Energy Audit of WASAsEngr. Abid Hussainy

Sr Specialist Environment Division The Urban Unit Lahore

22th February 2015 ( PWON Bhurbhan)

What is ENERGY AUDIT?

Inspection, Survey & Analysis Of Current

Energy Needs & Flows

Analysis Of Potential Areas of Interventions

(Weaknesses And Deficiencies),

Identification Of Effective Possibilities

Of Energy Savings Without Reducing the

Output

PCGIP- DLI 4 (Revenue Collection System)

• To Reduce Energy Consumption• Energy Efficient system • Improve service delivery - • Safety for the Staff • Asset Life is improved

Why Energy Audit in WASAs?

Old Energy Bill New Energy Bill

0

2

4

6

8

10

12

Billing

Role of Urban UnitCapacity Building•Training Workshops•Hands on Training of Instrumentation

Design of Tools•Technical Information Performa•Billing Information Performa•Conditional Survey Performa•EA Performa

Support in Data Collection•Conditional Survey•Data Entry

Data Analysis & Planning •Decision Making

Urban Unit Energy Audit Team

Engr. Abid Shah Hussainy – Task Manager

Engr. Rao Ali Raza

Mr. Syed M. Usman Ali

Mr. Abdul Basit

2 Day Energy Audit Training of WASA officials in Collaboration with NED (24-25 October, 2014) by International Trainer /Expert Mr Hashmi from Canada • Training to 15 WASA officials from 5 Cities• EA Exercises • Development of EA Tools (Technical, Billing, Conditional Survey &

Energy Audit Performa) for TWs, DSs, W&WWT Plants.

Hands on Training in the field by Urban Unit Experts in All WASAs ( 25 November- 19 December)• Instrumentation• Support in Data Collection• On Site Energy Audit Training• Conditional Survey

Urban Unit Capacity Building Initiative

Energy Audit Activities Status

Technical Data/ EA Assets

Billing Detail June 13 to June 14

Conditional Survey

Available Data Entry & Analysis by UU 0

50

100

WASA Lahore

Technical Data/ EA Assets

Billing Detail June 13 to June 14

Conditional Survey

Available Data Entry & Analysis by UU 0

50

100

WASA Rawalpindi

Technical Data/ EA Assets

Billing Detail June 13 to June 14

Conditional Survey

Available Data Entry & Analysis by UU 0

50

100

WASA Gujranwala

Technical Data/ EA Assets

Billing Detail June 13 to June 14

Conditional Survey

Available Data Entry & Analysis by UU 0

50

100

WASA Multan

Technical Data/ EA Assets

Billing Detail June 13 to June 14

Conditional Survey

Available Data Entry & Analysis by UU 0

50

100

WASA Faisalabad

Tubewell & Disposal Station Detail

Lahore Rawalpindi Multan Faisalabad Gujranwala

491

362

102 82 6799

21 43 22

Supply Tubewells & Disposal Stations

Supply Stations Disposal Stations

EA -Asset InformationWASAs No. of Pump- Motor Sets Design Capacity

(Cusec)Lahore 776 5668.5

Rawalpindi 362 109Multan 161 1061

Faisalabad 222 1284Gujranwala 112 640

Total 1633 8762.5MGD 5663

Comparison of Load Capacity MW ( Installed Vs Sanctioned)

WASA Lahore WASA Rawalpindi WASA Multan WASA Faisalabad WASA Gujranwala0

10

20

30

40

50

60

70

80

90

64.6

6.8

20.2

11.06.5

78.3

11.514.3

19.9

7.4

Installed Load (MW) Sanctioned Load (MW)

Energy Audit

Part 1

Part 2

Part 3

Energy Audit Findings

Conditional Survey & Analysis-Part 1

Conditional Survey

• Provide an orientation of the entire facility to observe the condition of each asset and the factors those influencing the asset condition towards operation.• Identify areas that warrant further examination for operational &

maintenance practices and potential energy management opportunities.• Identifies obvious opportunities for the room of improvements in the

operation and management side.

Conditional Survey Parameters-24 Parameters

Physical Condition of

Pump

Lubricant Leakage

Water Leakage

Cable Insulation

Cable Sizing

Transformer Condition

Energy Meter Condition

Performance of Starter

Pump Vibration

Pump Noise

Motor Temperature

Control

Cooling Fan Condition

Piping Condition

Condition of Return Valve

Pressure Gauge Condition

Ventilation

Conditional Assessment of E-Assets

•Rating <=40 % Poor•Rating <=60% Fair•Rating <=70 % Good•Rating >70 % Excellent

WASA Lahore – Conditional Survey Result & Financing

Conditional AssessmentRating <=40 % PoorRating <=60% FairRating <=70 % GoodRating >70 % Excellent

Poor 21%

Fair 64%

Good6%

Excellent 8%

Disposal StationsPoor 20%

Fair 60%

Good16%

Excellent 5%

Tubewell StationsRehabilitation Cost

for TW & DS62.10 million

(BOQs for Rehabilitation have

been Prepared)

WASA Multan – Conditional Survey Result

Conditional AssessmentRating <=40 % PoorRating <=60% FairRating <=70 % GoodRating >70 % Excellent

Poor 4%

Fair 38%

Good21%

Excel-lent 38%

Conditional Survey Result - Disposal Station WASA Multan

Poor 3%

Fair 56%

Good

41%

Conditional Survey Result - Tubewell Stations

Rehabilitation Cost for TW & DS11.16 million

(BOQs for Rehabilitation have

been Prepared)

WASA Faisalabad – Conditional Survey Result

Conditional AssessmentRating <=40 % PoorRating <=60% FairRating <=70 % GoodRating >70 % Excellent

Poor

41%

Fair 51%

Good7%

Disposal Station

Poor 2%

Good39%

Excel-lent 59%

Tube well Station Rehabilitation Cost

for TW & DS6.50 million(BOQs for

Rehabilitation have been Prepared)

WASA Rawalpindi – Conditional Survey Result

Conditional AssessmentRating <=40 % PoorRating <=60% FairRating <=70 % GoodRating >70 % Excellent

Poor44%

Fair56%

Tube well Stations

Rehabilitation Cost for TW & DS32.58 million

(BOQs for Rehabilitation have

been Prepared)

WASA Gujranwala – Conditional Survey Result

Conditional AssessmentRating <=40 % PoorRating <=60% FairRating <=70 % GoodRating >70 % Excellent

Poor

33%

Fair 14%

Good33%

Ex-cel-lent 19%

Disposal Stations

Poor 29%

Fair 23%

Good

15%

Ex-cel-lent 30%

Not Operational 3%

Tubewell Stations

Rehabilitation Cost for TW & DS8.01 million(BOQs for

Rehabilitation have been Prepared)

Billing Data & Power Factor Analysis –Part 2

Energy Audit Findings

Annual Electric Billing on TW & DSRs 4.69 Billion / Annum

WASAs Sanctioned Load from WAPDA

(Mega Watt-MW)

Bill AmountFiscal Year 2013-

2014 (PKR-In Million)

Low Power Factor Penalty

(PKR-In Million)

Lahore 78.3 3092.4 21.4Rawalpindi 11.5 382.4 1.9

Multan 14.3 355.5 5.5Faisalabad 19.9 580.1 6.3Gujranwala 7.4 286.9 5.1

Total 131.4 4697.4 40.2

Annual Billing & Annual Low Power Factor Penalty

Lahore Rawalpindi Multan Faisalabad Gujranwala0

5

10

15

20

25 21.4

2.0

5.5 6.3 5.1

Low Power Factor Penalty (PKR-In Million)

Power Factor DefinitionRatio b/w active power to apparent power is called the Power Factor.Disadvantages of Low Power Factor:-1. Penalty from Electric Power Supply Company

Penalty Formula (PKR)= (0.9-Actual PF)*2*Energy Charges

2. Large Line Loss (Copper Loss)3. High input current requirement4. Large KVA Rating of Transformer & large size of

equipment requirement5. Greater Conductor /cable Size & Cost6. Poor Voltage Regulation & Large Voltage Drop7. Low efficiency of equipmentGadgets for Improving Power Factor:-8. Static Capacitors (Fixed Compensation )9. Automatic Power Factor Improvement Relay

(Automatic Compensation)

0

500

1000

1500

2000

2500

3000

3500 3,092.5

580.1 355.5 286.9 382.4

Bill Amount Fiscal Year 2013-2014 (PKR-In Million)

Low Power Factor Penalty PAID by WASAs Since PCGIP Inception

WASA Lahore WASA Faisalabad WASA Multan WASA Gujranwala WASA Rawalpindi0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0 42.8

12.6 11.0 10.1

3.9

LPF Penalty Paid- 80.4 Mil l ion PKR (Last TWO Years)

Costing of LPF Correction of DS & TW WASAs Annual Low Power

Factor Penalty (PKR-In Million)

Cost to Remove L.P.F Penalty (using

Automatic Power Factor Relay / Static

Capacitors)(PKR- In Million)

Payback Time

(Months)

Lahore 21.4 11.4 7Rawalpindi

1.9 0.7 4Multan 5.5 3.9 9

Faisalabad6.3 3.7 7

Gujranwala 5.1 3.1 8Total 40.2 22.8

LPF Savings for Next Three Years- 2014-2017

WASA Lahore WASA Faisalabad WASA Multan WASA Gujranwala WASA Rawalpindi0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

64.2

18.8 16.6 15.2

5.9

Projected Savings 2016-2017 120.6 Million PKR

Energy Audit – Part 3

Measurement

Flow Meter

Power Analyzer

Tachometer

General Tool Kit

Vibrometer

Well Sounder

Temperature Gun

Safety Kit

Camera

Energy Audit Instruments

Equipment Procurement- Status

WASAs W- Faisalabad W- Lahore W- Rawalpindi W- Multan W- Gujranwala

Status Procured Tendered Purchasing Stage

Tendered Not Procured due to Insufficient budget.

Energy Audit Results – Chiniot & JICA Tube wells in WASA Faisalabad

Tube well Name

No.s Avg. Motor Efficiency

Avg. Pump Efficiency

Recommendations

Chiniot- Jhang Branch Canal(KSB & Siemens)

21 83.58% 58.95% i) There is no need to replace these motors & Pumps as they are operating at acceptable efficiency range.ii) 17 tube wells require PF improvement.Automatic PFI compensating up to 40KVARS should be installed on these tube wells.

JICA-KSB & Siemens

25 83.57% 75.79% i) There is no need to replace motors & pumps as they are operating at acceptable efficiency range.ii) 09 tube wells require PF improvement. Automatic PFI compensating up to 25KVARS should be installed on these tube wells.

Challenges in Energy Audit (EA)Data Collection

• Field Staff

Data Provision

• High Response Time

• Systematic Record Inadequate

Equipment

• No EA Equipment

• Funds

• No Training of Instruments

Dedicated Team

• Work Overload

• EA Experience

• Lack of Capacity

Recommendation of Energy Audit – Part 1 and 2

Energy Audit Recommendations WASA Rough Cost in Rs Million

Conditional Survey Improvement of All Assets as poor and

Average

All WASA from Power & Energy Head of PCGIP

120.39

PF Corrections 1. Static Capacitors (Fixed Compensation )

2. Automatic Power Factor Improvement

Relay (Automatic Compensation

All WASAs from Power and Energy Head of

PCGIP

22.87

Equipment Immediate Purchase of EA Equipment/Set –

All WASAs except WASA F 1.5 -2

Energy Management PlanStep 1 • Conditional Rehabilitation – Completed – Costing

done and need procurement

Step 2• Power Factor Correction• 10% Saving Potential- Completed – Costing done

and need procurement -

Step 3 • Energy Auditing- Procurement of Firm

Step 4• Efficiency Improvement- 4th Year Procurement

Plans• 15% Saving Potential -

Step 5 • Capacity Building in Energy Management- & System for Monitoring

Comparison of Annual Billing after EMP

Saving Potential 706 Million PKR

Lahore Rawalpindi Multan Faisalabad Gujranwala

3092.5

382.4 355.5580.1 286.9

2319.4

286.8 266.6 435.1 215.2

Annual Billing Vs Expected Billing after EA

Bill AmountFiscal Year 2013-2014 (PKR-In Million)Bill Amount After Implementing EMOs (PKR-In Million)

Cost of Energy Management Plan

Component Cost (Million PKR) Time Lines Remarks

Asset Improvement 120.39 Dec 2016

PF Correction 22.87 Dec 2016

Replacement of Pumps 161.50 Dec 2016 Replacement of 316 pumps

Replacement of Motors 129.48 Dec 2016 Replacement of 316 motors

Capacity Building & Monitoring

5.00 Dec 2016

Total 439.24

Add on Asset Management MIS Application • Each Asset has Unique Asset Number /Application Number 1. Attachment of Electricity Bill

Attach Electricity Bill from DISCO Entry of Monthly Bill Amount, Payment, Power Factor and Power Factor Penalty Responsible Authority: Concern XEN/SDO Frequency: 1 Month updating

2. Conditional of Asset Conditional Assessment of Asset Picture of Every Asset Responsible Authority: Concern XEN/SDO Frequency: 6 Month for updateing

Add on Asset Management Application continues …• 3Efficiency of Pump & Motor :Asset Efficiency

Data Entry of Name Plate Data of Pump & Motor (Year, Make, Sr. No. Rating, Head, Flow, Pump Type, RPM & Efficiency . Class )

Record of Power Parameters (kW, KVARS, PF, Volts, RPM and Amps) Record of Head, Water Table Depth, Flow & Pressure Gauge Suction Length, Delivery Length, Suction & Delivery Dia, Drawdown Attachment of Pump Curve Highlight the Poor Efficiency Equipment Responsible Authority: Concern XEN/SDO Frequency: 6 Month

• O&M History- Cost Centre Rewinding History (Date, Copper (Kg) Required & Labor Cost) Bearing Replacement (Replacement Date, Greasing Date, Bearing No. & Cost) Pump Wear & Tear (Repairing /Replacement Date, Trimming Date & Labor

Cost) Valves Wear & Tear (Valve Type, Repairing/Replacement Date, Cost & Labor

Cost) Next O&M Frequency for Planning - Responsible Authority: Concern XEN/SDO Action Frequency: Quarterly

THANK YOU