Fortis EA Report

Jadavpur University

Study on the Energy Consumption & Comprehensive Energy Audit of the Newly constructed

Fortis Hospital, Anandpur, Kolkata

Prepared as a compulsory part of Post Graduate Diploma in Energy Management &

Audit Course

by

Kingsuk Sarkar &

Amiya Das

June-July 2011

There might be some problems, but they needed to be and could be sorted out.

“We should not let problems defeat us. Instead, we should seek to defeat the

problems”.

A.P.J. Abdul Kalam

Honorable Ex. President of India

Acknowledgement

We are profoundly thankful to M. F. Siddiqui, General Manager, Mr. Jacob George, Sr. Manager-Administration and Mr. N. Basak, Manager-Maintenance for the permission & active support given in conducting this Energy Audit Study in the newly constructed Fortis Hospital at Anandapur, Kolkata.

We are also thankful to Dr. B. Ghosh, Director, School of Energy Studies, Jadavpur University, Mr. S. D. Modak, Ex. Director, NPC, Mr. R. Mandal, Assistant Professor, Jadavpur University & all the teacher’s of PGDEMA course for their valuable advice & guidance to conduct the entire study.

In general, we thank all the engineers and staffs of Fortis Hospital, for their timely assistance, co-operation and valuable information provided for the study.

Kingsuk Sarkar Amiya Das

Content

Page No Executive Summary………………………………………………………………………….. 1 Chapter : 1 Introduction……………………………………………………………………… 21.1 Salient Features of The Hospital………………………………………………………… 31.2 Scope of Work…………………………………………………………………………….. 31.3 Methodology……………………………………………………………………………….. 31.4 Instrumentation Support………………………………………………………………….. 4

Chapter : 2 Base Line Data………………………………………………………………….. 52.1 Load Distribution…………………………………………………………………………… 52.2 Connected Load in Pie Chart…………………………………………………………….. 62.3 CESC Billing History………………………………………………………………………. 62.4 Power Factor Correction………………………………………………………………….. 72.5 TOD Metering Feasibility…………………………………………………………………. 72.6 Energy Performance Assessment of Hospital………………………………………….. 8

Chapter : 3 Electrical Power Distribution………………………………………………… 93.1 Rated Specification……………………………………………………………………….. 9 3.1.1 Transformers…………………………………………………………………………. 93.2 Losses in Transformer……………………………………………………………………. 93.3 Operational Load & Transformer Loading……………………………………………… 9 3.3.1 Transformer 1………………………………………………………………………... 9 3.3.2 Transformer 2………………………………………………………………………… 103.4 Recommendation………………………………………………………………………….. 11 3.4.1 De-energization of Transformer……………………………………………………. 113.5 Estimation of Energy Savings……………………………………………………………. 12

Chapter : 4 Heating, Ventilation & Air Conditioning……………………………………. 134.1 Rated Specification………………………………………………………………………… 13 4.1.1 Chiller…………………………………………………………………………………. 13 4.1.2 Condenser Pumps…………………………………………………………………… 13 4.1.3 Chilled Water Primary Pumps……………………………………………………… 14 4.1.4 Chilled Water Secondary Pumps (Zone A)……………………………………..... 14 4.1.5 Chilled Water Secondary Pumps (Zone B)……………………………………….. 15 4.1.6 Cooling Towers………………………………………………………………………. 154.2 Measurements Made & Analysis………………………………………………………… 15 4.2.1 Chiller…………………………………………………………………………………. 15 4.2.2 Cooling Towers………………………………………………………………………. 164.3 Energy Conservation Opportunities……………………………………………………… 17 4.3.1 Chiller…………………………………………………………………………………. 17 4.3.2 AHU & FCU Cooling Coil & Filters…………………………………………………. 17 4.3.3 Cooling Towers………………………………………………………………………. 17

Chapter : 5 Air Compressor…………………………………………………………………. 195.1 Rated Specification………………………………………………………………………… 19 5.1.1 Air Compressor……………………………………………………………………….. 195.2 Performance Evaluation…………………………………………………………………… 195.3 Energy Conservation Opportunities……………………………………………………… 20

