Pumping Station

Exchanging the motors, motor controls and pumps leads to an energy and cost saving but requires an investment:

Loading data of component

  • Energy savings
  • Energy savings
  • 20,000 kWh/a (8%)
  • Cost savings
  • Cost savings
  • 14,500 JOD/a
  • Cost savings
  • Investment
  • 125,000 JOD

Would you like to implement the retrofit measures for this component?

Exchanging the pipes and valves leads to an energy and cost saving but requires an investment:

Loading data of component

  • Energy savings
  • Energy savings
  • 20,000 kWh/a (8%)
  • Cost savings
  • Cost savings
  • 14,500 JOD/a
  • Cost savings
  • Investment
  • 125,000 JOD

Would you like to implement the retrofit measures for this component?

Exchanging the automation components - which can only be done in combination with new motors, motor controls and pumps - leads to an energy and cost saving but requires an investment:

Loading data of component

  • Energy savings
  • Energy savings
  • 20,000 kWh/a (8%)
  • Cost savings
  • Cost savings
  • 14,500 JOD/a
  • Cost savings
  • Investment
  • 125,000 JOD

Would you like to implement the retrofit measures for this component?

Improving the operation leads to an energy and cost saving but requires an investment:

Loading data of component

  • Energy savings
  • Energy savings
  • 20,000 kWh/a (8%)
  • Cost savings
  • Cost savings
  • 14,500 JOD/a
  • Cost savings
  • Investment
  • 125,000 JOD

Would you like to implement the retrofit measures for this component?

Improving the maintenance leads to an energy and cost saving but requires an investment:

Loading data of component

  • Energy savings
  • Energy savings
  • 20,000 kWh/a (8%)
  • Cost savings
  • Cost savings
  • 14,500 JOD/a
  • Cost savings
  • Investment
  • 125,000 JOD

Would you like to implement the retrofit measures for this component?

Pumps
  • Operating pumps show leakage and vibration
  • Pumps of different manufacturers and of varying capacities are installed
  • Design data could not be obtained for every pump due to lack of manufacturers' data plates and in some instances, modifications, e.g. removed stages
Motors
  • Motors are without soft-starters
  • Supply cables are improperly routed
  • Motors of various manufacturers, ages and capacity are installed
Motor control planels
  • Panels need upgrading
  • Electrical installations are in bad condition, one panel is equipped with old fashion type liquid start.
  • Analogue ampere meter and voltage meter displays are not working, the main switch board needs upgrading
Pumps
  • Pumps are operating at pump curve best efficiency point
Motors
  • High efficiency motor has reached optimum performance level
Motor control planels
  • Panels are upgraded
Automation system
  • The pumping station is operated manually
  • The pumping station does not possess any automation equipment or sensors
Automation system
  • Automation system is operating the pumping station at optimum energy efficiency parameters
Automation system
  • Automatic operation according to available water level
Automation system
  • Flow meter generates real time water quantity data for the motor control center for operation according to required water quantity
Valves
  • Most of the gate and check valves are not working properly and need overhaul or replacement
Valves
  • New valves are installed
Operation
  • WAJ Staff is operating the pumping station manually according to ad hoc requirements
Operation
  • Private sector supported operation with focus on energy efficiency
  • Operation according to international best practice and equipment manufacturer standards
Maintenance
  • Quality of maintenance and repair processes is insufficient due to lack of qualified staff and substandard equipment
  • Responsibilities are split between different maintenance units
Maintenance
  • Private sector supported maintenance

Pumping Station 427

Results of the energy audit:
Power Consumption:  
Energy Costs:  
CO2 Emission:  
MTBF*:  
  • power consumption
  • Power Consumption
     
    Actual value:  
    Saving:  
  • co2 emission
  • CO2 Emission
     
    Actual value: 52,000 Mt/a
    Saving: 8 %
  • mtbf
  • MTBF*
    Actual value: 12.7 a
    Improvement: 24.5 %
  • investment
  • Finance
     
    Investment: 200,000 USD
    Cost savings:  
    Break even: 7.4 a

 

Pump Energy Efficiency

Your objective requires a complete optimization of the demand side energy efficiency of this pumping station. In general and besides optimising energy efficiency you should increase the reliability of the pumping station and reduce downtime (high MTBF) in order to demonstrate that installed high quality and high efficiency measures have important “side effects” for the service reliability of the pumping infrastructure.

