2

Creating an Energy Efficient Pumping Station

By developing an manual for a “Energy Audit”

By

M. Berning
R.B.S. Jonker

Supervisor:
Prof. dr. ir. L. C. Rietveld

Prof. dr. Z. Kapelan

Prof. E. L. Q. Rubiano

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Preface

On behalf of the Cinara office from Universidad del Valle, Cali, the research project will be done by Max Berning and
Reinier Berend Schelto Jonker.

The project will be about making an energy-audit for pumping stations in Colombia. The reason for making a energy
audit is that Colombia wants to improve the energy consumption and lowering cost on water evacuation systems.

We, Reinier and Max, are doing this project for our “free minor”. We have chosen this project because our
background is Civil Engineering and we want to do a project in the field of water management. Besides of this we
want to find out how our theoretical knowledge can be put in to practical understanding of problems.

For feedback on our thoughts and ideas we asked Prof. Dr. Zoran Kapelan from the TU Delft to assist us, we would
like to thank him for his support. At last we want to thank our supervisors: Prof.dr.ir. Luuk Rietveld and Prof. Edgar
Leonardo Quiroga Rubiano. For giving feedback on our report and providing us this great opportunity.

M.Berning & R.B.S.Jonker

Cali, October 2019

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 Contents
Contents 5

1. Summary 7

2. Introduction 8

3. Literature study 9
3.1 Location and Surroundings 9
3.2 General information pumping station 9
3.3 Stakeholder analysis 13
3.3.1 Consam 14
3.3.2 AcuaValle 14
3.3.3 Consumers 14
3.3.4 Local residents 14
3.4 Possible problems 15
3.4.1 Capacity 15
3.4.2 Operating Point vs BEP 18
3.4.3 Cavitation 18
3.4.4 Parallel interference (not finished) 19
3.4.5 Suspended solids 20
3.4.6 Bar screen 21
3.5 Energy efficiency 22

4. Research Methodology 23

5. Assessing efficiency of the pumps 23

5.1 Historical data analysis 23
5.1.1 Analysing flow (DWF -WWF - Total flow) 23
5.1.2 Analysing energy consumption (DWF - WWF - Total Energy consumption) 23
5.2 Energy efficiency 23
5.2.1 Total energy given to the water 23
5.2.2 Total energy supplied to pumps 23
5.2.3 Evaluation of efficiency 24
5.3 Interpretation 24
5.3.1 Yearly, Monthly, Daily, … 24
5.3.1 ... 24

6. Evaluating current situation 25

6.1 Initial findings 25
6.2 Assessment of technical condition of installed pumps and related assets 26
6.3 Assessment of existing pumping system operation 26

7. Interpreting situation & Identifying problems 27

8. Solutions 27

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9. Conclusions 27

10. Recommendations for further research 27

11. Literature 27

Appendix A 27

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1. Summary

7
 2. Introduction
When building a new neighborhood, a waste water pumping system was designed by the existing housing
cooperative. This pump system is handed over to the AcuaValle company for future management. Only AcuaValle
does not want to take over the pump system in its current state, because it is malfunctioning in its current state.
AcuaValle has asked for a report which maps out on which criteria the station is malfunctioning. And which solutions
are appropriate for improving the situation, and creating a proper functioning of the station.

The scope of this project is to show how a pumping station should be improved to function in a correct way. This will
be embodied by following the manual provided by this research, called the ‘Energy Audit’.

To get a good few on what kind of problems can affect the energy efficiency of a wastewater pumping station a
literature research will be done. For good understanding on what is described in the theoretical literature a basic
knowledge is required about pumps, pumping station and fluid mechanics. After the literature study the
methodology will be defined how to analyse the pumping station condition in perspective of energy consumption.
Conclusions will be subtracted out of analysis. This results into recommendation for the pumping station and a
general guide about how to perform a “Energy Audit” on other different pumpinstations.

