ENERGY MANAGEMENT SERVICES (ENERGY AUDIT) · 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

1

ENERGY MANAGEMENT SERVICES

(ENERGY AUDIT)

2

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$.

3

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.

4© SGS INDIA 2017 ALL RIGHTS RESERVED

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.



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



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.

7© SGS SA 2013 ALL RIGHTS RESERVED

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.


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.



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.



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.



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


ENERGY EFFICIENCY – ACTION PLAN


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



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



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.


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.)


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 √


THANK YOUTHANK YOU


WWW.SGS.COM

http://www.sgs.com/

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



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)


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


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


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.



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)


FLUOROSCENT TUBE (40W)

57 190

HPSV (150 W) 26 50

METAL HALIDE (400 W)

- 27

LIGHTING SYSTEMSaving Potential by Installation of Electronics Ballast



0.15 0.53


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



0.12 0.23


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



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



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



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.


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.


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


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

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