Saving energy and maintaining a pump station in India

Mansi Wakal pumping station under Dewas-I water supply scheme was commissioned in 2008 and the water from the dam is supplied to Udaipur city. Water is lifted from the Mansi Wakal dam and then sent to the Nandeshwar filter plant, at Udaipur, through a 16000 m, 800 mm MS pipeline and a 4500 m long tunnel. Secure has been working on this project since February 2018.

Operation and maintenance of

• plant and machinery installed at pumping station, dam and
  pipeline,
• Landscaped area inside the pumping station boundary,
• 33kV switchyard,
• pipeline up to the filter plant inlet.

Energy saving through

• ecient running of plant and machinery,
• refurbishment / replacement of pumping machinery.

• HT pumps were running at about 65 per cent eciency against their design eciency of 84 per cent, resulting in massive power wastage.
• Flow meters were not working properly, therefore water roduction was on assumption basis.
• Poor power factor due to the absence of proper capacitor bank.
• Performance and duty point of individual pump was not known.
• No water leakage identification from source to the inlet of filter plant.

• Deploy pump performance monitoring system and publish real time data including pump eciency, flow, head, power consumption, vibration, sound and other technical parameters of each pump on public URL with access rights to PHED ocials.
• To improve eciency of all the pumps either through refurbishment or replacement and to make them energy ecient so that specific energy consumption (SEC) of the pumping station could be improved.
• Ecient operation and maintenance (including preventive and periodical maintenance) of the entire plant, machinery installed in pump house and switchyard / GSS at the main pumping station.
• Maintain notified flow and to ensure smooth operation of pump house 24 by 7.
• Maintain power factor above 0.98.
• Identify and resolve leakages in the pipeline.

• Deployed web-based pump performance monitoring system for each pump. Published all important electrical and hydraulic parameters for individual pump on the web portal and mobile app, and provided access rights to PHED ocials.
• Refurbished all the pumps using best industrial practices and achieved an eciency of nearly 80 per cent.
• Installed three ultrasonic flow meters to determine actual water production and to identify leakages in the transmission pipeline.
• Installed capacitor bank to improve power factor.
• Constructed a 250 metre long and 2.75 metre wide CC road inside the pumping station premises for easy accessibility to pumping station for better management.
• Replaced all old incandescent bulbs with new energy ecient LED lights.

• PHED’s energy bill is reduced by about 17 per cent due to improvement in eciency of all pumps while keeping the same water production.
• Using flow meters, water production is now accurately measured and monitored eectively. Leakages are also being addressed promptly to stop wastage of water and to avoid pressure change in transmission.
• PHED is getting maximum incentive due to high power factor.
• No manual intervention for reading of electrical and flow measurement devices.
• Remote monitoring of all electrical and hydraulic parameters of each pump. PHED ocials can now see and monitor more than 20 operating parameters of each pump like flow, head, pressure, ower, eciency etc.