate fuel for Efficient Energy conversion.
Example:
Earlier Big Thermal Power Plants were based upon Coal with
Lower Efficiency & Heavy Pollution, they are replaced now by Gas
based Power Plants to improve Efficiency & reduce Pollution.
2. Energy Generation:
Identify Efficiency opportunities in energy conversion
equipment/utility such as Captive Power Generation.
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WHY ENERGY EFFICIENCY & CONSERVATION ?
Combined Cycle Co-generation Captive Power Plants, with Heat
Recovery Steam Generators (HRSG), which use Process Steam
to Run Steam Turbine.
Green Energy Generation opportunities as per feasibility for Solar
Power, Wind Power, Hydro Power, etc. which in turn reduces
Carbon Foot Print.
3. Energy Distribution:
Identify Efficiency opportunities network such as transformers,
cables, switchgears and power factor improvement in Electrical
Systems.
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WHY ENERGY EFFICIENCY & CONSERVATION ?
TYPES & PRIORITY OF ENERGY SAVING MEASURES:
1) TYPE:A: No Investment (Immediate)
Operational Improvement
Housekeeping
2) TYPE:B: Low Investment (Short to Medium Term)
Controls Equipment Modification
Process Change
3) TYPE:C: High Investment (Long Term)
Energy Efficient Devices
Product modification
Technology Change
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ENERGY EFFICIENCY – ACTION PLAN
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ENERGY AUDIT - METHODOLOGY
Orientation Meeting
Initial Data Collection /
Process Understanding
Field Studies / Observations
Energy Saving Opportunities –
• No / Low Investment (payback upto 6 months)
• Mid Term Investment (payback from 6 to 12 month)
• Long Term Investment (payback beyond 12 months)
Draft Report Submission & Presentation
Final Report Submission
Post Implementation Verification Audit
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WHY ENERGY EFFICIENCY & CONSERVATION ?
ENERGY AUDIT ASSESSMENT AND REPORTING:
S.No. Energy Saving
Recommendations
Annual Energy
(Fuel &
Electricity)
Savings
Annual
Savings
(Rs. In
lakhs)
Capital
investment
(Rs. In lakhs)
Simple
Payback
Period
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WHY ENERGY EFFICIENCY & CONSERVATION ?
Benefits of Energy Audit:
Reduction in Energy consumption results in energy costs reduction
- improvement in bottom line.
Reduction in energy costs results in production cost reduction –
larger market share / improvement in top line.
Contribution towards improving National energy security, reducing
fresh power generation capacity addition & reducing Global
Warming.
Industries / organizations has energy saving potential from 7% to
25% of annual energy bills, about 20% to 30% from no / low cost
energy saving initiatives.
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WHY SGS?
Reputation for independence, integrity, professionalism & expertise
Stringent policy not to Engage in any Manufacturing, Trading &
Financial activities which might compromise its independence &
Neutrality
Significant track record in delivering services for a variety of
industrial sectors
Global network of experts within SGS group
Technical knowledge
Financial solidity
Local presence and market knowledge (culture, business
practices, regulations, legislation, etc.)
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ENERGY EFFICIENCY SERVICES -
INSTRUMENTS
Equipment Name Purpose Nos. Calibration Status
Power Analyzer 3 - phase power measurement 8 √
Power Meter 1 - phase power measurement 4 √
Ultrasonic Flow-meter Liquid flow rate measurement 3 √
Anemometer (Digital) Air flow velocity measurement 4 √
Thermometer (Digital) Temp. measurement 2 √
Thermometer (Infrared) Temp. measurement 2 √
Lux Meter Lighting illuminance measurement 4 √
Tachometer (Digital) Rotational speed measurement 1 √
Hygrometer Temp. & humidity measurement 4 √
Ultrasonic leak detector Compressed air leak detection 1 √
Temp. Data Loggers Temp. data logging 4 √
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THANK YOUTHANK YOU
PRESENTATION
ON
ENERGY AUDIT(Electrical/Mechanical Components only)
FOR
WATER SUPPLY SCHEMES
INTRODUCTION
Saket Projects Limited is a public limited multi-functionary organization with access to TechnicalManagement and other allied services to thecustomers.
The activity areas include:
- Energy Management
- Event Management
- Industrial & Construction Publications
- Manufacturing Pharma Formulations
- Water Management
Energy Management Division
Saket has played a pivotal role inestablishing huge energy saving in largenumber of industries with the help ofhighly skilled manpower backed up bystate-of-the-art microprocessor basedinstruments.
SAKET first Company in Gujarat
to get the Authorization….
We were first to get the recognition as ApprovedEnergy Auditors from the Commissioner ofElectricity, Government of Gujarat. This wasfollowed by –
Authorization as an ESCO Company by the Bureau of Energy Efficiency (BEE ), Ministry of Power
Recognition from PCRA (Petroleum Conservation Research Association)
GEDA (Gujarat Energy Development Agency)
Continued… REDA (Rajasthan Energy Development Agency)
Recognition from IREDA (Indian Renewable Energy Development Agency)
MEDA (Maharashtra Energy Development Agency)
CREDA (Chhatisgadh Renewable Energy Development Agency)
NEDCAP (Non-Conventional Energy Development Corporation of AP Ltd.)
