North Sindh Urban Services Corporation (NSUSC) 

Consulting Services for Mapping, Planning,

Feasibility Studies, Detailed Design, and
Construction Supervision for Sindh Cities
Improvement Investment Program 04

WORKING PAPER NO. 3

Water Production Rationalization of
Sukkur, New Sukkur and Rohri Towns

MMP
MM Pakistan (Pvt.) Ltd.
in association with

i
Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

Issue and Revision Record

Rev Date Originator Checker Approver Description

A 12-12-2011 Warwick Weeks Mohsin Ali Raza Jahanzaib Chaudhry Working Paper
No.3, Water
Supply
Rationalization

This document is issued for the party which commissioned it and for specific purposes connected with the above-captioned
project only. It should not be relied upon by any other party or used for any other purpose.
We accept not responsibility for the consequences of this document being relied upon by any other party, or being used for any
other purpose, or containing any error or omission which is due to an error or omission in data supplied to us by other parties

Working Paper No. 3 Water Supply Rationalization (ii) December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

TABLE OF CONTENTS

PURPOSE OF WORKING PAPER……………………..…….……………………………………………………...1

METHODOLOGY…………..……………………………………………………………………………………….1

OPERATIONAL OVERVIEW………………………………………………………………………………………...1

SUMMARY OF MAIN FINDINGS……..…......……………………………………………………………………...4

RECOMMENDATIONS/CONSIDERATIONS.………………………………………………………………………...5

NEXT STEPS………………………………………………………………………………………………………5

SCHEMATIC DRAWINGS……………………………..……………………………………….…………………...6

Working Paper No. 3 Water Supply Rationalization (iii) December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
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Working Paper on Water Production Rationalization

Purpose of the Working Paper

The consultant has carried out an ‘operational study’ of the water supply of Tranche 1 towns to
understand how the future DNI zones will integrate into the operations of NSUSC.

The purpose of this short working paper is to report on the operational findings in Sukkur, New Sukkur
and Rohri particularly with regard to water production and water treatment facilities.

The findings are presented for NSUSC stakeholders to discuss and are expected to influence the
designs of the Distribution Network Improvements zones [DNIs] and the future water supply Master
Plan proposals.

It is suggested that the recommendations will also impact on how the core business of NSUSC will be
managed and operated in the future and will influence the Institutional Strengthening workstream.

Throughout the investigations the consultant has been aware of the NSUSC goal to provide improved
24/7 water services to customers and to become a sustainable utility.

The rationalization concepts recommended maybe applicable to other functions of NSUSC to include
SWM and WW as the operational activities of 6 towns merge and become managed by 1 Utility.

Methodology

All known documents on NSUSC water supply have been studied and field visits to the NSUSC
installations have been carried out.

The consultant has attempted to view the water supply operations of NSUSC from the perspective of
a utility operator especially with regard to understanding how the future DNIs will be incorporated and
sustained.

Of great value has been the consultations and discussions with the NSUSC mangers, staff and their
advisors for which much gratitude is extended.

Operational Overview

The operational review of the existing facilities found:-

1. That in spite of the very best endeavors by NSUSC employees, the utility was unable to
consistently/reliably operate the existing facilities to meet NSUSC’s service targets. Quantity,
quality and reliability targets are not being met due to operational difficulties.

2. ‘Layers’ of additional infrastructure have been constructed over several decades to support the
original water systems making the existing installations complicated and difficult to reliably
operate.

3. To a certain extent the water supply to the 3 towns has been developed independently even
though the towns are in very close proximity of each other. This has led to some operational
duplication and an unnecessarily complex water supply system.

4. The 3 towns Sukkur, New Sukkur and Rohri are supplied by 5 Water Treatment Plants and 11
different pumping stations. All of the locations require continuous manning with competent
operators and need to be supported by well trained maintenance crews. This is strain on NSUSC
financial and manpower resources. The resulting production interruptions impact adversely on the
service delivered to customers.

Working Paper No. 3 Water Supply Rationalization 1 December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

5. The intermittent electricity supply is a major problem for NSUSC and makes continuous
operations at all water supply locations near impossible. The consequence of electricity cuts is
intermittent water production and an overall loss in daily production. This leads to water shortages
for customers and a suppressed demand.