Within the site of the pumping station the improvement of the energy efficiency can be achieved through a number of Energy Saving Measure (ESMs). The ESMs to achieve improved energy efficiency shall target some, all, or additional aspects of the following areas.

Hydraulic conditions

Checking the hydraulic conditions of the facility and the equipment and, if deemed necessary, retrofitting or replacing of equipment linked to the following aspects:

  1. Pressure on the suction side
  2. Piping
  3. Valves
  4. Static and dynamic conditions
  5. Hydraulic conditions under operations

Electro-technical conditions

Checking the electro-technical conditions of the facility: It is expected that a considerable investment is needed to repair, retrofit and/or replacing of equipment linked to the following aspects:

  1. Total system performance (permanent and peak)
  2. Cabling
  3. Type and capacity of motors
  4. Type of motor starter
  5. Motor pre-heat equipment
  6. Variable frequency-drive
  7. Insulation losses / grounding and bonding

Mechanical conditions, pump quality (efficiency of the pumping equipment) and pump station design

Checking mechanical conditions, pump efficiency, quality and pump station design. It is expected that a considerable investment is needed to repair, retrofit1 and/or replace the equipment linked to the following aspects:

  1. Type of pumps/model depending on hydraulic demands and conditions – considering action principle and duty point
  2. Alternative ways of installation
  3. Frequent duty rotation
  4. Capacities and pressure control in regard to the multi-pump-operations principle
  5. Life Cycle and efficiencies – power absorption and load losses

1 Retrofitting refers to the addition of new technology or features to older systems

Available Energy Saving Measures

Motor, Motor Control and Pumps

Centrifugal pumps for the pumping of potable water that convert the driving power of the motor to the fluid via impellers to increase the pressure and velocity of the fluid, or in other words, to push it forward.

Motors to propel the water pumps by converting electrical energy into mechanical motion and power.

Motor Control Panels to run the performance of electric motors. They might include manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating speed, regulating or limiting the torque and protecting against overloads and faults.

Valves

Valves are used for regulating, starting, stopping, controlling or diverting the flow of water at the pumping station.

  • Gate valves with a sliding plate at the inside of the valve body are used to control the water flow and are able to close the pipeline.
  • Butterfly valves with a disc turning on a diametrical axis at the inside of the valve body are used to control the flow.
  • Non-return valves with a disc at the inside of the valve body that permits the water to flow only in one direction are installed to protect the pumping equipment from a sudden and unexpected “water hammer” (high energy backflow of water according to the pump head from the pipeline against the pumping equipment) .
  • Pressure control valve are installed in a pipe to monitor the pressure in the system to avoid the hydraulic system, especially the pump unit, to be damaged due to overpressure and are able to equilibrate the pressure in the system if pumps of different sizes and heads are installed.

Automation system

The automation system transfers functions of a process (in this case pumping station operation and monitoring), in particular process control and regulation from operational staff to a computer systems which follows self-acting a program according to defined parameters and takes decisions based on program parameters for the control and regulation of the process.

Flow meter: device to measure water quantity per time [usually in m3/h]

Operation

Staff is performing the function of operating and monitoring the pump station, including starting and stopping of the pumping equipment. The operation staff is responsible for pumped water quantities, coordinates deliverables with the different WAJ sections and reports failures or problems. The personnel is present 24hrs a day and 7 days a week.

Maintenance/preventive maintenance

actions and activities necessary to be undertaken to conserve the original specified working conditions of equipment to its optimum lifetime and efficiency while compensating the normal wear and tear. Preventive maintenance means hereby a systematic inspection on a regular basis to detect and correct incipient failures to avoid that they become major failures.

 Bundesministerium für Umwelt, Naturschutz und Reaktorsicherheit Development Coooperation: Hashimite Kingdom of Jordan -  Feredal Republik of Germany Germany's Clilmate Initiative - Climate protection pays off! Jordan Water Authority Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH