Masterdata of the Service Report - ESCAP

Masterdata of the Service Report

Number of pages: 26

Date: 18-May-2014Erst ausf?llen, wenn der Bericht vollst?ndig ist.

Information on the job

Author: Suttichai Yordkarw .

Qualification: Service Engineer .

Job order No. / MC: ZA1312-722 .

Assignment from: .

until: .

Work sheet No.: .

Service report No.: 20140530-ZA1312722(Lamtaklong PumpingStation) .

Job coordination / Name: Pichai / Piyachat .

Department : Aftermarket .

Information on the customer

Customer: GIZ .

Address: Nakornratchasima .

Postal / Zip code: .

Place: Nakornratchasima .

Site / Plant: Lamtaklong pumping station .

Contact: Khun Rashane .

Department: .

Telephon: 081-7022955 .

Telefax: .

Information on the pump

Type series : Lamtaklong Pumping Station (Total 6 pump sets) .

Works-No.: .

Repair commission: System Efficiency Service Inspection

KSB Pumps Co., Ltd.57 M.14 Suwintawong Road, Kratumrai, Nongchok, Bangkok, Thailand 10530

Tel: +66 2988 2324 Fax: +66 2988 2210 E-mail: [email protected]

Suttichai Yordkarw Date :

KSB pumps Co., Ltd. 57 M.14 Suwintawong road, Kratumrai, Nongchok, Bangkok, Thailand 10530

Tel: +66 2988 2324 Fax: +66 2988 2210 (service direct line) E-mail:[email protected]

Water Supply System

Lamtaklong Pumping Station

Author : 30/05/14

service report

page 1

SYSTEM EFFICENCY SERVICE

Raw Water Pump System

OF

Installation

Repair

Inspection/Check

Commissioning/Test run

Technical support

Maint.Inspect.

CONTENTPage

1. Overview 4

2. Objective 6

3. Activities & Summary 6

Piping Diagram 7

Single pump operating at site 8

LOAD 1 Check pump operating pumps 4 pumps at site 9

LOAD 2 Check pump operating pumps 3 pumps at site 9

New pump siggle pump operating 10

New pump operating according Load1 and Load 2. 11

Compare power consumption of the existing pumps with the new ones 12

Selection the new pumps 6

Compare power consumption of the existing pumps with the new ones 6

4. Annex 13

1. Existing Pump data 14

2. Measurement Techniques 17

3. Technical infomation of Siemens motor 18

4. Performance curve of new pump at original 1000 m3/h H 82 m 20

5. Performance curve of new pump at original 752.4 m3/h H 81 m 22

6. Discharge adepter for new pump at original 752.4 m3/h H 81 m. 24

7. Head loss calculation 25




service report

page 2

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.




Author : 30/05/14

service report

Page 3

Overview

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

1. Overview

The pump operating 4 or 3 indentical pumps are installed on parallel system.

Makamtheao Pumping Station.In order to determine actual operating condition, pump total flowrate,pump discharge presserure and

power consumption recorded by power meter in the cabinet control panel, the flow rate was checked by flow meter at header pipe line.

The pump are operating 4 pumps supply flow to discharge tank and supply gravity flowrate to Makamtheao Pumping, if the discharge

fully level maximum 6 meter, the pumps will operating 3 pumps.When the discharge tank level minimum 3.5 meter,the pumps will

operating 4 pumps.




service report

Page 4

Lamtaklong Pumping Station, there are six pump in processed.The pump are installed and being in service more than 25 year.On site.

The pump need to supply the flow to discharge tank on the mountain and supply gravity flow rate are depending on demand of water to

Author : 30/05/14

Figure 1-1-1: Pumps in the raw water supply system.

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.




Author : 30/05/14

service report

Page 5

Objective & Activities

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

2.Objective

3.Limited of inspection on site.

3.4 The header line do not have the position for installation pressure gauge..

3.4 The pump No.2 is repairing at site./not operated

4. Activities & Conclusion

The pump are operating(Load 1) 4 pumps supply flowrate about 3610 m3/h to discharge tank and supply gravity flowrate about 3200 m

3/h

to Makamtheao Pumping Station.If the discharge fully level maximum 6 meter, the pumps will operating(Load 2) 3 pumps.When the

discharge tank level minimum 3.5 meter,the pumps will operating(Load 1) 4 pumps.Note The on peak load time 06:00-10:00 PM The

pumps must be operating(Load 2) 3 pumps.

- Existing Pump duty point Q 1000 m3/h H 82 m, with coupled with 375 kW motor.

- New pump original is duty point Q 1000 m3/h H 82 m, the new pump is B-Pump/Size B20B/2 with coupled with 355 kW motor

- Existing Pump duty point Q 752.4 m3/h H 81 m, with coupled with 264 kW motor.

- New pump original is duty point Q 1000 m3/h H 82 m, the new pump is B-Pump/Size B16D/5B/2 with coupled with 250 kW motor

6.1 The existing operating condition will cost electricity 29,964,456 THB / year

6.2 The new ones operating condition will cost electricity 24,723,348 THB / year , saving 5,241,108 THB / year approx.

power consumption, energy saving and return on investment (ROI) within 3.3 year. showed in table 4-5, page 15-16




Author : 30/05/14

2.1 To optimize the power consumption of plant operation

4.3 LOAD 2 (Check the actual maximum capacity of 3 pumps (06:00 PM- 10:00 AM)

4.3.1 The history recorded and operator confirmed the maximum capacity of 3 pumps pumping station

4.3.2 The result showed in table 3-2, page 9

4.2 LOAD 1 (Check the actual maximum operating of 4 pumps (10:00 PM- 06:00 AM) and (6:00 AM-06:00PM)

6.3 We propose to replace the existing pump with the new one, total 6 pumps considering from the efficiency The comparision of

5.2 Replacment pump 1,2,4&6

service report

Page 6

6. Compare the power consumption of the exisiting pumps with the new ones

3.1 The customer not allowed to throttling valve due to they worry about water leakage in the piping system.

3.2 The pump No.1,2,3 and 6 power meter in the cabinet was damage.

3.3 The pump No.1,2,3,4,5 and 6 discharge pressure gauge were damage.(Use pressure gauge from KSB)

5. Selection the new pump according to the original duty point and the actual demand of the pumping station

4.2.1 The history recorded and operator confirmed the maximum capacity of 4 pumps pumping station


4.1 Check the actual capacity of single pumps operating at pumping stations

4.1.1 Test the pump individual performance and fixed position valve same condition.


5.1 Replacment pump 3&6

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

Piping Diagram

Fig 2-1-1 Piping Diagram of Pumping Station

1

2

3*

4

5

6*

Remark : *3 *6 is bigger than 1-2 and 4-5




service report

Page 7

Author : 30/05/14

PUMPFlow m

3/h Head(m) Motor(kW)

Duty Point

264

264

275

264

264

275

81

81

82

81

81

821000

752.4

752.4

1000

752.4

752.4

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

Measure discharge Pressure gauge

Header measure flow rated at pumping station

Single pump operating at site

Table 4.1 Shown data from pump single operating only one pump check at site

Density Ppump

(Kg/m3) (Cal)

m3/h P1 P2 T r H kW kW A

34% 1 770 7.0 6.2 6.9 25 997 71 261 268.9 56- - - - - - - - - - - -

100% 3 1120 7.0 5.9 6.6 25 997 67 374 374.5 7830% 4 775 7.0 6.3 7.0 25 997 72 269 273.7 5725% 5 780 7.0 7.3 8.0 25 997 82 268 273.7 57100% 6 1103 7.0 6.1 6.8 25 997 70 364 369.7 77

Single pump operating ( Check the actual capacity of single pump operating condition at pumping stations )

1 Check pump single pump operating.

2 Test the pump individual performance and fixed position valve same normal condition

3 The pump No.2 is repairing at site.




Author : 30/05/14

56.5

Pmotor input Motor

Current(Cal)

%

Sin

gle

pu

mp

op

era

tin

g 55.0

-

54.96

55.2

63.4

Level

water

(m)

Discharge

Pressure

(bar) ΔP (bar)

Operating

temp(°C)

TDH(m)

Actual

PEFF Flow

(Q)

Actual

service report

Page 8

LOAD% Open

Valve

Pump

Item

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

268.9

374.5

273.7 273.7

369.7

55.0 54.9 55.263.4 56.5

0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

400.0

Pump 1 Pump 3 Pump 4 Pump 5 Pump 6

Single pump Operating

Pmotor input(kW) PEEF(%)

Table 4.2 Shown energy from pump operating pumps Load 1 and Load 2 check at site

Density Ppump

(Kg/m3) (Actual)

m3/h P1 P2 T r H kW kW A

34% 1 7.0 6.4 6.9 25 997 71 261 268.9 56

100% 3 7.0 5.9 6.6 25 997 67 374 374.5 78

30% 4 7.0 6.3 7.0 25 997 72 269 273.7 57

25% 5 7.0 7.3 8.0 25 997 82 368 273.7 57

34% 1 7.0 6.2 6.9 25 997 71 361 268.9 56

100% 4 7.0 6.3 7.0 25 997 72 369 273.7 57

30% 6 7.0 6.1 6.8 25 997 70 364.0 369.7 77

LOAD 1 (Check the actual maximum operating of 4 pumps (10:00 PM- 06:00 AM) and (6:00 AM-06:00PM)

1 Check pump operating at fixed position valve same normal condition

2 The history recorded and operator confirmed the maximum capacity of 4 pumps pumping station

3 Pump operating about 20 hour/day

LOAD 2 (Check the actual maximum capacity of 3 pumps (06:00 PM- 10:00 AM)

1 Check pump operating at open position valve(%)

2 The history recorded and operator confirmed the maximum capacity of 3 pumps pumping station





Author : 30/05/14

63.4

LO

AD

2

(10

:01

PM

-06

:00

PM

)

2771

55

55.2

56.5

LO

AD

1

(10

:01

PM

-06

:00

PM

)

3610

55

55.2

54.9

Level

water

(m)

Discharge

Pressure

(bar) ΔP (bar)

Operating

temp(°C)

TDH(m)

Actual

PEFF

Pmotor input Motor

Current(Cal)

%

Total

(Q)

Actual

service report

Page 9

LOAD

%

Open

Valve

Pump

Item

Load 1 and Load 2 Check pump operating pumps 4 pumps at site

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

11

90

.8

91

2.3

36

10

27

71

L O A D 1 L O A D 2

ORIGINAL PUMP OPERATING LOAD 2&3

Total Power(kW) Total Flow(m3/h)

New pump siggle pump operating

Density PEFF MEFF

(Kg/m3) (ƞ) (ƞ)

m3/h m kW T r % % kW

752.4 81 212.1 25 997 80 95.2 222.8

752.4 81 212.1 25 997 80 95.2 222.8

1000 82 296.7 25 997 76 95.8 309.7

752.4 81 212.1 25 997 80 95.2 222.8

752.4 81 212.1 25 997 80 95.2 222.8

1000 82 296.7 25 997 76 95.8 309.7

Selection new pump single operating accordting to the original duty point of the pumping station.

- Existing Pump duty point Q 1000 m3/h H 82 m, with coupled with 375 kW motor.

- New pump original is duty point Q 1000 m3/h H 82 m, the new pump is B-Pump/Size B20B/2 with coupled with 355 kW motor

- Existing Pump duty point Q 752.4 m3/h H 81 m, with coupled with 264 kW motor.

- New pump original is duty point Q 1000 m3/h H 82 m, the new pump is B-Pump/Size B16D/5B/2 with coupled with 250 kW motor

Author : Suttichai Yordkarw Date :



30/05/14

Table 4-3 Show data from new pump

1. Replacment pump 3&6

2. Replacment pump 1,2,4&6

4

Pmotor

input

1

23

56

service report

Page 10

New pump Itemp Flow (Q)

Operating

temp(°C)TDH Ppump

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

222.8 222.8

309.7

222.8 222.8

310

80 80 76 80 80 76

0

50

100

150

200

250

300

350

Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Pump 6

New Pump Operating Only One Pump

Pmotor (kW) PEEF(%)

Table 4-4 Shown energy according to the original duty point and compare with new pump from demand of the pumping station.

Actual New Actual New Actual New Actual New

m3/h m

3/h m m % % kW kW

1 71 81 55.0 80 268.9 222.7

3 67 82 54.9 76 374.5 309.7

4 72 81 55.2 80 273.7 222.7

5 82 81 56.5 80 273.7 222.7

1 71 81 55.0 80 268.9 222.7

4 72 81 55.2 80 273.7 222.7

6 70 82 56.5 76 369.7 309.7

LOAD 1 (New pump operating of 4 pumps (10:00 PM- 06:00 AM) and (6:00 AM-06:00PM)


LOAD 2 (New pump operating of 3 pumps (06:00 PM- 10:00 AM)





30/05/14

LOAD 2

2,771 2,50406:00 PM-10:00 PM

LOAD 1

3,610

TDH

3,25610:01 PM-06:00 PM

Peff Pmotor input

New pump operating according Load1 and Load 2.

service report

Page 11

LOADPump

Item

Total Flow (Q)

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

933.60721.50

3256

2504

LOAD 1 LOAD2

New Pump Operating Load 2&3

Total Power(kW) Total Flow(m3/h)

Table 4-5 Shown energy from new pump operating pumps. : Replace all pump

kWh/y h/day kWh/day kWh/y THB/y THB/y THB year

Table 4-6 Shown energy from new pump only pumps No.3 and 6 operating pumps.:Replace only pump 3&6 (Big pump)


Tabel 4-7 Shown energy from new pump only 1,2,4 and 5 operating pumps.:Replace pump 1-2,4-5 (Small pump)


