Mandatory Water Audit for Domestic and Industrial Water Supply

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Karishma BistDy. Director

FICCI - Resource Conservation & Management GroupEmail: [email protected]

FICCI Water Audit Case Study of a Gas Based Power Plant in

India: Improving Water Use Efficiency

IWWTechnical Session on

“Mandatory Water Audit for Domestic and Industrial Water Supply”

About Resource Conservation & Management (RCM)

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Need for Water Conservation & Management

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Water Consumption Scenario: Indian industry Vs Global best

Sector Average water

consumption in Indian industry

Globally best

Thermal Power plant average 80 m3/ mwh(1) Less than 10 m3/mwh (2)

Textiles 200-250 m3/ tonne cotton cloth(3)

Less than 100 m3/ tonne cotton cloth (2)

Pulp & Paper • Wood based mills: 150 - 200 m3 / tonne(3)

• Waste paper based mills: 75 -100 m3/ tonne(3)

• Wood based mills: 50 - 75 m3 / tonne (4)

• Waste paper based mills: 10-25 m3/tonne(4)

Integrated Iron &

steel plant

10-80 m3 per tonne of finished product (average)

5 -10 m3 per tonne of finished product. (5)

Distilleries 75-200 m3/ tonne alcohol produced(6) Data not available

Fertiliser industry

• Nitrogenous fertiliser plant - 5.0 - 20.0 m3/ tonne(3)

• Straight phosphatic plant - 1.4 - 2.0 m3/ tonne (3)

An effluent discharge of less than 1.5 m3/ tonne product as P2O5 (2)

Source: 1. No credible data available. Estimates done by CSE from wastewater discharge data from "Water Quality in India, Status and trends (1990-2001), CPCB, MoEF" and annual electricity generation data from "Annual Report (2001-2002) on the working of state electricity boards and electricity department, Planning Commission." 2. Pollution prevention and abatement handbook, World Bank. 3. Environmental management

in selected industrial sectors - status and need, CPCB & MoEF, February, 2003. 4. Green Rating of Pulp and Paper Sector, CSE. 5. Integrated Pollution Prevention and Control (IPPC), Best available techniques reference document on the production of iron. 6. Environmental performance of Alcohol industry in UP, UPPCB, 2000-2001.

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Water Audit – Scope, Components and

Methodology

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• Water Audit study is a qualitative and quantitative analysis of water consumption which helps efficient water utilization & conservation.

• Water Audit determines the amount of water lost from a distribution system and the cost of this loss to the utility.

• Comprehensive water audit envisages a detailed profile of the distribution system and water users, thereby facilitating easier and effective management of water resources and improved reliability.

What is Water Audit?What is Water Audit?

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Water Audit Studies Can be Done for any Water Audit Studies Can be Done for any Water Utilizing Unit/System/Process/ProjectWater Utilizing Unit/System/Process/Project

• Industrial Units • Office Buildings• Residential Colonies and Individual

Houses• Hospitals and Hospitality Sector • Airports• Water Supply & Distribution Boards • Regional/ Cluster Level Audits

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Poor Availability or Non-Availability of Fresh Water Higher Specific Water Consumption High Water Bills Inconsistent Product Quality High Effluent Discharge Restriction on effluent Disposal to any Recipient Media Breakdowns, Leakages & Spillages

Cost of Pumping < Cost of Filtered Water from WTP < Cost of Softened Water < Cost of DM Water

Why Water AuditWhy Water Audit

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OverheadTank WTP

Process

Cooling

Domestic etc.Filtered water

DM Water

Soft water

a

a+b

a+2b

a+3b+c

a+3b+2c

a+3b+3c

a – cost of raw water b- pumping costc- treatment cost

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8m³/day @Rs.7.2/m³

112m³/[email protected]/m³


125m³/d 121m³/[email protected]/m³

66m³/dRs.11.54/m³


Colony

IRF 2Rs3.62/

m³

Softener 2Re0.57/m³

Process

RO [email protected]/

³m


Storage (10KL)

MGF2




Re 0.20/m³




408m³/day

3m³/dayRs.3.78/m³

32m³/day

Plant/Printing Hand Washing in Toilets

Canteen

MGF 1 IRF 1Rs.2.91

/m³

Reservoir 1Re 0.95/m³

Reservoir 2 Reservoir 3

Tube Settler

Softener 1

Re0.79/m³

420m³/day@ Rs.1.16/m³ 447m³/day

@Rs.2.31/m³

9m³/day @ Rs.3.78/m³

92m³/dayRs.6.69/m³

@Rs.1.47/m³

Plant/ Printing/Drinking Water

Re0.67/m³

Boiler

40 m3/dayRs 53/m3

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TYPICAL WATER AUDIT SCOPE

•Development of Water Circuit Flow Diagram

•Collection & compilation of basic data of pumps, reservoirs c.

•Measurement of Flow, Pressure & Power at major pumps.

•Performance Assessment of Pumps-actual v/s rated efficiency.

•Identification of inefficient pumps & recommendations.

•Preparation of Water Balance Diagram.

•Estimation of water losses.

•Recommendations on water conservation & cost reductions.

•Suggestions on recycling options for water conservation

IN ADDITION, FICCI DOES THE FOLLOWING………

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FICCI’S ADDITIONAL WATER AUDIT SCOPE

• Value added costing of water cost at various use locations.

•Assessing the logistics of existing water management practices & suggesting appropriate changes for reducing overall costs & improved water management.

• Incorporating latest water conserving equipments/ technologies in recommendations.

• Provide details on Rainwater Harvesting (RWH) potential for the given site and suggest possible RWH schemes.

•Evolving WATCON (Water Conservation) options with its techno-economic feasibility aspects.

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FICCI WATER AUDIT STUDY – SECTORS• Cement• Iron & Steel• Beverage• Pulp & Paper• Pharmaceuticals• Ore Beneficiation

The Scope of Water Conservation estimated to beabout 15-30 Percent in the above sectors

• Textile • Chemical• Oil Refinery• Aluminium• Power Plants• Buildings

More than 40 Water Audits done (ITC, NTPC, BPCL, BALCO, RBI, Essar Steel, JK Lakshmi Cement, UltraTech

Cement, UB Group, Coca Cola India Inc, HZL, ACC Ltd etc).

FICCI WATER AUDIT– CASE STUDY

GAS BASED POWER PLANT

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Current Water Scenario:

431 MW Gas Based Power Plant

Main Raw Water Source – Surface Water

Total Fresh Water Use = 13,800 m3/day

Cost of Raw Water=Rs 3.57/cubic meter

Cooling Tower Make Up = 11400 m3/month

MEASUREMENTS CONDUCTEDMeasurement Locations:The measurements at Water Source side were carried out at: Canal Water pumps The measurements at Distribution side were carried out at Raw Water Pump House - Clarifier Pumps Raw Water Pump House – PT Pumps Cooling Water Make Up Cooling Towers Pumps Cooling Towers – Uprisers, Common Header Output DM Plant – Filter Water Transfer Pumps DM Plant – Degassifier Pumps DM Plant – Regeneration Pumps Fire Water Pumps Tube Well Pumps Condenser Line Input Condenser Line Output

Water Balance Diagram

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Water Use Pattern

Observations

1. Clarifiers:Observation: 2 nos. of clarifiers; only one is operating at a time. Design Capacity of each Clarifier = 720 m3/hr. Operational capacity = 575-600 m3/hr. Turbidity reduced from 80 NTU to 40 NTU After subsequent sand filtration, turbidity reduced to 15 NTU. Filtered water stored, pumped to the cooling towers

Proposed Scheme:

Benefit of the proposed scheme: Improved efficiency of Sand bed Filters due to reduced turbidity of clarified water

Increased COC in the cooling Towers due to reduced turbidity in make-up water

Decreased effluent generation due to lesser blow downs in cooling towers reduced dependency on groundwater for making demineralized water

2. Existing Cooling Towers: The cooling Towers accounts for about 83% of total water use in the unit.

The unit has 3 nos. of pumps for pumping hot process water to process cooling area.

The flow in the main header is about 24,200 m3/hr.

The existing CT has total 18 no. of CT cells; 9 even numbered cell and other 9 odd numbered cell

Locations of measurements at Cooling Towers

Process Water Flow Distribution

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Odd Cells flow(m³/hr) % % Deviation from the Average1 1089 88.75 -11.253 1274 103.82 3.825 1132 92.25 -7.757 1367 111.40 11.409 1268 103.33 3.33

11 1276 103.99 3.9913 1328 108.22 8.2215 1256 102.36 2.3617 1054 85.89 -14.11

Even Cells2 980 85.78 -14.224 1054 92.26 -7.746 1180 103.29 3.298 1142 99.96 -0.04

10 1223 107.06 7.0612 1018 89.11 -10.8914 1235 108.11 8.1116 1380 120.80 20.8018 1070 93.66 -6.34

Percentage deviation of the hot process water distribution in Cooling Towers

RecommendationEnsuring Uniform Water Flow Distribution in all 18 cells of cooling towers by adjusting flow Control valves: The cells receiving higher flow rate are expected to have increased drift losses, reduced cooling and overall low efficiency whereas the cells receiving lower flow rates would remain under utilized.