Chapter : 6 Water Treatment & Distribution………………………………………………. 216.1 Rated Specification…………………………………………………………………………. 21 6.1.1 Softener Water Pumps……………………………………………………………….. 21 6.1.2 Flushing Raw Water Pumps…………………………………………………………. 21 6.1.3 Flushing Treated Water Pumps……………………………………………………… 22 6.1.4 Hydro pneumatic Pumps 1…………………………………………………………… 22 6.1.5 Hydro pneumatic Pumps 2…………………………………………………………… 236.2 Performance Evaluation……………………………………………………………………. 23 6.2.1 Softner Water Pumps…………………………………………………………………. 23 6.2.2 Flushing Raw Water Pumps…………………………………………………………. 23 6.2.3 Flushing Treated Water Pumps……………………………………………………… 24

Chapter : 7 Lighting…………………………………………………………………………….. 257.1 Lighting Loads………………………………………………………………………………... 257.2 Light Fittings Type……………………………………………………………………………. 257.3 Lux Level……………………………………………………………………………………… 257.4 LPD…………………………………………………………………………………………….. 257.5 Recommendations…………………………………………………………………………… 25

Chapter : 8 Elevators…………………………………………………………………………… 268.1 Rated Specification…………………………………………………………………………. 26 8.1.1 Bed cum Passenger Elevator………………………………………………………… 268.1.2 Dumb Waiter………………………………………………………………………………. 26

Chapter : 9 Hot Water Generation……………………………………………………………. 279.1 Rated Specification………………………………………………………………………….. 27 9.1.1 Water Tank……………………………………………………………………………… 27 9.1.2 Solar Collector………………………………………………………………………….. 27 9.1.3 Water Circulation Motor……………………………………………………………….. 27 9.1.4 Performance Evaluation: Solar Plant………………………………………………… 289.2 Estimation of Carbon Di Oxide Emission reduction……………………………………… 28

List of Drawing & Tables 1. SLD & Schematics :: 3 nos 2. Annexure - 1 :: 2 charts

1

Executive Summary

About Fortis A 400 bed super specialty Fortis hospital on EM By-pass road in Kolkata is the newest addition to the well established network of Fortis. It is a super specialty hospital with focus on Cardiology/Cardiac surgery, Urology/Nephrology, Neurosciences, Orthopedics, Minimal Access surgery and Critical Care. The hospital incorporates the most advanced design and material combination, being environment and patient friendly at the same time.

The hospital is commissioned to function from July 2010.

About JU School of Energy Studies, Jadavpur University pioneered post graduate education & research in the field of Energy Science & Technology in West Bengal.

From 2010, JU has introduced one year Post Graduate Diploma course in Energy Management & Audit (PGDEMA). Objective of the Study The study has been carried-out to fulfill the mandatory partial requirement for the PGDEMA degree of Jadavpur University.

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Introduction

Economy of power consumption is vital for overall efficiency for Fortis Hospital, Kolkata. Necessity for reduction of operational cost through energy conservation is one of the key concerns of the management. Concerned & organized efforts are on to optimize present power consumption & cost.

The objective of this study is to undertake Diagnostic Energy Audit study and suggest means & measures to optimize consumption. As per “The Energy Conservation Act (EC Act) - 2001”, Commercial buildings or establishments are fall in to the list of energy intensive industries and “Energy Conservation Building Code”(ECBC) is applicable to buildings or building complexes that have a contract demand of 600kVA or greater.

As Fortis Hospital which is a commercial building, has a contract demand of 800kVA, we have conducted the study to meet these requirements too.

The study has been conducted under the following terms of reference:

1) To study the present electrical load at various usage points and suggest further measures to reduce load and wastage of energy and increase energy usage efficiency.

2) To prepare an audit report fulfilling the requirements of the mandatory order and submit the same to the competent authority.

3) To furnish all information or any particular test as required by the authority.

The study has been carried out during the month of June-July, 2011.

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1.1 Salient Features of Hospital

1. Hospital Location : 730, Anandpur, Kolkata-700107 2. Capacity : 400 Beds (As of now around 200 beds are operational) 3. Site area : 6026 sq m 4. Built Up Area : 24143 sq m 5. Climate Zone : Warm & Humid

1.2 Scope of Work

• Analysis of major power supply parameters i.e. power factor, maximum demand, load factor, transformers optimization loading with suggestion for scope of savings and also feasibility study of TOD-billing.

• Operating performance of HVAC Systems with suggestions for sustainable energy savings.

• Study of Illumination system in the building with suggestions for energy savings.

• Performance evaluation of air compressor and water distribution pumps and exploration of energy conservation opportunities.

1.3 Methodology Methodology adopted for achieving the desired objectives viz: Assessment of the Current operational status and Energy savings include the following:

• Discussions with the concerned officials for identification of major areas of focus and other related systems.