6. The consequence of the electricity cuts to NSUSC is that significant operational resources are
diverted to respond to the demand for generators and to make repairs to the resulting damaged
electrical equipment.

7. Stand-by generators have been installed at most pumping stations and treatment works but due
to the large number generators they in themselves are an added operational complexity to
maintain, fuel and operate.

8. Maintaining Water Production is a very difficult task for NSUSC with the existing infrastructure and
this impact adversely on services to customers.

9. In principle water production [quantity] should not be difficult given the proximity, reliability and
adequacy of the River Indus as a water source.

10. It is estimated that there is an existing water production shortfall [suppressed demand] of
approximately 50%. There is no accurate data to verify this figure as it is based on assumptions.
However this figure has been discussed with NSUSC and their advisors and is broadly accepted.

11. The 3 towns are supplied from four water source abstraction points. Essentially all sources are
from the Indus River although the one source supplying the Airport Road WTP is via the NW
canal which is fed from the Indus River. The canal source is unreliable as the canal is closed 1
month a year for canal maintenance. NSUSC aim to make good the annual canal shortfall by
supplementing with tubewell water adjacent to the canal at Airport Road WTP. All of the source
abstraction points require 24 hour manning, all require mechanical and electrical maintenance,
standby generators etc.

12. It is suggested that operating the above source works apparatus is excessively complicated and
expensive for what should be a very straightforward process of abstracting water from the river?
Operating the existing source works systems ‘might’ be appropriate for a developed world utility
but it is suggested that for the fledgling NSUSC in the current Pakistan context the sources
system is overly complex.

13. The WTP operators seem well motivated but it is unknown how competent they are with the
scientific skills required to achieve Pakistan drinking water quality standards. The water plants are
not fully treating the raw water at the moment.

14. To achieve the targeted water quality standards 24/7 will require competent operators manning
level all 5 WTPs at 3 shifts per day. Thus a significant number of well trained operators required.

15. The WTPs require extensive investment which is fully recognized by NSUSC and this is being
addressed through the ICB-3 investments.

16. The level of effort required from NSUSC management and staff to produce and treat water is
large. This significantly dilutes the resources of NSUSC to develop the new business practices
envisaged for the utility. NSUSC water supply activities that require development include
distribution management, leak detection, commercial aspects, customer services, planning, etc.,
etc.

17. The condition and limitations of the Trunk mains are well documented and well understood by
NSUSC and their advisors. NSUSC have a program of new trunk mains in their investment
proposals. It is anticipated that additional new trunk mains will be identified during the SCIP-04
Master Planning activities.

Working Paper No. 3 Water Supply Rationalization 2 December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

18. The 3 main elevated Distribution Service reservoirs [shown ‘Blue’ on attached Schematics] seem
to be well located and provide gravity supplied water to the majority of Sukkur, New Sukkur and
Rorhi. The reservoirs would benefit from having increased capacity but the locations are good.

19. The condition of the distribution networks is an unknown. Through the DNI process the condition
and performance of the selected distribution systems will be better understood, renovated and
then managed. There are assumptions made that there is high leakage, misuse, illegal
connections, etc but this is unquantifiable at the moment. What is known is that the customers are
dissatisfied with the current service and unwilling to pay more for the current level of service.
Conversely it is known that customers are willing to pay Rs. 500+ per month for a good service.

20. Distribution Management is practiced as much as possible with the existing apparatus and the
NSUSC Operations Manager is to be commended for his efforts to equitably distribute the water
with limited resources and data. Without operational data it is not possible to manage the water
supply systems to their optimum. The Small Capital Works program will provide additional valves
to the distribution system. This will assist NSUSC to more equitably distribute the water in the
short term.

21. An anecdotal assessment during DNI investigations did not reveal excessively bad
habits/wastage of water by customers. The occasional roof tank was noted to be overflowing but
this was not thought to be common as the practice also entailed the wastage of electricity which
would regulate how the booster pumps were managed. No yard taps were observed to left
running unattended and the streets generally appeared dry with no obvious leaks left unrepaired.
Several NSUSC distribution teams were met during the DNI investigations and repairs and
maintenance work was being carried out.

22. NSUSC has no Operations Control room or formal method of collecting or recording operational
data. The NSUSC managers are supportive for these operational tools to be established and
have requested support to implement these systems.

23. NSUSC fully appreciates the need for Capital investment into the water infrastructure. Much of the
apparatus NSUSC has inherited is in a poor rundown condition. SCIP-04 is part of the delivery of
the investment program and Master Plan analysis. Capital investments will be addressed more
thoroughly in future SCIP-04 documents and reports.

24. Institutional observations:-

i. NSUSC recognizes that to achieve the target service levels it will be necessary to introduce a
program of Institutional changes.
ii. These institutional changes are particularly true with regard to managing and operating DNIs.
iii. Arguably Production and Treatment and managing DNIs is the core business of NSUSC and
the institutional changes should reflect that priority.
iv. Misguidedly Capital Works is perceived by some stakeholders as the core business of
NSUSC and it is given precedence in the utility over Operations.
v. NSUSC is not a construction company. The highest priority is to provide a service to
customers and the utility should be structured around the employees in Operations who
provide the service.
vi. It is not apparent at the moment that NSUSC is configured to provide this level of institutional
support to managing DNIs or Operations.
vii. It is suggested that the proposed Institutional strengthening will include a re-structuring
exercise and extensive training.
viii. The institutional strengthening should address operational budgets to ensure that operational
support is forthcoming to include the required manpower, maintenance, spare parts,
chemicals, etc.

25. NSUSC Operations Managers are well aware of the above points and are supportive of the
changes required.

Working Paper No. 3 Water Supply Rationalization 3 December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

26. The basic components of water system are sound. The river source is reliable and with
conventional treatment processes should yield safe quality water. The system is however
complex and expensive to operate and for the long term needs a review.

Summary of Main Findings

i. Operationally NSUSC water production and treatment facilities are complicated with too many
operational sites. Please refer to Schematic Drawing No 2.
ii. The complexity leads to high operational costs and unreliable services to customers.
iii. The unreliability is compounded by electricity outages at all NSUSC production facilities.
iv. The running of multiple generators at multiple sites is a major operational task and adds
significantly to NSUSC operational cost and is a cause of water supply unreliability.
v. Water Production & Water Treatment is a vulnerable component and arguably the weakest
element of the NSUSC water supply system and will potentially undermine the proposed 24/7
service.
vi. The water produced does not meet customer demand…..there is a suppressed demand
estimated to be in the order of 50%. Even with full DNI implementation production will not
meet demand.
vii. Significant human and financial resources are directed to operating the existing NSUSC
production and treatment facilities. This dilutes the level of effort that can be applied to other
important NSUSC development activities to include distribution management, leak detection,
etc.
viii. The water from the water treatment plants does not meet Pakistan WQ standards.
ix. The operation of 5 WTP’s to produce ‘safe’ water 24/7 requires significant skilled expertise.
x. The operation of 4 water sources 24/7 requires significant skilled resources.
xi. The River Indus is a reliable water source. NSUSC are proposing to relocate the main intake.
It is suggested this is a high priority investment.
xii. There seems to be no evidence of significant ground water in the quantities required by
NSUSC. Pursuing multiple ground water sources has possible water quality benefits but adds
operational complexity which results in maintenance, reliability and unit cost concerns.
Ground water requires further investigation but the existing evidence to support ground water
exists in reliable quantities is scarce. Tube well fields are relatively high in maintenance and
energy costs. The full evaluation of river source v. tube wells needs to be carried out.
xiii. Rohri is very close to Sukkur and New Sukkur and all towns can be supplied from a single
source and a single water plant. Schematic No 3 proposes one scenario.
xiv. Maintenance of M&E equipment is high and M&E costs could significantly be reduced if the
systems were rationalized.
xv. Skilled manpower needs could be reduced if the number of water plants and pumping stations
were reduced.
xvi. Reliability of the systems would improve if the resources of NSUSC could be focused on
fewer installations.
xvii. The locations of the elevated reservoirs are very good but there is a need to increase the
capacity of the reservoirs to improve the security of supply.
xviii. The principle pipelines are functional but need reinforcement and some cases replacement.
All pipelines are short, generally less than 5km.
xix. The distribution systems function reasonably well given the lack of apparatus and equipment
that is available to manage the systems not to mention the lack of reliable water production
and treatment that is provided. Clearly some new distribution pipelines will be required and
these will be identified during the DNI survey work. Only when the DNI investments are made
and the DNI operation is implemented will the distribution situation/customer behavior be fully
clear. The multitude of very long service pipes in some streets is a serious concern and these
need to be replaced with distribution mains and short service connections.
xx. Customer awareness and education will play a large part of implementing the future water
service. Anecdotal meetings with customers indicated dissatisfaction with the service.
xxi. There are no formal Operations control room or process for collecting operational data. This is
a priority recommendation and fully supported by the NSUSC operations team.
xxii. It is recognized that rationalization of water production and treatment would sacrifice some
operational flexibility. It will be contended that a higher level of service/lower unit cost will be
achieved by NSUSC through rationalization.
xxiii. All existing installations will be retained and reviewed in the future.

