GUIDELINES FOR OPTIMIZATION OF

POWER CONSUMPTION AND EFFICIENCY IMPROVEMENT IN WATER PUMPING SYSTEMS 1. Introduction Increasingly irregular monsoon rains, growing populations, and rising energy tariffs, leave municipal officials with the ever greater challenge of meeting urban water demand in a cost effective manner. Often options are limited, and many Indian municipalities must pump water over long distances, requiring the costly conveyance infrastructure and on-going maintenance costs associated with these systems. Municipalities without the means to make these investments are forced into the difficult situation of simply not meeting user needs, often supplying water just a few days each week. Municipal water pumping involves substantial energy use which constitutes a significant proportion of the property tax revenues of the ULBs. Energy Studies conducted under DFID funded APUSP project revealed that municipal energy costs range from 35% to 217% of property tax revenues and that a potential minimum energy saving of 12.63% of property tax revenues can be achieved through energy conservation and efficiency measures. Thus cost savings through energy conservation and efficiency improvement would lead to significant reduction of burden on the municipality and help the ULB in using the savings for improved O&M or in providing better services to the citizens and in improving environmental sustainability through reduction of green house gas emissions. They also revealed that if we spend 1/3rd of the total amount we can achieve 80% of potential savings through NO-COST and LOW-COST actions like: i) ii) iii) rationalizing Contracted Maximum Demand by revising agreement with DISCOM providing capacitors to enhance power factor (PF) and thus avoiding Low PF surcharge segregating Light and Fan loads from pumping loads thus preventing higher tariff for pumping loads also etc.

2. Optimizing use of water & power Energy consumption in most water systems worldwide could be reduced by at least 25 percent through cost-effective efficiency actions. As per the Energy Studies conducted in 7 towns, the cost of implementation of energy efficiency measures and its annual savings and projected figures are for all 118 municipalities are as follows. Towns 7 Towns 118 Towns Population in Implementation Costs of Lakhs as per Energy Efficiency 2001 census measures in Lakhs of Rs 22.22 332.23 143.14 2096.14* Annual Savings in Lakhs of Rs 533.65 3365.10*

(* Projections only)

The above figures themselves tell the potentiality for the power savings through taking up Energy Efficiency Measures. Unfortunately, relatively little attention has been given to reducing energy use in municipal water systems. If we continue on the current path, energy consumption by municipal water utilities will double as well. The city of Pune quickly identified more than Rs.70 lakh of energy savings opportunities after kicking off an energy efficiency program; it has only managed to implement one-fifth of the projects. 1

3. The guidelines are prepared for Optimization of Energy consumption and efficiency improvements in Pumping Systems and Street Lighting based on the Energy Studies conducted by Engineering Staff College of India (ESCI), Hyderabad and The Energy Resource Institute (TERI), Bangalore. Firstly, the pumping systems are discussed and detailed tables are given for opportunities for energy savings/efficiency and actions to be taken for achieving the benefits. 4. Well Designed Pumping Systems The study of entire systems is more important than the study of individual component for arriving the most energy efficient pumping system i) ii) Selection of motors Selection of Pumps to match Head/Flow requirements iii) Improving Efficiency of Pumps iv) Number of Pumps in a system v) Optimizing Piping Design vi) Leakage and loss control vii) Preventative Maintenance viii) Monitoring and Control 5. Motors Motors can run without problems for 20 years or more with good protection and routine maintenance. However if they are running inefficiently, it is worthwhile replacing them as running costs are much more than first costs. Motors can be considered as consumable items and not capital items, considering the current energy prices. Even a small difference in efficiency can make a significant difference in running cost When economically justified, motors may be replaced, even if these have been installed
100 90 %Efficiency & Power factor 80 70 60 50 40 30 20 10 0 0 25 50 % Load 75 100
Eff iciency Pow er factor

Fig 1 Fig 1 shows that variations of motor efficiency and power factor with load. It may be seen that efficiency is nearly constant up to 40% of shaft load and then drops sharply at lower loads. However power factor drops continuously with shaft load. The efficiency of motors operating at loads below 40% is likely to be poor and energy savings are possible by replacing these with properly sized motors. 2