EMC-Kerala (Energy Management Centre -Kerala)
State and National Recognition came our way…
Our efforts stand recognized by Government
of Gujarat through an award and at National
Level SAKET won runners up award of the PCRA.
OBJECTIVES OF STUDY
Performance Evaluation of pumps
Parallel pump study
Study of pumping mains and System Characteristics
Leak Assessment
Study of Electrical Demand profile
Transformer and Capacitor Rationalization
Illumination Study &
Study of Harmonics
METHODOLOGY & APPROACHWater Pumping System:
Evaluation of pump performance shall bedone by simultaneous measurements ofhead, flow and power.
Flow measurements shall be done usingTransits time Ultrasonic Flow Computer.
Power measurement shall be done usingmicroprocessor based power analyzer. Weshall measure the Voltage, Ampere,Frequency, Active & Reactive power,harmonics etc.
Measurement of head shall be done byusing digital pressure indicator.
Every minute data logging of eachmeasured parameters namely flow & powershall be made.
Based on measured parameters, we canevaluate the operating efficiency of theindividual pump sets.
Continued…
Continued… Measured parameters shall be compared with
design requirements to identify the oversized equipments, if any.
We shall study the parallel operation of pumpsets to identify mismatched parallel operation.
Study of sizing of pipes/control devices toidentify in-adequate sizing of equipments.
Study of flow distribution network along withmeasurements of flow & pressure at keylocations.
Identifying Energy Saving Opportunities:
Retrofit in oversized pumps to cater thesystem requirements such as reducing sizeof impeller, re-design of impeller,replacement of existing motor by lowerRPM motor etc.
Replacement of existing pumps by properduty and energy efficient pumps.
Continued…
Continued…
Elimination of throttling and properbalancing of flow distribution network.
Adequate sizing of pipes
Installation of Variable Speed Drives forefficient flow control.
Technical specifications of Ultrasonic Flow meter, Pressure Transmitter & Power Analyzers to be deployed are as mentioned under:
1) Portable Clamp-on Transit-time/Doppler Ultrasonic Flow Display Computer:Model : WDP3-1010 Make : Controlotron, USARange : upto Velocity of 6 m/sec & pipe diameter
from 1.25” to 60”Accuracy : +/-1% or betterFeature : Inbuilt Tantalization, Data logging at
proprammable time interval Measures real time flow of any liquid and for any liquid condition.
2) Pressure/Head Measurement:Make : Fisher RosemountModel : 3051TG-2-A-2B-2-1-A-M5.Range : 0-150 Psig
3) Nanovip:Make : Alacrity India Ltd.Model : NANOVIP PLUSFeatures : Measures Electrical Parameters for single phase
and three phase balanced load along withHarmonics and data logging facilities.
Electrical System:
Operating electrical parameters at majorPCC’s & MCC’s shall be measured usingMicroprocessor based power analyzers havingdata logging capabilities. Also, ratings andlocations of major capacitors shall bereviewed to suggest Power FactorImprovement Schemes, if required.
Load study of all the major motors shall alsobe carried out for identification of underloaded/overloaded motors.
Illumination study shall also be made bymeasurement of Lux level and lightingpower, operating voltage etc.
Study of Electrical Distribution networkincluding transformer, capacitors andmeasurement of harmonics at key locationsetc. for minimizing the network losses.
Analysis of the Electricity Bills for last 12months.
Continued…
Continued…
Historical data collection & analysis to bring out the present specific energy consumption indices/bench mark level identify the variations of highs & lows.
Study of the existing status of energy metering,reporting and monitoring system in thecompany and identification of gaps, if any.
Determination of Specific Energy Consumptionnorms for the unit.
Identifying Energy Saving Opportunities:
Tariff Structure analysis with the help ofelectricity bills and suggest power factorimprovement, demand reduction, TOUcharges etc.
Analysis of Plant Demand Profile by 24 hrsload cycle at mains of plant and identify thevariation in voltage, power, frequency,ampere, harmonics etc
Transformer Rationalization
Continued…
Continued…
Power Factor Optimization by installingcapacitor
Motor Load Rationalization and replace themotors with high Energy Efficient motorswith suitable size.
Voltage Reduction in Lighting system byinstalling Lighting Transformer
Technical specifications of Power Analyzers to
be deployed are as mentioned under:
1) NANOVIPMake : Alacrity India Ltd.Model : NANOVIP PLUSFeatures : Measures Electrical Parameters for single
phase and three phase balanced load along with Harmonics and data logging facilities.
2) ALM 3 (Alacrity)Make : Alacrity India LimitedModel : ALM3Features : Measures Electrical parameters for Single
Phase, Three Phase balanced and unbalanced load with data Logging facilities.