Remark : Electrical rate 3 THB/kWh




30/05/14

New Pump

2 1,120.7 20 22,414

3 850.7 4 3,403

5.33 911.2 4 3,645

Existing

Pump

2 1,186 20 23,720

1,695,060 9,048,400 8,181,110

28,269,396

Cost savingNew pump

CostROI

New Pump

2 1,043.1 20 20,862

3 719 4 2,876

Conditio

n

Total Power OperatingPower

Operating

LOADTotal Power Operating

Power

Operating

Existing

Pump

2 1,186 20 23,720

3,971,346 8,337,000 2.1

3 911.2 4 3,645

Electrical

Cost/yearCost saving

New pump

CostROI

Electrical

Cost/year

New Pump

2 977.9 20 19,558

3 755.1 4 3,020

7,138,670

1,102,446

29,964,456

24,723,348

5,241,108 17,385,400 3.3

3 911.2 4 3,645

Existing

Pump

2 1,186 20 23,720

service report

Page 12

LOADTotal Power Operating

Compare power consumption of the existing pumps with the new ones

Electrical

Cost/year

8,657,800

1,330,352

Power

Operating

Electrical

Cost/yearCost saving

New pump

CostROI

1,242,022

8,657,800

29,964,456

1,330,352

7,614,630

25,993,110

1,049,740

Electrical

Cost/year

8,657,800 29,964,456

1,330,352

Electrical

Cost/year

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

1. Existing Pump data

2. Measurement Techniques

3. Technical infomation of Siemens motor

4. Technical information of ABB motor

5. Performance curve of new pump at original duty point / at Middle Pumping station

6. Performance curve of new pump at new duty point / at Middle Pumping station

7. Performance curve of new pump at original duty point / at Back Pumping station

8. Performance curve of new pump at new duty point / at Back Pumping station

9. Head loss calculation




service report

Page 13

ANNEX

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

1. Existing Pump data

Reference pump no.1

Pump Design Motor Design

Pump TECO Motor

Type 350/2 VGM AT 0417 Type AEJW

IMP.DIA Frame 355 AB

S/No 1370 Sr. D90219-5

Flow rate Q 12.54 m3/min Power 264 kW /355 HP

Head 81 m. Volts 3300

Suction pipe - Current 55 A

Discharge pipe - Phase 3

Speed 1450 min-1

Frequency 50 Hz

Power 250 kW INS.Class F

Speed 1483 min-1

2.3.2 Pumping Station

Reference pump no.2


Pump TECO Motor



S/No 1368 Sr. D90219-2





Speed 1450 min-1

Frequency 50 Hz


Speed 1483 min-1




service report

Page 14

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

Reference pump no.3


Floway Pump TECO Motor

Type 18 MKH Type AEJW-PA 001

IMP.DIA SET,4:78 Frame 400AB

S/No G1431-1-1 Sr. Fo.D36024-1

Flow rate Q 1000 m3/h Power 375 kW




Speed 1460 min-1

Frequency 50 Hz

Power - INS.Class F

Speed 1483 min-1

Reference pump no.4


Pump TECO Motor



S/No 1367 Sr. D90219-3





Speed 1450 min-1

Frequency 50 Hz


Speed 1483 min-1




service report

Page 15

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

Reference pump no.5


Pump TECO Motor



S/No 1369 Sr. D90219-4





Speed 1450 min-1

Frequency 50 Hz


Speed 1483 min-1

Reference pump no.6


AWAMURA Pump HIGH THRUST Motor

Type 250×3 VGM CX-0857 Type IV

IMP.DIA Frame 5811 P

S/No H 0940 Sr. D90219-3





Speed 1450 min-1

Frequency 50 Hz

Power 372 kW/500 HP INS.Class F

Speed 1487 min-1




service report

Page 16

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

2. Measurement Techniques

2.1 Pressure measurment

The head generated by the pump equals to the mechanical power transferred on the mass flow of the pumped fluid. Pump head

can be explained as a discharged fluid.

2.2 Flow meter measurement.

Flow meter has been installed at discharge header line during pump tested at one pump at a time.

2.3 Power measurement.

The electrical power consumption measured in the cabinet control panel.




service report

Page 17

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

3. Technical infomation of Siemens motor

3.1 Used for calculate the energy saving for new pumps at original duty point 1000 m3/h H 82 m.




service report

Page 18

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

3.2 Used for calculate the energy saving for new pumps at original duty point 752.4 m3/h H 81 m.




service report

Page 19

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

4. Performance curve and data sheet of new pump at original 1000 m3/h H 82 m. duty point / at Lamtaklong Pumping station




service report

Page 20

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.




service report

Page 21

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

5. Performance curve and data sheet of new pump at original 752.4 m3/h H 81 m. duty point / at Lamtaklong Pumping station




service report

Page 22

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.




service report

Page 23

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

6. Discharge adepter for new pump at original 752.4 m3/h H 81 m. duty point / at Lamtaklong Pumping station




service report

Page 24

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

7. Head loss calculation

1. Pump no 3 at Lamtaklong pumping station

Found that during pump running at normal condition at discharge valve 100% opened the pressure P2 and P3 show as following;

P2 = 5.9 bar, therefore, DP = 6.6 bar at Q 1120 m3/hr

P4 = 5.87 bar (after losses from valve, check valve and pipe lines)

Therefore, the H of new pump should be same P2 as below calculate.

H = DP/rg

67.4807

12. Pump no. 1 at Lamtaklong pumping station.

Found detail as following.

- Discharge valve could be opened at only 34%.

- Pressure at header line P3 is 5.87 bar.(60.01 m).

- Discharge pressure P2 is 6.2 bar (63.2m), DP = 6.9 bar

- Pump TDH is 70.5

Therefore, the calculation head loss at discharge valve 35% is

= (P2 - Head loss before valve) - (P3 + Head loss after valve)

= (P2 - Head loss before valve)

= 63.2 -0.19

= 63.01 m

(P3+Head loss after valve) = 60.01+0.04

= 60.05 m

Therefore, the head loss at discharge valve at 35% opened is

= 63.01 - 60.05

= 2.96 m

From from above calculation, H of new pump can be calculate as following

DH - Hloss at discharged line. = 70.5-2.96

= 67.52 m.




service report

Page 25

Author : 30/05/14

Installation

Repair

Inspection/Check


Technical support

Maint.Inspect.

Masterdata of the Service Report - ESCAP

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