Even a small difference in efficiency can make a significant difference in running cost. When economically justified, motors may be replaced, even if these have been installed S.N o
1 2 3

Factors affecting Action/ Remedy efficiency

Oversized Motors Idle/redundant running of motors Old and inefficient motors Motor failures Selection of correct size motors Stop the motors working below capacity Evaluate the economics with the recurring cost and capital cost & replace old motors with new Provide proper protection devices and maintain good working condition, ensure proper O&M Rewinding of motors as per original data, with proper gauge and no. of windings Use high efficiency motors though they may cost more.

Benefits
1. Huge investments saving 2. Less running costs 3. Good PF Savings of unnecessary power consumption Long term recurring costs can be saved Increase the life of motors

Long /Medium/Sh ort term measures

L S L

Burnt motor windings

Recurring rewinding costs can be saved Recurring high power bills can be reduced. The extra capital cost can be recovered from the saving of electricity bills.

Low efficiency motors

6. Selection of Pumps and improving efficiency

160

120
Pump Head(mWC)

80

40
System Curve Pump Curve

0 0 1600 3200 Capacity (lpm) 4800 6400

Fig 2 Fig 2 shows the typical pumping system depicting the operating point for a given pump and system characteristic. The stable operating point is decided by the intersection of pump head/flow curve with system head/flow curve. Size the pumps to achieve operation in best efficiency zone under most of the operating conditions

S.N o
1

Factors affecting Action/ Remedy efficiency

Incorrect Size of pump

Benefits

Long /Medium/Short term measures

Select correct size of 1. Huge investment saving pump based on the 2. Less running costs actual requirement of 3. Good PF Discharge and Head Realistically arrive at the required Discharge and Head, avoiding unnecessary safety margins Evaluate the economics with the recurring cost and capital cost Existing pump capacity & design can be reviewed for improvement Always avoid throttling of valves at normal working condition. Savings of unnecessary power consumption

Assessing actual Head and Discharge

3 4

Replacement of old (worn out) pumps with new Existing pump capacity High / Low

Long term recurring costs can be saved

L L

Throttling of Valves leading to high friction losses

Pump will work at rated H& Q with high efficiency Overall efficiency of pumping system can be maintained high

Pumps of different1. Select pumps with capacity running similar characteristics in parallel 2. Increase the pipe size to accommodate the extra flow High capacity of standby pump sets Go for 33% or 25% stand by units instead of 50%. Use more no. of smaller capacity pump sets

Capital cost can be minimized. More flexibility to meet variable flow requirements

Inappropriate pump characteristics

1. By

reducing impeller dia. 2. Changing impeller for correct H & Q 3. Change of speed 4. Change of pump, if efficiency of pump is reduced in old pump

Improving the efficiency

7. Piping Design a) Promote gravity flow as far as possible. b) Always consider Long term/Life Cycle operating costs while sizing pipes (working economics of pumping mains with different dia. and materials) c) While estimating the flow requirements through the pipe net works, ascertain long term availability of water in that source. S.N o
1

Factors affecting efficiency

Low C value

Action/ Remedy

Benefits

Long /Medium/Short term measures

Provide low friction pipes, Less frictional losses lead to power fittings & appurtenances saving Design the pipe network for 1. Reduced leakage optimum pressure to reduce 2. Lower stress in pipes & joints loss of head. 3. Extended life of equipment 4. Reduced system deterioration 5. Reduced need for repairs Identify the old corroded, 1. Increase in carrying capacity silted up pipes and replace 2. less power consumption them with new pipes of high C value Identify leakages by site 1. Minimize the wastage of water inspection & take steps to 2. Saving of power arrest them immediately 3. Better and more water to people

High

residual pressures in distribution mains

Old pipes

Leakage arrest

8. Leak & Loss reduction Leakage problems are forced not only to pump more water than is actually needed, but also to increase system pressure to assure that the water reaches the consumer. Increasing pressure is usually less cost effective than fixing the leaks and maintaining a lower pressure. Furthermore, higher system pressure actually exacerbates the leakage, wasting even more water and energy. Water Accounting Systems: 5