Working Paper No. 3 Water Supply Rationalization 4 December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

Recommendations/Considerations

i. Consider simplifying the water production of the 3 towns to make water production more
reliable and to reduce operational costs.
ii. Consider simplifying water production to One reliable source and One reliable Water
Treatment Plant for example as shown in Schematic Drawing No 3.
iii. Consider simplifying water production and treatment as a method of fast tracking DNIs across
all 3 towns.
iv. Consider simplifying water production and treatment as a method of fast tracking customer
service targets for quantity, quality and reliability [24/7 service].
v. Consider reviewing the current Investment Program/Master Plan to fast track reliable water
production and treatment components.
vi. Consider simplifying water production and treatment as a way of reducing dependency on
multiple electricity locations. Reduce to just 2 locations/2 generators?
vii. Consider retaining all the existing infrastructure for operational flexibility.
viii. Consider the benefits of reducing the manpower requirements for water production and
treatment [reducing the Unit Cost of production] and redeploying manpower resources to
other priorities including distribution management, leak detection and DNI management.
ix. Consider simplifying the water production as a way of reducing mechanical and electrical
maintenance costs.
x. Consider the potential for focusing on NSUSC commercial and business activities.
xi. Consider the overall benefits to NSUSC which has much of its current resources directed to
maintaining production and treatment. NSUSC resources could be redirected to implementing
new initiatives to increase revenues, reduce leakage, etc.
xii. Consider the impact on customer’s willingness to pay and the revenue advantages of
accelerating the customer metering program.
xiii. Cost recovery could be possible across entire towns not just selected DNIs.
xiv. The schematics show one rationalized scenario….there are other scenarios and variations to
be considered.
xv. Consider reviewing the institutional strengthening program to ensure NSUSC is being
prepared for rationalization if approved.

Next Steps

• Hold conceptual discussions with principle stakeholders

• Include rationalization concept in Master Plan/Investment Plan evaluation process
• Carryout cost benefit analysis of the capital investment required.
• Incorporate operational needs into the Institutional Strengthening program

Working Paper No. 3 Water Supply Rationalization 5 December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

Base Conditions:
1. Sukkur, New Sukkur & Rohri schematic town boundaries.
2. River Indus - Reliable water source.
3. Elevated Distribution Reservoirs – Gravity water supply to customers – Good Assets.

Working Paper No. 3 Water Supply Rationalization 6 December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
Nippon Koei (UK)

Existing System:

1. System is operationally complex. 5 WTP’s ,10 Pumping Stations .

2. Layers of technical investments have added operational complexity.
3. System is unreliable: Dependent on electricity and manpower expertise at 10
locations.
4. Results in intermittent and poor water quality to customers.
5. System has high operational costs.
6. Poor service results in low revenue and customers unwilling to pay.

Working Paper No. 3 Water Supply Rationalization 7 December, 2011

Consultancy Services for Mapping, Planning, Feasibility Studies, MM Pakistan (Pvt.) Ltd
Detailed Design and Construction Supervision for SCIP-04 Mott MacDonald Limited
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Rationalization Concept:
1. Operationally simple. One reliable source. One reliable WTP
2. High quality water produced & delivered 24/7 to entire populations of
Sukkur, New Sukkur and Rohri.
3. Gravity supply from Distribution Reservoirs to customers including
DNI’s.
4. Potential for increased revenue is significant.
5. Operational costs are reduced.
6. Enables ‘New Management Processes’ to be introduced.

Working Paper No. 3 Water Supply Rationalization 8 December, 2011