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 3. Literature study
3.1 Location and Surroundings
The pumping station is located south of Jamundi and is build for the new
neighborhood named “Ciudadela Las Flores”. Wastewater that is collected
in the pumping station is driven to the Gaitán collector located at 3500 m
away.

But due to malfunctioning of the pump in Gaitán collector the waste water
is now currently pump to a other collector located in Jamundi, 5000 m
away.
The neighborhood is build for capacity of approximately 10,000
inhabitants. In the neighborhood there is a swimming pool, sports fields,
and lakes.

3.2 General information pumping station

For calculations about how the design of the total system came about can
be read in detail in appendix XX.

The pumping station is connected to a combined system . So on rainy days

the pump need to discharge rainwater as well. The pumping station can be
divided in the following parts:
1. Input chamber
2. Settlement chamber
3. Approach channel and screening system
4. Suction well
5. Machine house (pumps)

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Input chamber
This is the chamber where the swega will first enter the pumping station. In order to make the proper distribution of
the wastewater flow in the settlement chamber, the dimensions are based on a inflow of 95 [L/s], ensuring that
retention time in this it is minimal to avoid the accumulation of solids contained in the wastewater.

The dimensions are:

- Width = 2.25 m
- Length = 1.30 m
- Average water depth = 0.25 m
- Volume = 0.73 m3

The holding time of the water in the chamber is 7.68 seconds.

Two gate valves are be installed at the exit of the arrival chamber to control the entry of water to the settlement
chamber during maintenance and eventual removal activities and arenas.

Settlement chamber
After the input chamber the water flows through the settlement chamber in order to retain possible sent deposits.
There are two chambers next to each other.
The dimensions are:
- Width = 1.00 m
- Length = 2.25 m
- Sheet of water = 0.3 m

A cleaning team will be hired to remove the settled solids.

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Approach channel and screening system
The approach channel to the screening allows to maintain a uniform flow with an approach speed
minimum to ensure an adequate accumulation of solids in the grid.
The dimensions are:
- Width = 2.25 m
- Length = 2.37 m
- Degree of bottom = 0.25%

Flow conditions:
- Sheet of water = 0.07 m
- Approach speed = 0.62 m/s

To prevent damage to the pumping systems big particles need to be filter out. Therefor a bar screen is put in place.
The dimensions are:
- Bar screen thickness = 12,72 mm
- Bar depth = 120 mm
- Bar spacing = 38 mm
- Number of bar = 45
- Tilt bar = 75 degree

Flow conditions:

- Head loss = 0.01 m

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 - Pass through speed = 0.71 m/s

The bar screen is cleaned by a scraper.

Suction well
The suction well is the compartment intended to receive and accumulate wastewater during the
periods of turning on and off of the pumps.

The considerations for its sizing are the following according to the recommendations of literal D.7.4 of the SAN
(2000):
● Two centrifugal pumps will be used working alternately for minimum and medium flow; working in a
complementary way for maximum flow.
● The number of starts allowed for the pumps is four per hour.
● Pump cycle time between 10 and 20 minutes.
● Operating cycle should not be less than 5 minutes.

Volume of the suction well needed:

- Minimum cycle time = 15 [min]
- Pumping flow = 0.095 [m3/s]
- Well volume = 21.38 [m3]

Time to drain the well is 7.5 minutes and the fill time is as well 7.5 minutes.

Dimensions of the suction well:

- Separation between the pumps = 1.60 [m]
- Wall separation = 1.40 [m]
- Diameter of the pump = 0.25 [m]
- Input distance = 5.93 [m]
- Length suction well = 7.33 [m]
- Wide suction well = 6.00 [m]
- Area suction well = 43.98 [m2]
- Water level variation in suction well = 0.50 [m]

Machine house (pumps)

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The pumping system is composed of three centrifugal pumps, each with 47 [l/s] capacity and with the following
operation logic:

● During minimum and average flows, when the level of the suction well reaches a height that determine a
volume of 10.69 m3 start of Pump 1 to empty the tank.
● During wet weather flow, when the inflow increases to the maximum, Pump 2 will also start.Pump 1 and
Pump 2 are working in parallel setup. An additional volume of 10.69 m3 is reached. The two pumps will
continue to work together until the entire well has been emptied.
● Pump No.3 will be kept in reserve and will start operating when it is required to remove operation of pump
No.1 or pump No.2 for failure or maintenance (corrective or preventive).

After determined what the energie loss is over the system the total dynamic height is determined. Together with the
required flow the pump power is calculated:
- Pumping flow = 95 L/s
- Total dynamic height = 54.48 m
- Pump efficiency = 0.66
- Pump power = 104 HP

NPSH that is required is 2.76 m.

The operation curves of the company's pumps were used to select the pumping equipment SUMOTO and the
following data: Qb = 48 [l/s] and HDT = 55 [m]. When using the company's equipment selector get the following
equipment:
● Centrifugal pump.
● Brand: Suoto / Model: H6 IMP
DIAM 12 ½ ”1800 RPM.
● Calculated flow: 48 l / s.
● TDH: 55 m.
● Efficiency: 66% and nominal
power: 75 HP.
● NPSH required: 2.35 (< to available
NPSH, OK).

3.3 Stakeholder analysis

Ethics is about thinking well and doing well, it is needless to say an overview of the ethical dilemmas constricted
within this project need to be well understood. Thinking well is all about trying to grasp the different points of view,
reference frames and interests from all different stakeholders. All different parties involved will be listed below.
● Consam (Building corporation)
● AcuaValle (Urban water company)
● Consumers
● Local residents
● Londono Ingenieria
In order to obtain an objective view upon the circumstances and ethical dilemmas, all prescribed parties and their
perspectives will be explained below.

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3.3.1 Consam
The housing corporation Consam is building new houses near the town of Jamundi, Valle de Cauca. These houses will
be future homes for a community of approximately 10,000 residents. Consam has a need for a pumping station to
pump away all residual wastewater and rainwater collected by the new neighborhood.
It is in Consam’s best interest to keep customers, the future residents, happy while also trying to maintain a healthy
profit. In the context of this research we are looking into the urban water system of this neighborhood. This urban
water system must be must be as cheap as possible, while still able to function properly in order to keep customers
happy. Because the pumping station is planned to be adopted by the local water company, only the construction
phase will be coordinated by Consam.

Because consam is specialised in building new houses, and not in urban water systems, the need exists to carry over
the management of the pumping station into the arms of a regional water system company. The situation as if now is
not optimal. During negotiations stating the management of the pumping station being transferred under
AcuaValle’s name, difficulties have arised. The pumping station is not working efficiently due to multiple causes.
Consam is trying to hand over the pumping station with minimal extra investment.

3.3.2 AcuaValle
AcuaValle is a regional urban water company, it has drinking water and wastewater facilities all around department
‘Valle de Cauca’. AcuaValle is asked to adopt the pumping station that is build by Consam.
AcuaValle has the interest to create happy customers, and earn a profit by managing a well functioning and efficient
urban water system. In this case it is in their best interest to take over management of good working, and efficient
stations. Because the construction phase has already been completed by Consam, AcuaValle will only be doing the
operational and maintenance phase.

AcuaValle only has interest in taking over management of efficiently functioning pumping station. This however is
not what they encountered upon arrival. The station is in bad shape according to their observations. AcuaValle is
trying to get Consam to improve the pumping station before taking over management.

3.3.3 Consumers
Consumers will be the new residents, and facility holders of the neighborhood currently being build by Consam. They
will be the users and payers of the eventual urban water system.
Interests of the consumers is fairly clear. Monthly costs must be as low as possible because need to be paid solely by
the consumers. These costs will contain mostly the operational and maintenance costs.

Consumers have little influence on the negotiations between AcuaValle and Consam. But it can be seen the users
have similar interest as AcuaValle, namely, an efficient pumping station leading to low operational and maintenance
costs. Although consumers have little influence, their interests must certainly be processed when determining final
design of the pumping station.

3.3.4 Local residents

Local residents will be a subgroup within ‘Consumers’. Because this subgroup lives closest to the pumping station,
people suffer most when the pumping station is malfunctioning.
The interest of the local residents is to maintain a clean and healthy environment. Therefore the pumping station
must fulfill its function without production of bad odours, and without littering the surrounding environment.

Consumers have little influence in negotiations. Although local residents have little influence, their interests must
certainly be processed when determining final design of the pumping station.

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3.4 Possible problems
In this chapter a broad view is presented on all problems that could contribute to a inefficient pumping station,
based on selected literature.
Every problem has its own paragraph, which first explains the basic theory and points out the causes leading to the
problem, secondly provides a quick indication to conclude if this problem should be further investigated. Lastly an
overview is given of the possible consequences.

● Explanation of the basic theory

● Causes leading to the problem
● Quick analysis on how to identify
● Overview of the possible consequences
3.4.1 Capacity
Urban areas generate inconsistent flows of wastewater. The amount of wastewater fluctuates over the following
time periods:
● Year
● Season
● Month
● Week
● Day
● Hour
To be able to deal with variation of inflow, a collection tank
(sump) is made. This collection tank must be designed so that a
constant outflow is possible during the day. An example of varying
flow is shown in figure 6.4.

This collection tank will be filled during high flows and emptied during low flows. When a constant outflow is
guaranteed, pumps can work on their BEP for most of the time, resulting in an efficient working pumping station. But
when the collection tank is not designed well it could lead to inefficient use of energy and damage to equipment.

Causes

To identify if the capacity of the pumping station is sufficient to ensure a stable outflow, multiple criteria must be
checked.

1) Operations of the pumping cycle

2) Design of the collection well
3) Pump specifications

These criteria are further explained below.

Operation of the pumping cycle

A pumping cycle is defined as the stretch of time between two starts of a pump. For further explanation on all
activities during this pumping cycle, table 6.1 has been included.

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 Water level collection tank Activity

Upper boundary water level is reached Pump(s) start

Water level lowers Pump(s) operating

Lower boundary water level is reached Pump(s) shut off

Water level rises Pumps off

Collection tank is filled to boundary level Pumps off

Pump cycles should preferably take ten to twenty minutes to complete, according to Colombian guidelines written in
‘…’. Therefore, a pumping cycle should consist of ± 7,5 minutes of collection well drainage, and ± 7.5 minutes of
collection well rising. Depending on existing flows and water levels in the collection tank, pumping cycles may be
manipulated slightly to ensure no undesirable water levels are reached. If the pumping cycle is not operated as
stated above, capacity drops substantially.

Design of the collection well

Collection wells fulfill the function of a hydraulic buffer, dampening the variations of flow during the day. Dimensions
of the collection well must be determined with care to eliminate the chance of flooding. The volume of such a
collection tank is dependent upon certain parameters, such as:
● T= Pump cycle time [s]
● Qo = Design outflow [m3/s]
● QI = Design inflow [m3/s]

Parameters for design in- and outflow are derived from respectively hydraulic balance. This hydraulic balance is
made considering, future trends, developments of the neighborhood, etc. Once the design in and outflow is
determined, the volume of the collection well is estimated using the following formulae:

Pump specifications
Design outflow is determined by the flow produced by pumps. Pumps should be selected on the flow they produce.
The hydraulic balance is an important indication when choosing what type of pumps and how many should be
installed to create a desirable outflow.

Identification
Operation of the pumping cycle

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An analysis must be made of the activities during the pumping cycle and their durations. Differences of the observed
and the prescribed pump cycle give indications of a bad functioning, and therefore a decrease in capacity.

Design of the collection well

Dimensions of the collection tank must be noted and compared to values given by the formulas prescribed.

Pump specifications
Specifications and layout of the pumps should be noted. With this information it is possible to conclude if pumps are
suitable for current and future flows. The hydraulic balance should be determined and used. Also take note of the
general settings at which the pump is installed, these should be in correspondence with the BEP. For further
investigation into this subject, a reference is made to chapter 6.2.

Consequence(s)
When the criteria above are not met, capacity is not sufficient, and flooding can occur. A flooding can lead to
damages concerning equipment inside and near the pumping station. Urban waste is able to flow freely overland,
leading to pollution of surroundings and bad odours. The consequences can be severe, maintenance and cleaning will
result in excessive costs.

3.4.2 Operating Point vs BEP

A pump should work on the best operating point, also called ‘best efficiency point’ (BEP). The best operating point
can be found by the intersection of the ‘pump characteristic curve’ and the ‘system characteristic curve’.

Pump characteristic curve

The hydraulic performance of a pump can be summed up by the pump characteristic curve, a graph of the head
added to the liquid, plotted against flow-rate. This graph is given by the manufacturer of the pump.

System characteristic
The pipe system to which the pump will be connected will have a characteristic curve of its own: the ‘system
characteristic’. Water must be given
head in order to:
● Static lift
● Overcome energy losses due to pipe friction and local losses at bends, valves etc. As flow-rate increases,
energy losses increase in proportion to the square of velocity (as set out in Section 8.3)
● provide velocity head if the water is discharged to atmosphere at a significant velocity.

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Best efficiency point
The operating point of the working pump should lay close to the theoretical operating point. If this is not the case the
pump works improperly and future research in whether the pump is not suitable for the situation (incorrect pump)
or other problems causes the pump not working on the BEP.

Causes
There are some causes that lead to an other operating point of the pump then the BEP. Below summed up the causes
that are mainly common to occur:
● Cavitation
● Coarse solids
● Change in system characteristic curve(s)
● Too much discharge needed
● Too much head needed
● Wrong settings of the pump
For further information on ‘Cavitation’ & ‘Coarse solids’ references are made to respectively 6.3 & 6.5.

Identification
To evaluate if the pump is working on the right operating point measurements need to be taken. To find the
operating point the pressure that the pump gives to the pipe system and the flow rate needs to be measured at the
same time. This two values gives a point the is the actually operating point. The point need to lay in a specific margin
in order to be efficient. The point on the graph gives a identification of what could be the problem of energy loss.

Consequences
Consequences of a other operating point than the BEP is inefficient use of the pump. This result in unnecessary cost
and shorter life cycle.

3.4.3 Cavitation
Cavitation is the formation of bubbles (or cavities) in liquids under low pressure circumstances. When these bubbles
implode inside the pump, they create a shockwave. This shockwave can cause damage to the impeller and/or the

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pump housing. These damages can lead to the decrease of capacity and efficiency of a pump. After a long time of
cavitation a pump can also break down.

Causes
A pump is always used in combination with a collection well, this collection well is emptied and filled when the pump
is respectively in of or out of use. When levels in a collection well are too low, highly negative pressures can arise in
the suction pipe. Under these circumstances bubbles can form in the liquid that can lead to cavitation in the pump.
To avoid this, a boundary value is introduced called NPSHRQ. If the actual water level, called NPSHAV, present at the
pumping station drops below this level, the pump can be suffering from cavitation.

Identification
A first diagnose of cavitation can be done by confirming the following qualitative observations:

● Noise -
more noise than prescribed
● Capacity loss -
pump is not able to deliver as much capacity as prescribed
● Pitting -
corrosive holes in metal surfaces on the impeller and/or housing

But in order to ensure you are indeed dealing with a cavitating pump, direct measurements must be carried out to
verify the prescribed guideline below:

NPSHAV ≥ NPSHRQ

This can be done by simply installing a pressure gauge (that measures both vacuum pressures as well as light positive
gauge pressures). When pumps are running, this pressure gauge will display the NPSHAV without the vapour pressure.
In order to check the guideline a value for NPSHRQ is determined by calculation.
If this guideline is not in correspondence with the actual situation, it is concluded the pump is cavitating.

Consequence(s)
Consequences of cavitating pumps is mostly seen in the decrease of capacity and efficiency of pumps. This decrease
is worsened over time as the damages done due to cavitation will build up. This leads eventually to efficiency loss
and increased costs due to excessive amounts of energy being consumed.
When cavitation is ignored for a long period of time, pumps could break and stop functioning. This leads to abundant
maintenance and thus costly investments in equipment.

3.4.4 Parallel interference (not finished)

Incompatible pump combination can lead to unfavourable interference. How?

Causes
-

Identification
-

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Consequence(s)
-

3.4.5 Suspended solids

Sewer systems transporting urban water contain varying quantities of solids, dependent upon dry or wet weather
flow. To further specify the solids in a combined sewer system a bullet point list is provided, from small to big:
● Suspended solids
● Coarse solids
● Objects

In third world countries inorganic concentrations are relatively high, special care is taken to remove these solids and
objects. Grid chambers, bar screens and filters are meant to reduce concentrations of solids present in the water. If
the processes above are designed and operated properly, an acceptable concentration of solids is achieved at the
inlet pipe of the pumping station.
Pumps can handle certain concentrations of solids in the water that needs to be pumped away. But if design or
operational activities are lacking, undesirable concentrations can occur at the inlet of the pipe.

Causes
Because different types of solids are present in the inflowing water, multiple tests or observations are needed to
identify if a problem is present. The following things should certainly be checked to ensure concentrations are
controlled.
1) Design and operation of grit removal systems
2) Design and operation of screening system

For design and operation of the screening system, a reference is made to subchapter ‘6.5 Bar screen’. Grit removal
systems vary from fully automatic or manually operated equipment. The most common in Colombia for small
pumping stations are manually cleaned grit chambers, therefore, focus will be on this design specifically.

Design of the grit chambers

Grit chambers are designed to remove course solids (mainly sand and gravel). Due to gravity these solids will slowly
sink to the bottom through the process of sedimentation. For this process to take place, the following criteria must
be considered when designing the grit chamber:

● Laminar flow
● No short circuiting
● V0 > VA

Operation of the grit chamber

Grit chambers need to have a catchment area to collect and store all sedimented particles. The sedimentation
process is continuous and over time this catchment area is filled with coarse particles. To ensure particles stay
collected, and don’t find their way over to the sump, the collection area needs to be cleaned regularly. This can be
done automatically or manually, depending on the design. During high flows, flow velocities increase causing
particles to lift catch a draft and float away into the pumping station. This process is described by scouring and can
lead to undesirable amounts of coarse particles to end up in the sump. Therefore, certain guidelines need to be
made to ensure particles are removed before these conditions arise.

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Identification
High concentrations of coarse solids in the collection tank arise when grit chambers are not working properly. Coarse
solids can make their way to the approach channel and later to the collection tank. Observations stating excessive
amounts of sedimented coarse material are present in these parts of the pumping station is a strong indication that
grit chambers are functioning ineffectively.

Consequence(s)
High concentrations of coarse solids in collection tank can have a lot of effects, all leading eventually to a lower
efficiency of the pumping system. The most important effects are listed below.
● Pump impeller abrasion
● Reduction of hydraulic capacity
● Blockages on screen or in pipes
● Formation of gasses due to biological degradation

3.4.6 Bar screen

Wastewater carries certain solids materials such as wood, plastic and fibrous material. These particles are causing
serious problems regarding the pump. To prevent the pump from clogging it is important to filter out solids that are
to big for pump. Therefore a bar screen is used. But wrong use of a bar screen can lead to inefficient working
pumping station.

Design of bar screen

The design of the bars is characterized by the following:
● An angle between the surface water line and the bars of ±75°
● The opening between the bars is 50-100 mm bars for coarse screening.
● 3-20 mm for fine screening.

Resistance of the screen

Resistance of the screen creates against the water flow is the most important parameter to take in account for
designing a screen. This resistance will increase as a result of clogging. The resistance during a clean screen is the
function of:
● Velocity of flow
● Profile of bars
● Thickness of bars
● Distance between the bars
● Angle of the bars

Velocity is preferred to be kept at 0.6 to 1.0 [m/s], this is to prevent friction losses reaching undesirable values. The
intake velocity in the approach channel must be higher than 0.4 to 0.5 [m/s] to ensure coarse particles don’t settle.
Due to the resistance of the bar screen there will be a loss of energy, the resulting head loss is is preferred to be
lower that 150 [mm]. A formula to calculate the head loss is given below:

2 2
1 𝑉 − 𝑣
ℎ𝐿 = ⋅( )
𝐶 2⋅𝑔
● hL = head loss [mm]
● C = the empiric friction factor and this depends on the degree of clogging of the screen
● Clean screen à = 0.7

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 ● Clogged screen à = 0.6
● V = pass through velocity
● v = approach speed

Causes
Causes of dysfunctioning of the bar screen is concluded when comparing measurements with the theoretical
explanation above. First the bar screen need to be designed correctly and constructed correctly. Wrong design and
construction can be cause of inefficient working bar screen. No cleaning of the bar screen makes the bar screen
ineffective.
Friction losses occur when velocity is to high.

Identification
Measurements of water level height, velocity and dimensions of the bar screen need to be done in order to find the
head loss that occur. On place one and three height of the water level need to be measured when the bar screen is
clogged and clean. From the clogged you can find the head loss ( H1 - H3 = hL).

The levels with the clean bar screen will give a indication whether the dimensioning of the bar screen is correct. A
incorrect design will give a head loss due to resistance of the bar screen itself without clogging.

Velocity need to be measured on place one and two. With these values and the formula mentioned above the head
loss can be calculated theoretically. So there can be evaluated whether the velocity is the problem of the head loss.

Consequences
A higher head loss then 150 mm, may result in a pass-through of solids or even over flooding of the well. The solids
will be a problem for the efficiency of the pump, see 6.4 “Suspended Solids”.

3.5 Energy efficiency

When situations arise where gravity flow is not sufficient for transporting the water, hydraulic pumps are used to
overcome height differences. The function of these pumps are to add energy to water, in the form of statical height,
or most commonly in the form of ‘Head’ (energy per unit weight). The station where this is realised is called a
‘Pumping Station’.

The hydraulic pumps used in a pumping station make use of energy, often this is in the form of electrical energy. In
order to assess if a pumping station is functioning well, it is of importance to check if the efficiency. When a pumping
system is assessed with a low efficiency, too much energy is being used and/or equipment is not used in a durable
way.

Efficiency can be evaluated with the simple formulas shown below:

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 𝜂 = (𝑃𝑇 ÷ 𝑃𝐴 ) ⋅ 100%
And because: because: 𝐸 = 𝑃 ⋅ 𝑡
𝜂 = (𝐸𝑇 ÷ 𝐸𝐴 ) ⋅ 100%

From this formula the efficiency is calculated by dividing the ‘power/energy given to the water’ by the ‘power/energy
delivered to the pump’. The difficulty in finding the overall efficiency is to estimate and read off these parameters.
How to assess these values is explained in paragraph 5.2 and 5.3.

4. Research Methodology
The research approach will be set of bullet points for evaluating the energy efficiency of the pump. The evaluation
will be based historical data, observations, and other information of the pumping station. When concluded that the
station is inefficient, possible causes of loss of efficiency are presented. After which, measurements on-site are
conducted to verify what causes are contributing to an inefficient pumping station. The problems determined are
prioritised on multiple criteria. Eventually, suitable solutions leading to an efficient improvement are addressed. The
mentioned above is presented in a summary of bullet points:

● Assessing efficiency of the pumps

● Evaluating current situation
● Interpreting current situation & Identifying possible problems
● Solutions

The result of the research will be a general manual for performing an ‘Energy Audit’ to ensure more pumping stations
can be evaluated and improved making them more efficient.