Implementing a system of water accounting is a valuable first step in controlling losses. Water accounting should ideally begin at the source and extend to end users to determine water losses. Even under good management conditions, unaccounted for water normally constitutes 1015 percent of the water produced; thus, if water loss is greater than 1520 percent of water produced, corrective action is necessary. It is important to stress that unaccounted for water reduction programs need constant maintenance; leaks will reoccur if authorities are not vigilant. 9. Preventive maintenance Proper and regular operation and maintenance duly maintaining the necessary records carrying out repairs and replacing the worn out parts, gauges, meters with guanine and standard company products in time is required, apart from supervision by senior officers at regular intervals helps as indicated below a) Prevents spending of huge amount if a break down occurs b) Avoids interruptions in water supply and power supply to public c) Extends life of the equipment and its smooth function and avoids early high investment

10. Bore wells S.N o

1 2 3

Factors affecting Action/ Remedy efficiency

Defunct bore wells -lead to min. power charges Less yield from power bore wells Fixing timings power bore wells for Immediately disconnect the power connection Immediately convert them into hand bore Operating timings can be maintained by municipal staff / local residents committee Evaluate pump efficiency and its working parameters with requirement

Benefits
Huge savings charges in power

Long /Medium/Short term measures

S S S

Elimination of unnecessary power charges Reduced power consumption and water loss Reduced power consumption and water loss

Fixing pressure gauges

11. Importance of CMD & PF and dealing with Power Distribution Companies (DISCOMS) Always keep an eye on the electricity bill, the Contracted Maximum Demand (CMD), energy meter readings, the different charges, surcharges, penalties and levies included in the bill and verify them with corresponding meter readings. If any difference is observed, immediately it must be brought to the notice of the higher authorities for necessary rectification after reconciliation with the DISCOM.

S.N o
1 2 3

Factors efficiency

affecting Action/ Remedy

Benefits

Long /Medium/Sh ort term measures

High Maximum Demand (MD) Low MD Low Power Factor

4 5

Non-segregation of Light & Fan (L & F) loads High and Low MD in different seasons due to variations in demand and supply

Address concerned DISCOM Surcharge can be avoided due to to enhance the CMD as per excess consumption recommended KVA. Address concerned DICOM Penalty can be avoided by to reduce the CMD as per maintaining high power factor recommended KVA. Provide correct rated capacitors at all pumping 2. High losses in transformers and lines stations 3. Minimum voltage drop in pipe lines 4. Improvement of power quality. Segregate L&F loads of water supply & Sewerage, Bore wells Analyze the MD in different seasons and arrive at an optimum MD that will minimize the excess demand charges and address the DISCOM to either reduce or increase the CMD.

Immediate Immediate S

S S

12. Implementation of energy efficiency projects After identifying the list of potential efficiency opportunities/measures, the municipality can make decisions on which measures to implement and how to make that projects happen. The municipal team must prepare the project with critical information that will make the project more attractive to the funding agencies. The project proposal needs to address the following key issues. i) Equipment sizing and specification ii) Impact of the project on other parts of the system iii) Planning growth iv) Maintenance scheduling and accounting for depreciation v) Prioritization in accordance with (a) Overall capital investment needed (b) System technical constraints (c) Available financing Doing the financial analysis: i) To allow the project financial decision makers to assess projects, expected cost & revenue for the project must be quantified ii) Identifying project cost and savings allow for the calculations of payback, return on investment iii) Change of equipment, correcting to work with existing system iv) Additional manpower and training to them Should we start with pilot projects? i) There is heavy risk to take up large scale project initially ii) Small investments iii) Verifying technology and savings iv) Identifying unforeseen technical or logistical problems How sure are the savings? i) Start small and build a track record of success ii) Be conservative with estimates, if technology promises 10 15% savings. Assume only 10% 7

iii)