A
CASE STUDY
ON
NAND INTAKE WELL, BHARUCH
Scheme : Nand Intake well
Nand Narmada Base R.W.S.S
Year of Commissioning : 1999
Coverage : 186 Villages
Design Drawl : 36 MLD
Main Source : Narmada River
Structure : Intake well
Water Distribution : M.S., A.C., P.V.C. Pipes
SCHEME AT A GLANCE….
TOTAL SAVING POTENTIAL
TOTAL 1 7 . 9 7 3 . 1 0 2 - 3
0.06 0.10 20-21
Wat er Pumping
Syst em
Saving Pot ent ial by f or ref urbishment &
impeller t r imming of all 06 nos. pumps 14.91 3.00 2-3
Immediat e
Saving pot ent ial by replacement of GEB
Met er2.20 Nil Immediat e
S ugge st e d M e a sur e s I nv e st me nt Ene r gy
S a v i ng
P a y - ba c k
M ont hs
Elect r ical Syst em
Saving Pot ent ial by reducing t he exist ing
demand0.80 Nil
Saving Pot ent ial by replace exist ing
Convent ional choke at Single Tube Fixt ure
wit h Elect ronic Ballast
De sc r i pt i on
(Rs. in Lacs per Annum)
Installation Details
Nand Intake well
Make : Flow more
Type : Vertical Turbine
Head : 43 m
Flow : 420 m3/hr
Motor : 75 KW
BKW : 57.19
RPM : 1475
Voltage : 415
Total nos. : 06
Generally, 04 pumps are running in parallel (02 in stream - 1 and 02 in stream – 2) at raw water pumping stations. The operating hrs of the pump sets is 24hrs/day.
Operating Practice
MEASURED PARAMETERS Nand Intake well
1,3,4&6 49.8 23.4 12.23 35.63 1668.23 264.71 1674.93 35.92 267.91 67.99 0.1600
1,3,5&6 49.5 23.4 12.49 35.89 1670.04 270.50 1686.91 36.62 278.78 67.08 0.1653
3,4,5&6 49.7 23.4 10.09 33.49 1690.29 273.20 1700.49 33.90 278.18 62.73 0.1636
1,4,5&6 49.9 23.4 12.03 35.43 1607.77 268.50 1610.99 35.57 270.12 64.23 0.1677
1,4,&5 49.7 23.4 6.52 29.92 1322.48 207.20 1330.46 30.29 210.97 57.82 0.1586
1,3&4 49.4 23.4 9.58 32.98 1337.94 207.30 1354.19 33.79 214.95 64.45 0.1587
1,3&5 49.5 23.4 9.68 33.08 1341.03 207.90 1354.58 33.76 214.26 64.61 0.1582
1&6 49.1 23.4 5.56 28.96 900 140.90 916.50 30.03 148.79 56.00 0.1623
1&4 49.2 23.4 5.50 28.90 950 138.00 965.45 29.85 144.84 60.24 0.1500
3&5 49.5 23.4 5.50 28.90 900 141.30 909.09 29.49 145.63 55.74 0.1602
3&6 49.7 23.4 5.81 29.21 925 142.90 930.58 29.56 145.50 57.25 0.1564
1&5 49.6 2.5 90.88 88.38 2958.05 963 2981.91 89.81 986.49 82.19 0.3308
1,2,4&6 49.6 2.25 99.90 97.65 5171.23 1839 5212.93 99.23 1883.85 83.13 0.3614
1,2,5&6 49.6 2.15 99.85 97.70 5141.54 1823 5183.00 99.28 1867.46 83.42 0.3603
1,3,5&6 49.4 2.15 99.26 97.11 5171.11 1792 5233.92 99.48 1858.09 84.84 0.3550
1,3,4&6 49.6 2.25 99.69 97.44 5274.28 1830 5316.81 99.02 1874.63 85.03 0.3526
1,3,4&5 49.7 2.25 99.16 96.91 5323.42 1856 5355.55 98.08 1889.81 84.15 0.3529
1,2,4&5 49.3 1.75 97.43 95.68 5187.97 1810 5261.63 98.41 1888.20 83.03 0.3589
Efficiency
%
Norm
kw/m3
Power
in Kw
C. flow in
m3/hr
C. Head
in mtrs.
C. Power in
Kw
Power
in Kw
Frequency in
Hz
Suction head
in Mt. Pump No.
Discharge
head in Mt.
Total Head
in Mt.
Discharge
head in Mt.
Total Head
in Mt.
Flow in
m3/hr
Suction
head in Mt.
C. Head
in mtrs.
C. Power
in Kw
%
Efficiency
Norm
kw/m3
C. flow
in m3/hr
Frequency
in Hz
Flow in
m3/hr
MEASURED PARAMETERS
No. of Pump Avg. Flow Avg. op. Total flow Total power Norm
Running (m3/hr) Hrs/day (MLD) KW KW/M3
2 965.45 24 23.17 144.84 0.1500
3 1330.46 24 31.93 210.97 0.1586
4 1670 24 40.08 273.75 0.1639
Head (m) 42
Flow (m3/hr) 1050
Estimated Efficiency (%) 80
Power (kw) 166.9
Impeller Replacement
SYSTEM HEAD CURVENAND INTAKE WELL
OBSERVATION (Nand Intake well)
The Present measured flow of the individual pump is 420 m3/hr with four nos. pumps are running in parallel, which are matches with the rated individual flow of 420 m3/hr.