Theoretical references to be used:

● ‘Urban Drainage’ by David Butler and John W. Davies
● Course material from the course ‘Pumping Stations and Transport Pipelines’
● Internet sources

5. Assessing efficiency of the pumps

5.1 Historical data analysis
5.1.1 Analysing flow (DWF -WWF - Total flow)
(Needs to be done when historical flow data comes in)
5.1.2 Analysing energy consumption (DWF - WWF - Total Energy consumption)
(Needs to be done when historical energy data comes in)

5.2 Energy efficiency

5.2.1 Total energy given to the water
Total volume estimation -> Total energy given to water
5.2.2 Total energy supplied to pumps
Total energy consumption pumping station

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5.2.3 Evaluation of efficiency
determining η

5.3 Interpretation
5.3.1 Yearly, Monthly, Daily, …
Look at trends etc. -> recommendations of possible problems
5.3.1 ...

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6. Evaluating current situation
6.1 Initial findings
Pumps
The pumping station is equipped with 3 pumps regulating the water level in the collection tank. All serve a different
function.
● ‘Pump 1’ is supposed to function during dry and wet weather conditions
● ‘Pump 2’ is supposed to be activated when wet weather conditions arise, because the incoming flow is too
much to be handled solely by Pump 1
● ‘Pump 3’ has the function of a back up pump. This pump is only activated when pump 1 or 2 is out of order or
being repaired.

The current situation shows the following:

● Pump 1 is damaged, and has already been repaired in the past
● Pump 2 is working properly
● Pump 3 is broken down, taken apart, and out of order.

Pump 1 is functioning worse than Pump 2. Pump 1 has stopped working two times upon visiting the pumping station
and Pump 1 is not able to reach the same pressure head as Pump 2. The operating chiefs have tried to explain what
the situation was when the pump stopped working

Occasion #1
Pump 1 was working alone in standard conditions and settings. The liquid in the pump was mixed with gas, possibly
air.

Occasion #2
Pump 1 was working parallel with Pump 2 in standard conditions and settings. The pressure displayed on the
pressure gauge attached to the discharge pipe of Pump 1 showed a significantly lower pressure than was displayed
on the same pressure gauge attached to the discharge pipe of Pump 2.

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Bar screen
The bar screen protecting big particles from flowing in, was not working properly. This was concluded because the
bar screen hadn’t been cleaned for a long time, and big particles were floating in the collection well. Multiple causes
can for the malfunctioning were observed:
● Gap between bar screens and the concrete approach channel directing the flow, due to a constructional
mistake
● Malfunctioning of the cleaning system of the bar screens, due to erosion

Collection well & capacity

Floodings of the collection tank occur during heavy rainfall. This was concluded because the operating chiefs told this
phenomenon happens sometimes, and visual evidence of pollutants on the ground was present.

General network
The pumping station was designed to transport the water to another pumping station 3500 meters away. From here
the water must be pumped away an addition 1500 meters to the central collection point of wastewater. But due to
dysfunctioning of this 2nd pumping station, water must be transported approximately 5000 meters away directly to
the central collection point.

6.2 Assessment of technical condition of installed pumps and related assets

1) NPSH-level
2) Changes in headflow
3) Changes of characteristic curves
4) Degree of wear and tear

6.3 Assessment of existing pumping system operation

1) Historical energy use
2) Frequency of pumps switching on/off
3) Actual efficiency vs BEP
4) Energy consumption and related carbon footprint
5) Cost of pumping

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7. Interpreting situation & Identifying problems
8. Solutions
9. Conclusions
10. Recommendations for further research
11. Literature
Appendix A

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