Training Session

“Learning never exhausts the mind.”

Operation & Maintenance of FCP Ajmer on
ESCO cum O&M
Part 1 Part II

ESCO O&M
Energy Saving Operation &
Maintenance

PUMP House Maintenance of Rising mains of RWSS/ Clusters

PLC/ SCADA OHSR,CWR

Water Treatment Plant and Switchyards

 ESCO
Energy Service Company

Base line is made on basis of the power consumption for the per KL Water
production by the present pumping system of the PHED , under presence of
Base Line PHED Engineering staff. An value for KWH/KL was decided and an order for that
base line will be raised by concerning officer.

Pump Selection We have to select energy efficient pumps as per future water
demand on the basis of required head.

We have to replace the old inefficient pumping system with

Pump Installation energy efficient pumping system free of cost.

After installation of New Energy Efficient pumping system, again the KWH/KL

Energy Saving will be taken by the daily and monthly reading of electromagnetic flow meter,
and energy meters. And also total power consumption and water production
will be recorded and reported to PHED, for saving calculations.
 Next to be discussed
General guidelines for pumps and Preventive and breakdown maintenance
motor. of pumps

Operations guidelines for the VFD How to monitor and maintain Standard
Based Pumping Stations. line.

Guidelines for energy saving Monthly Budget.

Operation maintenance of PLC/SCADA. Documents filing of project.

 ESCO Model-Concept
After installation of New Energy Efficient pumping system, again
the KWH/KL will be taken by the daily and monthly reading of
electromagnetic flow meter, and energy meters. And also total
power consumption and water production will be recorded and
reported to PHED, for saving calculations. For example if for a
month total water production by a pump is 100000 KL and total
electricity consumption is 20000 Units (KWH).

Energy saving for that Out of this ,minimum 10% will be

month will be = 0.60 * This units cost
Pass on to PHED and rest will
100000 – 20000 = for Rs. 160000
be provided to contractor after
40000 units. @ 4 Rs. /Unit
additional sharing to PHED.
.
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 Energy Saving
Base Line = KWH/KL

Energy Saving = Base line x Water

Production – power consumption

Tariff = Energy Saving x Tariff per

unit
 Monitoring and Maintenance of Standard Line
Base line is made on the basis of power and water production for each pumps and it can calculated by
measuring power consumption per KL water production(KWH/KL).

For Energy Saving ,We replace old pump set by new energy
efficient pump sets.

Standard line will be fixed by maintaining

maximum flow at minimum power consumption(Base line).

Whenever standard line will be fluctuate then its indicates that the system required maintenance.

When pump operates below the base line it will beneficial for us.
Definition
Pump: When a fluid has to be "moved" in a system, pumps are used. The
pump is a machine which has the function of increasing the total energy of
a liquid; this means that the pump transfers energy to the fluid that it
receives from the driving motor”.

Need Of a Pump:
 Used to pump a liquid from lower pressure area to a High pressure area.

 To increase Flow rate.

 To move liquid from lower elevation to higher elevation.

 PUMP TYPES
Horizontal Split Case
Vertical Turbines
Vertical Multistage
Horizontal Multistage
 End Suction
 Mono-block
 Booster Pump
Sewage & Dewatering
 Non Clog
 Sump pump
 Fire fighting systems
 Pump Terminology
Head

Shaft power

Suction head

Efficiency of pumps

Static head
Basic Terms of Pumps
Volumetric Flow rate:
Flow rate /Capacity of a pump is the amount of liquid delivered by the pump per unit of time (m3/hr).

Total Head:
It is term that defines how high the pump can lift a liquid./Pressure in terms of height.

Hydraulic Power:
Power transferred by the pump to the liquid.

VACUUM:
Pressure lower than the atmospheric pressure.
Dynamic Pump
Centrifugal Pumps:-
This pumps generate high rotational velocities, then convert the resulting kinetic
energy of the liquid to pressure energy.
Two parts: It contains impeller and casing.

Use:
1.Centrifugal pumps are generally used where high flow
rates and moderate head increases are required.

2. Can handle fluids containing suspended solids

Centrifugal Pump
How do they work?
• Liquid forced into impeller.

• Vanes pass kinetic energy to liquid:

liquid rotates and leaves impeller.

•Volute casing converts kinetic

energy into pressure energy.
 Multistage Centrifugal Pumps
In order to achieve a higher discharge pressure multiple impellers are used
within a single pump. Depending upon the requirement.
Vertical Pumps
Construction of Centrifugal Pumps
Why do we face problems in pumps ?

Pump not delivering at all ?

Pump not giving sufficient discharge ?
Pump not developing sufficient head ?
Coupling failures ?
Abnormal noise and vibrations ?
Motor overloading ?
Bearing failures ?
Cavitations ?
 Do’s and Don’ts
Do not run the pump at zero flow i.e. at shut-off point.

Always provide pressure gauges at delivery and suction side.

Do not let your pump run dry.

Do not run the pump beyond its operating range.

Keep suction piping small and simple.

Avoid pump operation with throttled discharge.

Check the pump periodically for performance, noise and vibrations.

Check bearing lubrication and gland leakage periodically.

Replace worn out parts periodically as per regular maintenance schedule.

 Maintenance Philosophy
“Equipment is a mechanical employee,
Give it a long and healthy career”

Maintenance is done on to the machine in order to

improve system reliability. Maintenance may be :
•Inspection
•Preventive (Basic Care)
Predictive (Conditional Monitoring)
Periodic
• Break down
Check points for maintenance
Period Tests
Daily Monitoring Noise and vibration
Daily Monitor pump leakages
Monthly Check Pressure Gauge
Monthly Monitor Oil or grease of pumps
Daily Clean the pump and pump house

Monthly Monitor performance is matching with pump duty point.

Monthly Monitoring of stand by pumps at least for 5 minutes.

Monthly Monitor Electrical motors

Quarterly Check suction and Discharge pipe lines.
Preventive Maintenance of Pumps
Check Pump
Check pump parts
performance (Head, temperature (bearing) and
Flow) as per data sheet monitor pump leakage.

Check pump vibration Monitor the motor parts and

and noise on daily check voltage, Amp and make
basis. sure motor speed should be
ok with pump performance.

Check System Monitor oil or grease

Characteristics leakage.
analysis( pipes suction&
delivery valve)
Shaft PUMP MAJOR Diffuser Casing
& Bearings
COMPONENTS

Impeller Stuffing Box

and Gland

Wear Rings
 Shaft Run Out
• Runout checks are made to determine out of roundness conditions (eccentricity)
in a shaft. Whether shaft is concentric or not ?
• Runout occurs due to:
a) Machining Process
b) Dents from handling.
c) Rust patches.
d) Rotor bow / sag due to thermal effects, gravity, or other influences/loads.
e) Defective or worn bearings in the machine or lathe supports
• Moderate to excessive run out will create moderate to excessive
vibration within a pump
(may cause rubbing).
• Firstly shaft itself is checked and then
along with its attached components
(wear ring , impeller etc.)
•Dial Indicator is attached on axially
given points. Variation in readings
indicates:
 Balancing & Float Check
• Balancing of a rotor is carried out to eliminate the vibration.

• Balancing correction weights may eliminate the dynamic forces but

they will not resolve the eccentricity issue.

• Correction weights may added or material may remove for the

balancing.
• FLOAT
 Wear Ring Clearances
• Wear ring provides close clearances to minimize leakage from the discharge
to the suction of the impeller.
• As the wear ring wears with use , leakage will gradually increases , effecting the
pump efficiency.
• The gap is destroyed if there is
misalignment or shaft
deflection.
• Clearances is taken through the
Feeler
Gauge.
• Material : SS or Bronze
 BEARING
• Providing Support to a shaft for smooth Running.
• Lubrication prevents metal-metal contact.
• Thrust Bearings are used to
compensate/bear axial
load.

Bearing inspection is very

important during
Pump maintenance.
Causes of Bearing Failure:
Flaking , Spalling , Rust & Corrosion, wear ,
Babbit metal remove , loss of lubrication etc.
 Shaft Alignment
• Shaft alignment is the process to align two or more shafts with each other to
within a tolerated margin. It is an absolute requirement for machinery before the
machinery is put in service. Therefore pump and motor shafts are aligned before
they put into service.
• Misalignment between the pump and drive can result in premature bearing
failure or other damage.
Shaft Alignment
 Inspection During Maintenance
Pump Impeller

Mechanical Seal

Gland Packing

Shaft Sleeve

Relieve Valve

Pump Element (PD).

Gland Packing
 Motor
An electric motor is a machine that converts
Mechanical energy into electrical energy.
Most electric motors operate through the
interaction between the motor's magnetic
field and electric current in a wire winding to
generate force in the form of rotation of a
shaft.
Mainly we are using INDUCTION MOTORS in ESCO.
 Induction motor
An induction motor is an AC electric motor in which the electric
current in the rotor needed to produce torque is obtained by
electromagnetic induction from the magnetic field of the stator
winding.

Working principle of induction motor

When ac supply is given to the stator winding of induction motor, the
alternating current starts flowing through the stator or main winding.
This alternating current produces an alternating flux called main flux. This
main flux also links with the rotor conductors and hence cut the rotor
conductor.
 About Induction Motor
 Induction motors are used worldwide in many
residential, commercial, industrial, and utility
applications.

 Induction Motors transform electrical energy into

mechanical energy.

 It can be part of a pump or fan, or connected to

some other form of mechanical equipment such as
a winder, conveyor, or mixer.
 It consists of two parts:

1. Stator - It is the stationary part of the motor.

2. Rotor - It is the rotating part of the motor.

 Stator has three main parts:
Outer Frame – It is the outer body of the of the
motor. It protects the inner part of the
machine.

Stator Core – Built up of high grade silicon

steel. Carries the alternating magnetic field

Stator winding – Has a three phase winding.

 CORE
SLOTS

WINDINGS
 Control Panel
Electrical control panels are designed and used
to control mechanical equipment. Each one is designed for a
specific equipment arrangement and includes devices that allow
an operator to control specified equipment. Electrical Control
Panel. Electrical panel components control every piece of
equipment in every industry.
 MCB Timer
Current Transformer

Bus Bar
Relay Contactor

MCCB
 Components and type of Control Panel
Relay
Contactors
MCCB
Soft Starter
MCB Star –Delta Starter
Timer
Bus Bar
VFD (Variable Frequency Drive)
Current Transformers
 Relay
A relay is an electrically operated or electromechanical switch composed of an electromagnet,
an armature, a spring and a set of electrical contacts. The electromagnetic switch is operated
by a small electric current that turns a larger current on or off by either releasing or retracting
the armature contact, thereby cutting or completing the circuit. Relays are necessary when
there must be electrical isolation between controlled and control circuits, or when multiple
circuits need to be controlled by a single signal.
 Contactors
The contactor is an electrical component that serves to connect or disconnect AC
power. Contactor or often also called the relay contactor we can find on the electric control
panel. In electrical panels, the contactor is often used as a selector or transfer switch and
interlock on the ATS system.
 MCCB (Molded Case Circuit Breaker)
It is another type of electrical protection device which is used when load current
exceeds the limit of a miniature circuit breaker. The MCCB provides protection
against overload, short circuit faults and is also used for switching the circuits.
 MCB
A miniature circuit breaker (MCB) automatically switches off electrical circuit during an
abnormal condition of the network means in overload condition as well as faulty condition.
MCB is much more sensitive to over current than fuse. Handling an MCB is electrically safer
than a fuse.
 Current Transformer
The Current Transformer ( C.T. ), is a type of “instrument transformer” that is designed to produce an
alternating current in its secondary winding which is proportional to the current being measured in its
primary. Current transformers reduce high voltage currents to a much lower value and provide a
convenient way of safely monitoring the actual electrical current flowing in an AC transmission line using a
standard ammeter. The principal of operation of a basic current transformer is slightly different from that of
an ordinary voltage transformer.
 Bus Bar
An electrical bus bar is defined as a conductor or a group of conductor used for collecting
electric power from the incoming feeders and distributes them to the outgoing feeders. In other
words, it is a type of electrical junction in which all the incoming and outgoing electrical current
meets.
 Soft Starter
Soft-Starter is an electronic starter designed to
accelerate, decelerate three-phase induction motors and
to control the voltage applied on the motor during start and
stop.

Un-Necessary Mechanical & Electrical Effects:-

 The sudden impact at start up on the load, followed by the rapid acceleration to full
speed causes excessive wear on :-
• Belts and pulleys
• Gears and chains
• Couplings and bearings
• Cavitation in pumps etc.
A heavy current surge on the electrical supply which can be severe enough to cause
voltage dips and flickering lights.
Burning of contacts due to high currents which are many times the motor full-load current.
A Soft Starter is a device that starts motors with reduced power supplied at start-up. Reducing
the power reduces potentially damaging electrical and mechanical shocks on the system. As
the name implies , starters "start" motors. They can also stop, reverse, accelerate and protect
them.

Why Soft Starters are Needed

(1) To avoid overloading the power distribution system
(2)To avoid unnecessary wear and tear on equipment by reducing starting torque
 Problems Arises by these Effects

01
Continuous maintenance.
02 Greater chance of unscheduled
shutdowns
Oversized mechanical and electrical components to cater 03
for the power surge on start up.

04 Short component life.

 Characteristics of soft starter
By Adjusting voltage during starting, the current drawn by the motor and the torque produced by the motor can
be reduced and controlled.

DOL
DOL
Soft start

Soft start

Load
Torque

Torque/speed curve with Soft start Current/speed curve with Soft start
 Features of soft starter

Soft start and soft stop

Dual Adjust - start/stop characteristics for varying loads

Pump Control characteristics

Current Control ramps

Pulse (kick) start

Tacho/Encoder feedback
 Some applications
Vacuum Pumps; Pulverisers

Centrifugal Pumps; Mixer Ball Mill

Compressors Large Pumps

Fans / Exhaustors / Blowers Mixers Crushers/Grinders

Conveyors Ball mills/ Hammer Mills

Axial Blowers Escalators

 Propeller Fans  Bottling Lines

Axial Fans (low inertia – low load)

All these and many other applications have been obtained by soft starter.
 Guidelines for VFD
The VFD responds to a pre-programmed input signal, usually a
pressure transducer, to vary pump speed to match your exact
requirements.
This can dramatically boost efficiency and energy savings by preventing

VFD over pumping and over pressurizing of your irrigation equipment.

It controls the frequency of the electrical power supplied
to a pump or a fan. Significant power savings can be
VFD means Variable Frequency achieved when using a VFD. A variable-frequency
Drive, i.e., adjustable speed AC motor drive is a system for controlling the rotational speed of
drive system to control and/or an alternating current electric motor.
optimize processes.
VFD also depend on the level transmitter at OHT and
Input AC power is converted to DC the pressure transmitter at outer line. If the pressure is
(Rectification) & this DC power is less at the outer line the pump will run with high
inverted to AC power of required speed, after the pressure will maintain, the motor will
Voltage & frequency to get Torque & run on constant speed.
Speed as per process requirement.

Rectification & Inversion are We can vary the pump speed though the VFD on multiple set
point of level and pressure.
achieved through power electronics
devices (Diodes, IGBT, Thyristors).
 Electromagnetic Flow-meters
What is flow-meter:
Electromagnetic flow-meters are basically use for measuring the
water flow passing through a pipe line.

Principle of Electromagnetic flow meter:

Basically electromagnetic flow-meter works on the principal of
Faraday’s low of induction that states that when a metal particle
moving in a magnetic field it induced electrical voltage,
as the electrically charged particles of a fluid cross the artificial
magnetic field generated by two field coils, an electric voltage is
induced. This voltage, tapped by two measuring electrodes, is
directly proportional to the velocity of flow and thus to the flow
volume.
The magnetic field is generated by a pulsed direct current with
alternating polarity. This ensures a stable zero point and makes the
flow measurement insensitive to multiphase or inhomogeneous
liquids, as well as low conductivity.
 Electromagnetic Flow-meters
Measuring system:
In Electromagnetic flow meter there are 4 electrodes in flow tube two
electrodes works
as measuring electrodes and
another two electrodes works as one for empty line and another one for
grounding.

Input supply:
electromagnetic flow meter works on both 24Volt DC as well as 230volt AC.

Communication protocol:
in electromagnetic flow meter having RS485 communication port.

Benefits of electromagnetic flow meter :

-Accuracy ± 0.5%
-Long time durability
-Easy to calibration
 Ultrasonic level transmitters
Introduction:
Ultrasonic level transmitter is basically a level measuring instrument work
on the principle of ultrasonic waves emits on the liquid or material filled in
the container/tank.

How Does It Work?

Ultrasonic level sensors work by the "time of flight" principle using the
speed of sound. The sensor emits a high-frequency pulse, generally in the
20 kHz to 200 kHz range, and then listens for the echo. The pulse is
transmitted in a cone, usually about 6° at the apex. The pulse impacts the
level surface and is
reflected back to the sensor, now acting as a receiver , and then to the
transmitter for signal processing.
 Advantages
Effective starting & braking of Motors.

Effective speed control over wide range.

Match to load profiles.

Enhance overload capability of motors.

Provide additional protections to motors.

Improve source PF.

 Components of Automation and why
automation
Reduce man-power.

Decrease Errors.

Increase Productivity.

Data Analysis.
 Operation and Maintenance of PLC/SCADA
1.First of all, Keep the Back-up of PLC Programme before preventive maintenance.

2.Power removed: While doing maintenance, connections should always be checked with power
removed from the system.

3.Check the power and battery LED Indication for battery replace - Check the power and battery
LED indicators, that backs up the RAM memory in the CPU

4.Check operating environment: Check the environment temperature, humidity and other factors
satisfies the PLC operating conditions.

5.Check the PLC Panel Lighting- OK or Not

6.The dust in the PLC panel and circuit board should be clean. If moisture and dust reach the
electronic boards, it could be short circuit cause. Blower should be use from some distance to
terminal blocks.
 Operation and Maintenance of PLC/SCADA

1.Fan and louvers in the PLC Panel should be clean properly, Filter should be clean or
replaced to ensure that the clean air circulation in the PLC Panel.

2.Connection to the I/O modules and terminal block should be check for tightness, because
Loose connections may result not only in improper function of the controller but also in
damage to the components of the system.

3.All field I/O cards should be inspected to ensure that they are adjusted properly.

4.Heavy noise or heat generating machines and instruments should not place close to the
PLC.

5. The UPS Supply should be check.

6. Main supply and 24 VDC supply should be checked.

7.Communication cable should be check b/w controller to HMI or SCADA.

 Sr.
Particular

Budget Heads
No.
1 Food Expenses
2 Freight & Cartage
3 Material Used at Site
4 Official Tour Expenses
5 Office Expenses
6 Repair & Maintenance
7 Repair & Maintenance Vehicle
8 Rent Guest House/Go down
9 operation & Maintinance /Plant Operator
10 Power and Fuel
11 Salary
12 Machine and Equipment
13 Interest on CC Limit and bank charges
14 Advertisement
15 Electricity
16 Labor Cess/ Civil work
17 Incentive and Commission
18 Conference, Training and Exhibition
19 Insurance Expenses
20 Tender fees / Testing fees
21 HO Guest House Common & Business Development
22 Unloading charges
23 Car EMI
24 Profit sharing
25 Vehicle hiring charges/ Machinery hiring (JCB)
26 Telephone & mobile Expenses
27 consultancy charges/ professional fees
28 M2M data charges
 Monthly Budget of ESCO Ajmer
Sr. ESCO - AJMER
Particular
No. O&M
1 Food Expenses 150000.00
2 Freight & Cartage 8000.00
3 Material Used at Site 40000.00
4 Official Tour Expenses 50000.00
5 Office Expenses 20000.00
6 Repair & Maintenance 80000.00
7 Repair & Maintenance Vehicle 25000.00
8 Rent Guest House/Go down 30000.00
9 operation & Maintenance /Plant Operator 1250000.00
10 Power and Fuel 80000.00
11 Salary 537654.00
12 Machine and Equipment 10000.00
13 Interest on CC Limit and bank charges
14 Advertisement
15 Electricity 8000.00
16 Labor Cess/ Civil work
17 Incentive and Commission 5000.00
18 Conference, Training and Exihibition 5000.00
19 Insurance Expenses 5000.00
20 Tender fees / Testing fees
21 HO Guest House Common & Business Development 115000.00
22 Unloading charges
23 Car EMI 35000.00
24 Profit sharing
25 Vehicle hiring charges/ Machinery hiring (JCB) 20000.00
26 Telephone & mobile Expenses 16612.00
27 consultancy charges/ professional fees
28 M2M data charges
Total 2490266
Purpose of Budget Planning
 To provide means for measuring and recording financial success
with the objectives of the organizations.
 For accountability.
 To provide visibility into the company's performance.
 To motivate to achieve budget goals.
 To evaluate the performance.
 It also helps co-ordinate the activities of the organization by
compelling managers to examine relationships between their
own operation and those of other departments.
 To control resources.
 It enhances fiscal planning and decision-making.
 It clearly recognizes controllable cost areas.
 It offers a useful format for communicating fiscal objectives.
 It allows feedback of the utilization of budget.
 It helps to identify problem areas and facilitates
effective solution.
 Advantages
Eliminates high inrush current and high mechanical torque on startup.
Reduction in cable and switch-gear rating in the power supply network.
Limits line voltage dip.
Soft, step less acceleration & deceleration.
Kick-start function for heavy duty and functional loads with high starting torque.
By-pass contactor increases energy savings.
Avoid current and torque peaks, Put less electrical stress on the power supply network and
mechanical stress on entire drive.
Reduce stress on couplings and other transmission devices (gear boxes, shafts, belts, etc).
Extend lifetime of motor and mechanical components/parts due to reduced mechanical shocks.
Less space required in the switchgear cabinet(Devices are much narrower than other
electromechanical motor starters).
Simple electrical wiring.
Easy operation, programming and maintenance.
Thank you