The present operating head with four pumps running in parallel is in the range of 34 –37 m., which is less compared to rated head of 43m.
Measured parameters indicate that all the pumps not follow rated performance curve closely. Also all the pumps are running in low efficiency zone, with operating efficiency is in between 63 – 68%, while rated efficiency of pumps are 86%.
The specific power consumption norm is varies in between 0.15 to 0.1639 KW/M3 with two pumps & four umps running in parallel respectively.
Generally, four pumps are running in a day 24 hrs/day. Looking to the operating practice, almost 40.08 MLD water is drawing from the river against the design water drawl of 36 MLD.
RECOMMENDATION (Nand Intake well)
We recommend for trimming the existingimpeller dia and Refurbishment of all thepumps after consults with the pumpManufacturer, for exact impeller dia.
Head : 38 mFlow : 420 m3/hrEstimated efficiency : 80%Power : 60.40 KW
SAVING POTENTIAL (Nand Intake well)
Present avg. power consumption :273.75kw (with four pumps running)
Present avg. flow of four pumps :1670 M3/hr (with four pumps running)
Present specific power consumption :0.1639 Kw/m3
Proposed power consumption :241.60 kw
Proposed flow :1680M3/hr
Proposed specific power consumption :0.1438 Kw/m3
Saving in norms :0.1639 - 0.1438 kw/m3
:0.0201kw/m3
Saving in potential :0.0201kw/m3x1670m3/hrx 24hrs/dayx365days
x5.07Rs./Kwh
Total Saving :Rs. 14.91 Lacs/Annum
Estimated investment for refurbishment
& impeller trimming of 06 nos. pumps :Rs. 3.00 Lacs
Simple Pay back period :2- 3 Months
REDUCTION IN C.D.(SAVING POTENTIAL)
NAND INTAKE WELL
PRESENT C.D. 500 KVA
PRESENT AVG. B.D. 425 KVA
PRESERNT DEMAND CHARGES RS. 66,937/Month
PROPOSED C.D. 450 KVA
PROPOSED DEMAND CHARGES RS. 60,243/Month
SAVING IN DEMAND CHARGES Rs. 0.80 Lacs/Annum
INVESTMENT NIL
PAYBACK IMMEDIATE
POWER FACTOR IMPROVEMENT(SAVING POTENTIAL)
NAND INTAKE WELL
PRESENT P.F. 0.966
PROPOSED P.F. 0.999
REPLACEMENT OF GEB METER
SAVING POTENTIAL Rs. 2.20 Lacs/Annum
INVESTMENT NIL
PAYBACK IMMEDIATE
LIGHTING SYSTEM(INSTALLATION DETAILS)
TYPE OF FIXTURE NAND INTAKE WELL
FLUOROSCENT TUBE (40W) 11
FLUOROSCENT TUBE (2X40 W)
03
HPSV (250 W) 06
LIGHTING SYSTEMSaving Potential by Installation of Electronics Ballast along with Energy Efficient T/L
NAND INTAKE WELL
Saving Potential (Rs. Lacs/Annum)
0.06
Investment Required( Rs. Lacs)
0.10
Simple Payback Months 20 - 21
* 35% Saving is considered by installation of Ballast
A
CASE STUDY
ON
DHAROI DAM BASED WATER
SUPPLY SCHEMES
Scheme : Dharoi R.W.S.S. Year of Commissioning : 2001 Coverage : 596 Villages,
8 Towns Design Drawl : 223.58 MLD Per Capita Water Supply : 60 lpcd for Rural
: 145 lpcd for Urban Design Population : 1193387 Main Source : Dharoi Dam Structure : Intake Well Cost of Scheme : 20696.97 Water Distribution : M.S., A.C., P.V.C. Pipes
SCHEME AT A GLANCE….
SCHEME AT A GLANCE….
DHAROI DAM BASED GROUP SCHEMES Sr.No. Group Schemes
Rural Urban Rural Urban
1 Dharoi Group W.S Scheme 378 5 699080 206000 71.81
2 Chanasma Pilot Project-1 34 - 71422 - 4.29
3 Chanasma Pilot Project-2 (Proposed) 77 2 122550 24393 10.89
4 Danta, Vadgam Group W.S Scheme 107 - 129834 - 7.79
5 Palanpur Urban Scheme - 1 - 99160 14.38
Total 596 8 1022886 329553 109.16
Population CoveredCoverageWater
Requirememts
(MLD)
SCHEME AT A GLANCE….
WATER DRAWAL
Sr.No. Group
Rural Urban Total
1 Dharoi 7 - 7
2 Kheralu/Vadnagar 12.12 4.81 16.93
3 Visnagar 9.8 10.97 20.77
4 Unjha 6.24 8.04 14.28
5 Sidhpur 8.45 7.73 16.18
6 Der-Balisana 5.37 3 8.37
7 Mudvada 8.25 - 8.25
Total 57.23 34.55 91.78
Water Requirement (MLD) - 2004
SCHEME AT A GLANCE….
POPULATION
Sr.No. Group
Rural Urban Total
1 Dharoi 116712 - 116712
2 Kheralu/Vadnagar 202058 48155 250213
3 Visnagar 163441 78338 241779
4 Unjha 104020 57423 161443
5 Sidhpur 140983 55219 196202
6 Der-Balisana 89511 - 89511
7 Mudvada 137527 - 137527
Total 954252 239135 1193387
Population- 2004
TOTAL SAVING POTENTIAL
PROPOSED MEASURES INTAKEWELL
Rs.
FILTER HOUSE
Rs.
INVESTMENT Rs.
PAY BACK MONTHS
OPTION - I
IMPELLER REPLACE MENT & REFURBISHMENT
OPTION - II
PUMP INTERNAL CORRO-COATING
-
-
126.27
141.73
10
4.0
1-2
1-2
DEMAND REDUCED DUE TO IMPELLER REPLACEMENT
- 7.73 Nil Immediate after Impeller Replacement
POWER FACTOR IMPROVEMENT 23.11 6.75 Nil Immediate
INSTALLATION OF AUTO VOLTAGE STABILIZER
0.12 0.23 0.78 27
APPLICATION OF ELECTRONICS BALLAST
0.15 0.53 1.11 20
TOTAL 23.38 156.97 15.89 1- 2
(Rs. in Lacs per Annum)
Total Saving : Rs. 180.35 Lacs per Annum
ELECTRICITY BILL ANALYSES(Avg. Monthly Data)
INTAKEWELL CLEAR WATER PUMP HOUSE
CONTRACT DEMAND
2400 KVA 1600 KVA
AVG. MONTHLY DEMAND
2114 KVA 1245 KVA
AVERAGE UNIT CONSUMPTION
9.06 LACS KWH 5.44 LACS KWH
AVERAGE POWER FACTOR
0.937 0.975
AVERAGE BILL 41.82 LACS RS. 29.53 LACS RS.
VARIABLE UNIT COST
4.28 RS./KWH 5.07 RS./KWH
AMU – INTAKE WELL, DHAROI
Oct.'03 862830
Nov.'03 971820
Dec.'03 893850
Jan.'04 828240
Feb.'04 760830
March'04 941100
April'03 990390
May'03 1091610
June'03 1063530
July'03 871680
Aug.'03 759510
Sept.'03 839610
Seasion
Summer
Moon
Soon
Average
889185
945982.5
883582.5
Winter
Monthly Unit
Consumption Month
No seasonal variation in water supply
AMU – CLEAR WATER, VAV
Oct.'03 530400
Nov.'03 603500
Dec.'03 496480
Jan.'04 456740
Feb.'04 534680
March'04 625640
April'03 576720
May'03 639400
June'03 611680
July'03 479340
Aug.'03 451340
Sept.'03 526220
Winter
Summer
Moon
Soon
Average
521780
594110
517145
Monthly Unit
Consumption MonthSr. No.
No appreciable seasonal variation in water supply
POWER FACTOR IMPROVEMENTCAPACITOR INSTALLATION DETAILS
INTAKEWELL CLEAR WATER PUMP HOUSE
PRESENT POWER FACTOR
0.937 0.975
INSTALLED CAPACITORS
990 KVAR
165 * 6 Nos.
750 KVAR
75 * 10 Nos.
CAPACITORS UNDER USE
330 KVAR
165 * 2 Nos.
375 KVAR
75 * 5 Nos.
POWER FACTOR IMPROVEMENT(SAVING POTENTIAL)
INTAKEWELL CLEAR WATER PUMP HOUSE
PRESENT P.F. 0.937 0.975
PROPOSED P.F. 0.999 0.999
CAPACITORS REQUIRED TO GET 0.999 P.F.
650 KVAR
4 nos. Bank
223 KVAR
3 nos. Bank
SAVING POTENTIAL
23.11 LACS RS./A. 6.75 LACS RS./A.
INVESTMENT NIL NIL
PAYBACK IMMEDIATE IMMEDIATE
LIGHTING SYSTEM(INSTALLATION DETAILS)
INTAKEWELL CLEAR WATER PUMP HOUSE
FLUOROSCENT TUBE (40W)
57 190
HPSV (150 W) 26 50
METAL HALIDE (400 W)
- 27
LIGHTING SYSTEMSaving Potential by Installation of Electronics Ballast
INTAKEWELL CLEAR WATER PUMP HOUSE
Saving Potential (Rs. Lacs/Annum)
0.15 0.53
Investment Required( Rs. Lacs)
0.25 0.86
Simple Payback Months
20 19-20
* 30% Saving is considered by installation of Ballast
LIGHTING SYSTEMSaving Potential by Installation of Auto voltage Stabilizer
INTAKEWELL CLEAR WATER PUMP HOUSE
Saving Potential (Rs. Lacs/Annum)
0.12 0.23
Investment Required( Rs. Lacs)
0.18 0.60
Simple Payback Months
18 31
Present Voltage : 240V Proposed Voltage : 220V
Installation Details
Raw Water
Make : Voltas
Type : BK 620 –030
Head : 78.2 m
Flow : 2000 m3/hr
RPM : 960
BKW : 484
Motor : 600 kw
Voltage : 6600
Total nos. : 06
PRESENT OPERATING PRACTICERaw Water Clear Water
Phase – I Phase - IIDesign Actual Des. Act. Des. Act.
Water Drawl 160 125 40 40 80 80(MLD)
Operating Practice 20 *22 20 **20 20 24
(Hrs/day)
Pump operation 4 03 2 2 3 3
* Three pumps running for 19 hrs/day and 02 pumps for 4 hrs/day. ** Two pumps running for 14 hrs/day and one pump for 12hrs/day.
MEASURED PARAMETERS –RAW WATER PUMPING STATION
850 & 1422 mm 2, 4 & 5 49.7 18.5 58.87 77.37 6070 1894.3 6106.64 78.31 1928.81 75.06 0.3159
850 & 1422 mm 5&2 49.6 18.5 56.37 74.87 4350 1262.32 4385.08 76.08 1293.11 78.11 0.2949
1422 mm 5 49.6 18.5 55.15 73.65 2200 642.33 2217.74 74.84 658.00 76.37 0.2967
1422 mm 5 49.3 18.5 55.05 73.55 2160 628.33 2190.67 75.65 655.48 76.54 0.2992
850 mm 2 49.03 18.5 63.07 81.57 1780 572 1815.22 84.83 606.63 76.85 0.3342
1422 mm 4&5 48.79 18.5 58.61 77.11 3900 1195.33 3996.72 80.99 1286.49 76.17 0.3219
Pump No.Frequency in
Hz
Suction head
in Mt.
Inter connection valve open
Inter connection valve close
Norm
kw/m3
Norm
kw/m3
Stream Frequency in
Hz
Suction head
in Mt. Pump No.
C. Head
in mtrs.
C. Power in
KwEfficiency %
Discharge
head in Mt.
Total Head in
Mt.
Flow in
m3/hr
Power
in Kw
C. flow in
m3/hr
% Efficiency Total Head in
Mt.
Flow in
m3/hr
Power
in Kw
C. flow in
m3/hrStream
Discharge
head in Mt.
C. Head
in mtrs.
C. Power in
Kw
Raw Water Pumping station
• Present operating practice by running 3 pumps with inter-connection valve open is beneficial.
MEASURED PARAMETERS
No. of Pump Avg. Flow Avg. op. Total flow Total power Norm
Running (m3/hr) Hrs/day (MLD) KW KW/M3
1 2200 22 48.4 656.97 0.30
2 4350 22 95.7 1293.11 0.30
3 6070 22 133.54 1924.12 0.32
4 7200 22 158.4 2426.52 0.34
Raw Water Pumping Station
Almost 160 MLD water drawl is feasible with the same system configuration and 04 pumps operation.
SYSTEM HEAD CURVE –RAW WATER PUMPING STATION
Inter connection valve fully open
Operating Practice
73.65, 2200
(48.4 MLD)
78.10, 6070
133.54 (MLD)
4 Pump Running80.19, 7200
(158.4 MLD)
60.00
70.00
80.00
90.00
100.00
0 1000 2000 3000 4000 5000 6000 7000 8000
Flow rate
Tota
l
Head
3 Pump Running1 Pump Running
• Present operating practice by running 3 pumps with inter-connection valve open is beneficial.• 4 pumps can be operated without adverse effect, allowing 158.4 MLD drawl.
INSTALLATION DETAILS
Clear Water
Make : Voltas
Type : H 250 M1
Head : 52 m
Flow : 1000 m3/hr
RPM : 1440
BKW : 162.77
Motor : 220
Voltage : 6600
Total nos. : *10
* 05 nos. each pumps are installed in Phase – I & II.
MEASURED PARAMETERS –CLEAR WATER (Phase-I)
•The pump operation in throttled condition leads to substantial Energy loss.•Substantial de-rating of pumps is observed.