Check with other agencies to verify technology and results of similar projects

13. Identify project funding options in Energy efficiency measures For funding a project, the municipalities have to identify internal and external funding options. i) Internal funding: The municipality can fund the new efficiency projects (short term measures) and get the full benefit of returns/savings directly into its own account. After initial success in reducing the operating costs through efficiency, they can utilize previous project savings to take up additional activities. Another alternative with payback threshold: While taking up efficiency projects setting a payback threshold, the ULB has to incur some initial investment. Preferably, the payback period should not exceed 2 years. Financing through ESCO(Energy Saving Company): If the municipality lacks the needed financial resources and /or technical capacity to implement a energy efficiency project, the ESCO will finance & take all the risk of implementing that project by investing combination of money, equipment and know-how. The savings got through implementing that energy efficiency program can be shared by ESCO & the municipality as per the terms and conditions. Equipment Leasing: Taking equipment such as energy efficient motors, pumps and other costly energy saving equipment on lease.

ii) iii)

iv)

Advantages 1. The municipality need not go for huge financial commitment 2. Through leasing, the municipality can determine in real working environment to evaluate the vendors product and its performance 3. The municipality can pay back the leasing amount through the energy savings 4. Leasing is not always the best option 14. Technology & Vendor selection It is important to remember that many firms often make many claims on the performance of their products, but in the field the performance commonly varies from the vendors claims. To investigate the project risks and make best investment: i) contact the agencies, which have already implemented similar projects and to gain advices about technology & vendor ii) know the product benefits and drawbacks iii) obtain the opinion of certifying agencies on those products iv) ask the firm for performance guarantee and warranty

Water Pumping: Issues & Remedies in a Nutshell 1 CMD - excess demand charges 2 Low PF surcharge - levy Study demand pattern Request rationalization Install Capacitors

3 Excess charges due to nonInstall separate LT meter for L&F load segregation of Light & Fan (L&F) loads in pump stations 4 Delayed payments Penalties inCollect bills in person- Make prompt payment energy bills 5 Excess charges due to inappropriateConvert - HT to LT or LT to HT category as power connection category needed 6 Defunct power bores 7 Motors - old & rewound 8 Pumps efficiency damaged Disconnect - avoid minimum charges. Transfer them to new LT connections - thus avoid initial deposits for new connections. Replace with energy efficient (eff 1) motors conforming to IS: 12615-2004 reducedRetrofitting of pumps or replace high efficiency pumps wrongAvoid unnecessary bends & valves & prevent leakages-reduce head

9 High friction losses fixation of head

10 Unnecessary pumping waste ofAvoid unnecessary pumping - convert to energy gravity where possible 11 Inadequate maintenance ofProcure amorphous core type- reputed make. Transformer and poor quality Maintain transformer as per manufacturers instructions 12 Lack of attitudes and skills in staffImpart training and awareness in a campaign and public representatives mode and renew them at intervals to staff 13 Poor operation and maintenance Establish operating procedures, guidelines-training in O&M supply

14 Airlocking in pipe lines, leakagePrevent air entry into reservoirs, sumps, pipe and pipe bursts lines. Provide necessary air valves. 15 Poor O&M of electrical utilities Establish operating procedures for pump sets, transformers, generators. Training, supply tool kits, measuring equipment

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KURNOOL GRAVITY in place of pumping (Feb-2006) Saving : Rs 1.65 lakh/ month

PRODDUTUR & KADAPA LT category converted to HT category Change of Tariff Proddatur - Saving : Rs 1.95 lakh/ month Kadapa - Saving : Rs 1.20 lakh/ month TIRUPATI HT converted to LT category & Deration of CMD Savings (July 06) : Rs 3.02 lakhs/month Deployed Municipal staff for ON/OFF Switches Savings (since March 06) : Rs 13.69 lakhs ONGOLE Transfer of connections of defunct bore wells & boosters to new street light Services Savings in development charges Adjustment of outstanding deposit amount of temporary connection - Savings : Rs.4.38 Lakhs Detection of payment made by ULB for street lighting services of panchayat / other institutions from 1994

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