• A team of engineers visited the Site and had discussions with the concerned officials/ supervisors to collect data/ information on the operations and Load Distribution within the Building Complex. The data was analyzed to arrive at a base line energy consumption pattern.

• Measurements and monitoring with the help of appropriate instruments including continuous and/ or time-lapse recording, as appropriate and visual observations were made to identify the energy usage pattern and losses in the system.

Computation and in-depth analysis of the collected data, including utilization of computerized analysis and other techniques as appropriate were done to draw inferences

Develop a Base Line of the Energy Consumption Pattern

Obtaining Energy Consumption data

from the Site

On Site Measurements based on the Mutually Decided Action Plan

Active involvement of

the Site Officials

Draft Report Submission

Feedback

Final Report Submission

4

and to evolve suitable energy conservation plans for improvements reduction in specific energy consumption.

1.4 Instrumentation Support Following instruments are used for undertaking the study:

Online KWh Meter Clamp-on type Voltage and Ampere Meters Digital Temperature Meters with appropriate Probes Psychro Meter TDS Meter Solarimeter Lux Meter Anemometer

Solarimeter Lux Meter Anemometer

Thermometer Psychro Meter

5

Base Line Data Power Supplier: CESC Ltd. Supply Voltage: 11kV Contract Demand: 800kVA Tariff Type: Flat 2.1 Load Distribution

SL NO

DESCRIPTION CONNECTED LOAD(KW)

OPERATING LOAD(KW)

DIVERSITY MAXIMUM DEMAND

(KW)

LOAD ON DG

SET(KW)

UPS LOAD(KW)

1 LIGHTING 120 110 0.8 88 88 64

2 COMPUTER /PRINTER /HUB ROOM 150 100 0.7 70 70 70

3 MEDICAL EQUIPMENTS

UPS 100 80 0.8 64 64 64

NON UPS 200 120 0.6 72 72

4 HVAC

CHILLER # 3‐250 TR WATER COOLED SCREW 513 342 0.9 307.8 307.8 0

PRIMARY PUMPS #3 33 22 1 22 22 0

SECONDARY PUMPS#5 127 78 1 78 78 0

CONDENSER PUMPS#3 66 44 1 44 44 0

COOLING TOWER#3 22 15 1 15 15 0

AHU/TFA 200 150 1 150 150 0

VENTILATION 89 60 1 60 60 0

5 ELEVATORS

BED ELEVATORS #5 75 45 1 45 45 0

DUMBWAITER #1 10 10 1 10 10 0

6 FIRE FIGHTING

FIRE HYDRANT PUMP 55 0 0 0 0

SPRINKLER PUMP 55 0 0 0 0

JOCKEY PUMP 30 15 0.5 7.5 7.5 0

STAND BY PUMP 55 0 0 0 0

7 PLUMBING LOADS

HYDROPNUMATIC PUMP# 3 4.5 1.3 1 1.5 1.5 0

HYDROPNUMATIC PUMP# 3 9 2.7 1 3 3 0

BOREWELL FILTER PUMP#2 6 2.7 1 3 3 0

OVERHEAD TANK#2 8 3.6 1 4 4 0

RAW WATER TRANSFER PUMP#2 6 2.7 1 3 3 0

STORM &SEWAGEWATER SUMP#3 12 5.4 1 6 6 0

STP 35 25 1 25 25 0

HOT WATER GENERATION 48 24 1 24 24 0

8 KITCHEN‐ADHOC 100 100 0.6 60 60 0

9 MEDICAL GAS & PIPING SYSTEM 55 18.5 0.9 16.65 16.65 0

TOTAL (APPRX) 2183.5 1086.9 1045 1045 200

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2.2 Connected Load in Pie Chart

2.3 CESC Billing History (Source: CESC Bills)

YEAR MONTH

06-12 HRS

12-17 HRS

17-20 HRS

20-23 HRS

23-06 HRS

CHARGEABLE UNITS

UNITS PER DAY

2010 JUN 7473 6963 4420 4507 9510 32873 1095.772010 JUL 2010 AUG 60403 63773 32473 19806 41390 217845 7027.262010 SEPT 78109 71226 37593 31636 68819 287383 9579.432010 OCT 91419 79356 44923 41603 91656 348957 11256.682010 NOV 79059 70236 38930 32556 64926 285707 9523.572010 DEC 71676 61746 38853 35723 69316 277314 8945.612011 JAN 74219 71303 39300 35373 67796 287991 9290.032011 FEB 78269 69936 41673 36170 58256 284304 10153.712011 MAR 97879 92496 52166 47706 84722 374969 12095.772011 APR 103742 95096 52453 48113 90622 390026 13000.872011 MAY 122705 111829 61026 50756 94969 441285 14709.502011 JUN 123252 111436 59493 49230 91832 435243 14508.10

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2.4 Power Factor Correction For improvement of Power Factor, suitable capacity of capacitor bank (2x300kVAR) is already installed. 2.5 TOD (Time of the Day) Metering Feasibility The type of billing is flat (Non TOD).