3&5 50.08 2 51.63 49.63 2050 447.27 2046.73 49.47 445.13 68.87 0.2175
4&5 49.66 2 54.69 52.69 2029 440 2042.89 53.41 449.10 73.56 0.2198
4 49.5 2 52.40 50.40 1105 219 1116.16 51.42 225.70 76.98 0.2022
3&4 49.6 2 52.80 50.80 1997 441 2013.10 51.63 451.76 69.65 0.2244
3 49.7 2 52.70 50.70 1034 223 1040.24 51.32 227.06 71.17 0.2183
2&3 49.8 2 53.92 51.92 2045 450.5 2053.21 52.34 455.95 71.36 0.2221
2 49.7 2 53.62 51.62 1030 224.33 1036.22 52.24 228.42 71.75 0.2204
2,3 &5 49.8 2 54.94 52.94 3050.5 642.66 3062.75 53.37 650.43 76.08 0.2124
5 50 2 57.90 55.90 920 207 920.00 55.90 207.00 75.22 0.2250
50.2 2 54.33 52.33 1060 226 1055.78 51.92 223.31 74.31 0.2115
49.9 2 45.57 43.57 1270 239 1272.55 43.74 240.44 70.09 0.1889
49.9 2 41.08 39.08 1420 245 1422.85 39.24 246.48 68.58 0.1732
2 49.9 2 53.62 51.62 1065 226.67 1067.13 51.83 228.04 73.43 0.2137
49.6 2 45.36 43.36 1325 241 1335.69 44.06 246.88 72.18 0.1848
49.7 2 40.67 38.67 1510 248 1519.11 39.14 252.52 71.29 0.1662
49.7 2 38.53 36.53 1600 250 1609.66 36.97 254.55 70.79 0.1581
C. Power in
Kw% Efficiency
Power
in Kw
Discharge
head in Mt.
Total Head in
Mt.
Frequency
in Hz
C. Head
in mtrs.
Phase - I (40 MLD)Norm
kw/m3
Flow in
m3/hr
C. flow in
m3/hr Pump No.
Suction head
in Mt.
MEASURED PARAMETERS –CLEAR WATER (Phase-II)
6,8 &9 49.9 3 53.01 50.01 3360 661 3366.73 50.21 664.98 76.96 0.1975
6&9 49.98 3 52.85 49.85 2250 444.33 2250.90 49.89 444.86 76.43 0.1976
6 49.8 3 52.19 49.19 955 208 958.84 49.59 210.52 68.38 0.2196
6&8 49.8 3 52.40 49.40 2210 433.67 2218.88 49.79 438.92 76.21 0.1978
8 49.7 3 52.55 49.55 1150 222.5 1156.94 50.15 226.55 77.53 0.1958
8&9 49.8 3 52.80 49.80 2260 454.67 2269.08 50.20 460.17 74.95 0.2028
9 49.9 3 52.50 49.50 1130 232.67 1132.26 49.70 234.07 72.78 0.2067
C. Head
in mtrs.
C. Power in
Kw% Efficiency
Norm
kw/m3 Pump No.
Suction head
in Mt.
Discharge
head in Mt.
Total Head in
Mt.
Flow in
m3/hr
Power
in Kw
C. flow in
m3/hr
Frequency
in Hz
Phase - II (80 MLD)
•The pump operation in throttled condition leads to substantial Energy loss.•Substantial de-rating of pumps is observed.
MEASURED PARAMETERS
No. of Pump Avg. Flow Avg. op. Total flow Total power Norm
Running (m3/hr) Hrs/day (MLD) KW KW/M3
1 1082.67 24 25.98 220.67 0.20
2 2246 24 53.90 448 0.20
3 3366.73 24 80.80 664.98 0.20
Phase - II
MEASURED PARAMETERS
No. of Pump Avg. Flow Avg. op. Total flow Total power Norm
Running (m3/hr) Hrs/day (MLD) KW KW/M3
1 1025 20 20.50 226.5 0.22
2 2050 20 41 448.5 0.22
3 3050.5 20 61.01 657.53 0.22
Phase - I
SYSTEM HEAD CURVE – CLEAR WATER
System Head Curve - Phase I
(Head vs. Flow rate)
0.00
30.00
60.00
90.00
0 1000 2000 3000 4000
Flow rate
Tota
l
Hea
d
Syst em C urve ( D is. V alve
f ully opened)
Syst em C urve ( D is.
V alve t hro t t led )
Pump C urve ( D is.
V alve thro t t led )
Pump C urve D is. V alve
f ully open)
• *A static head predominant system, Friction head is 5% of Total head. • *74 KW Power loss due to throttling of 13.25 mt.
SYSTEM HEAD CURVE – CLEAR WATER
System Head Curve - Phase I
(Head vs. Flow rate)
0.00
30.00
60.00
90.00
0 1000 2000 3000 4000
Flow rate
Tota
l
Head
Syst em C urve ( D is.
V alve f ully opened)
Two pump operat ion
One pump operat ion
RECOMMENDATION (CLEAR WATER)
We recommend impeller replacement &Refurbishment with corro-coating in existingpump at Filter water pumping station Phase – I &II with following duty point conditions. Thefamily curve of the present pump model shouldbe referred and discuss with pump manufacturerfor exact impeller dia.