This can be achieved by adjustment in setting of valves in each cells so that the flow is equally distributed and regulated.

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3. Existing Wastewater Collection & Treatment

Wastewater Collection Pit

Cooling Tower Blow Down

Boiler Blow Down

Wastewater from DM plant

Wastewater from other sections of the unit

Effluent disposed to Surface Water

Lime dosing

RecommendationsWastewater Treatment Scheme I

Wastewater containg oil

Rain water from oil tank yard

Storage tank

pH balancing

tank

Waste water from CT and Boiler blow down

Oil Seperator Tank

congulating sedimentatio

n tank

Activated Carbon Filter

Ultra Filtration

Membranes

Treated effluent

tank

wastewater from general sections

Wastewater from DM plant

neutralizing tank

Recycle in raw water pump

house clarifier

Reuse in Landscaping/Horticultur

e

RecommendationsWastewater Treatment Scheme II with RO

Schematic Diagram of RO plant with pre-treatment

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4. Rainwater Harvesting The unit has implemented RWH to certain extent, it is observed that the present RWH system is not very efficient. The unit has four recharge pits, two are located within the premises of the unit and another two are located in the township. The 2 nos. recharge pits in the unit are designed to recharge ground water in rooftop runoff. It is also observed that the bore well no. 1(near DM plant storage tank) has very low yield, about < 40 % of its rated capacity

Implementation of Rain Water Harvesting Scheme to Recharge Ground Water:

The rainwater harvesting potential of the plant is about 77,408 m3 per year. The unit can store the rainwater in reservoirs or artificially recharge the groundwater

S.No.

CatchmentDetails

Area (Sq. meter)

Permit area* (Sq.

meter)

Avg. Rainfall/ Year

(m)

Runoff coefficie

nt

RWH Potential

(m3)

1 Roof-Top Area 20234 14164 0.564 0.75 5991

2 Open Area (Paved/ unpaved/ Green)

602982 422087 0.564 0.2-0.5 71417

Total RWH Potential (m3) 77408

5. Replacement of Less Efficient Pumps: Location/Pump Pump No. Water Delivered To Power KW Flow Press

Actual PumpDescription Actual m3/hr m Eff(%)

Canal Raw Water Pump

RWC Plant Reservoir 97.5 1260.0 17.0 70%RWB 117.2 1336.0 20.0 73%

Cooling Water RW Pump

P4A Clarrifier 35.4 576.0 6.5 34%P4B 35.8 588.0 7.0 37%P4C 36.7 574.0 6.0 30%

PT Raw Water Supply Pump

P3A PTPlant 17.3 128.5 23.5 56%P3B 17.5 131.0 24.0 58%P3C 16.6 137.0 23.5 62%

Filter Water Transfer Pump( DM Plant)

P1A DM Plant 27.8 107.0 34.5 43%P1B 24.9 96.5 38.0 47%P1C 27.5 99.0 32.0 37%

Degassifier Water Pump

P2A DM Storage 39.6 100.0 36.0 29%P2B 34.9 101.0 41.0 38%P2C 34.4 102.0 39.0 37%

Regeneration PumpsP3A SAC, WAC 1.6 50.0 5.6 56%P3B 1.7 70.0 5.8 79%

CT Make Up (Filter Water Transfer

Pumps)

A Cooling Towers 25.7 520.0 9.5 62%B

25.2 581.0 11.5 85%

CW Pumps

CWP-A Cooling Water in Process 1180 13800.0 22 82%CWP-B 1188 12375.0 24.2 81%CWP-C 1190 14200.0 22.8 87%

Blow Down PumpsBDP/P1 Blow Down 8.6 75.0 11.0 31%BDP/P2 10.9 106.0 14.0 44%

Tube Wells Pumps

2.0 Plant & ADM Building 12.6 41.7 40 42%1.0 DM Plant 12.7 22.4 39 22%3.0 DM Plant 18.1 45.3 46 37%

Filter Back Wash PumpsA Steer Chamber 5.8 27.0 20.5 31%B Steer Chamber 6.2 28.3 9.5 14%

• Overall the study identified the potential of about 20% saving of total freshwater consumption and ‘Zero Discharge’ potential by implementing the suggested schemes.

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Conclusion

•Proactive Approach•Incentives - Certification•Quantitative Guidelines•Effective Enforcement •Stakeholders Responsibility

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Karishma BistDy. Director

FICCI - Resource Conservation & Management GroupEmail: [email protected]

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Mandatory Water Audit for Domestic and Industrial Water Supply

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