Head : 40mFlow : 1050 m3/hrEstimated efficiency : 84%Power : 151.38 kwNorm : 0.1442 kw/m3
SAVING POTENTIALPhase – I
Present power consumption : 450 kw (02 pumps running)
: 225 kw (01 pump running)
Avg. running hrs : 14 hrs/day (02 pumps running)
: 12 hrs/day (01 pump running)
Power consumption : 450 kwx14 hrs + 225kw x12 hrs
: 6300 + 2700 kwh/day
: 9000 kwh/day
Proposed power consum. : 151.38 kw
: 151.38kwx12hrs+317.9 x14 hrs
: 6055.20 kwh/day
Saving in KW : 9000 – 6055.2 kwh/day
: 2944.80 kwh/day
: 2944.8x5.07rs/kwhx 360 days
: 53,74,849 Rs./Annum
SAVING POTENTIALPhase – II
Present power consumption : 655 kw (03 pumps running)
Avg. running hrs : 24 hrs/day 03 pumps running)
Power consumption : 655 kw x 24 hrs
: 15720 kwh/day
Proposed power consum. : 454.14 kw (03 pumps running)
: 454.14 kw x 24 hrs
: 10899.36 kwh/day
Saving in KW : 15720 – 10899.36 kwh/day
: 4820.64 kwh/day
: 4820.64 x5.07Rs./kwhx 360 days
: 87,98,632 Rs./Annum
Total Saving (Phase-I & II) : 141.73 Lacs/Anuum
Total Investment : 14.0 Lacs (for 07 pumps)
Simple pay back : 1 – 2 months
REDUCTION IN DEMAND CHARGES DUE TO IMPELLER REPLACEMENT Motor Power Factor : 0.92 Present Consumption of Pump : 225 KW Proposed Power After
Impeller Replacement : 159 KW Nos. of Pump Running : 5 Present Actual Demand : 1245 KVA
(225–159)* 5 Proposed Demand Reduced :-----------------
0.92: 358 KVA
Saving : 358KVA* Rs. 180: Rs. 64440 / Month: Rs. 7.73 Lacs / Annum
MAINTENANCE SPECIFIC OBSERVATION
Auto Tap Changer not functioning…. Auto tap changer is not working. Manual setting of
tap leads to secondary voltage variation.
The high supply voltage @10% was observed duringthe site visit. (6.6-7.3)
The combined effect of high supply voltage & manualtap setting adversely affects the motor efficiency.
In the event if 04 pumps are run, the demand canshoot-up beyond the sanctioned contract demand.
Auto tap changer requires to be repairedimmediately.
MAINTENANCE SPECIFIC OBSERVATION
Electrical panel related problems…..
In some breakers, power fuses are not installed. It isrequired to maintain the sufficient inventory level offuses to avoid probably delay in pump operation.
Though capacitors are installed but due to powerfuses and tripping coil problems they are not put inuse which leads to poor power factor and higherdemand charges.
Automatic system of capacitors is not working .It isrequired to check & rectify the automatic operationsystem of capacitor at intake well on priority.
MAINTENANCE SPECIFIC OBSERVATION
Control Panel related problems…. The Flow meters are erroneous.
Suction water level indicator is not functioning.
Pressure gauges are erroneous.
Proper on -line instrumentation is essential for proper Analysis , Review and Energy Management.
ACTIONS TAKENSr. No Measures Actions
1 Power Factor Improvement Immediate actions have been taken by the competent authority GWSSB
2 Installation of Auto Voltage Stabilizer Action has been initiated by the competent authority GWSSB
3 Application of Electronics Ballast Competent authority GWSSB may decide implementation eg. In phased manner
4 Inventory of power fuse Immediate actions have been taken by the competent authority GWSSB
5 Demand Reduction Actions may be taken by the competent authority after implementing suggested pump retrofit.
6 Impeller Replacement, Refurbishment & Pump Coating
Competent authority GWSSB shall initiate suggested retrofit & refurbishment immediately in consultation with pump manufacturer.
RECAP…..
The study has pin pointed the saving potential of is Rs.180.35 Lacs per Annum – Electrical & Mechanicalcomponents together.
Intake Well - Saving Filter Water - Saving
Rs. 23.38 Lacs / Annum Rs. 156.97 Lacs / Annum4.66 % of Total Bill 44.29% of Total Bill
Much more savings can be envisaged through study of leakassessment of distribution network as well as study of subheadworks which is in progress…
SAVING POTENTIAL
Phase – III Present avg. Power consumption : 53 kw
Present avg. flow : 255 M3/hr
Present specific power consumption : 0.2078 Kw/m3
Proposed power consumption : 40.37 kw
Proposed flow : 260 m3/hr
Proposed specific power consumption : 0.1553 Kw/m3
Saving in norms : 0.2078 - 0.1553 kw/m3: 0.0525 kw/m3
Saving potential : 0.0525kw/m3x255m3/hrx9hrs/dayx365daysx5.9 Rs./Kwh
Total Saving : 2,59,470 Rs. /Annum
Estimated Investment : 1.25Lacs
Simple Payback period : 5-6 months
POWER FACTOR IMPROVEMENT(SAVING POTENTIAL)
PANTHAWADA FILTER HOUSE
PRESENT P.F. 0.950
PROPOSED P.F. 0.999
CAPACITORS REQUIRED TO GET 0.999 P.F.
50 KVAR (APFC)
SAVING POTENTIAL 10.22 LACS RS./A.
INVESTMENT 0.36 LACS
PAYBACK IMMEDIATE