CESC Demand Charge

Rs. 220/kVA per month

CESC Unit Rate

Unit charge for Flat (paise/unit) Unit charge for TOD (paise/unit) Summer Monsoon Winter Period Summer Monsoon Winter

468 465 462 Normal 461 458 452 06:00-17:00&

20:00-23:00 Peak 692 687 683 17:00-20:00

Off-peak 318 316 314 23:00-06:00

CESC Meter Rent Flat: Rs. 350/month TOD: Rs. 1200/month

CESC PF rebate & Surcharge @ 98% PF

Power Factor rebate & Surcharge on Energy Charge in Percentage For consumers under TOD tariff For consumers

under flat tariff Normal Peak Off-peak Rebate

in % Surcharg

e in % Rebate

in % Surcharg

e in % Rebate

in % Surcharg

e in % Rebate

in % Surcharg

e in %

5 0 6 0 4 0 3 0

Load Factor Rebates Load Factor = Average Load / Maximum Demand

RANGE OF LOAD PAISE/KWHABOVE 50 % UPTO 55% 3ABOVE 55 % UPTO 60% 4ABOVE 60 % UPTO 65% 8ABOVE 65 % UPTO 70% 10ABOVE 70 % UPTO 75% 16ABOVE 75 % UPTO 80% 20ABOVE 80 % UPTO 85% 25

8

ABOVE 85 % UPTO 90% 30ABOVE 90 % UPTO 92% 35ABOVE 92 % UPTO 95% 37ABOVE 95 % 40

From the above table, it is clear that higher load factor provides more tariff benefits.

Example: Benefits of TOD

Below example (June 2010, from table 2.3) will show how Fortis can save energy charge by opting TOD billing. Considering:

i. Govt. Duty, LF rebates & Timely Payment rebate not considered in both the case. ii. Maximum Demand= 917.3kVA iii. Power Factor= 98%

A. Bill Value (Non TOD) in RS.

Demand Charge= 917.3x220= 201750 Unit Charge= 435243x5.14= 2237150 PF Rebate= 2036937x(-3)/100= -61108 Meter Rent= 350 -------------------------------------------------------- Net Bill= Rs. 2378142

B. Bill Value (TOD) in Rs. Demand Charge 917.3x220= 201750 Unit Charge @ Normal=283918x4.61= 1308862 Unit Charge @ Peak=59493x6.92= 411691.6 Unit Charge @ Off-Peak=91832x3.18= 292025.8 PF Rebate @ Normal=1308862x(-5)/100= -65443 PF Rebate @ Peak=411691x(-6)/100= -24701 PF Rebate @ Off-Peak=292025x(-4)/100= -11681 Meter Rent= 1200 ------------------------------------------------------------------------------------ Net Bill= Rs.2113703

Net Savings= Rs. (2378142-2113703) = Rs.264439 Adverse Effects

a. Improper usage pattern in TOD metering may cause huge energy charges.

2.6 Energy Performance Assessment of Hospital 2.6.1 Energy Performance Index (kWh/annum/m²): 184.98 2.6.2 Energy Performance Index (kWh/annum/bed): 19805.59

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Electrical Power Distribution

3.1. Rated Specifications 3.1.1. Transformers

Rating = 1000 KVA

Make = Crompton Greaves Ltd

Type = Dry

Voltage Ratio = 11 KV/433 V

Current Ratio = 52.48 A/1333.37 A

Type of Colling = AN

Frequency = 50 HZ

No of Transformer installed = 02

3.2 Losses in Transformers The no load losses in the transformers can be measured at the site by isolating the HT side of the transformer and feeding it from the LT side. Since it was not possible to isolate the Transformers, therefore, the standard No Load and Full Load Losses have been considered for calculation purposes.

Particulars No Load Loss(KW) Full Load Loss(KW)

Tr-1 & Tr-2 2.2 10 Source: Transformer Purchase order Copy

3.3 Operational Load & Transformer Loadings

3.3.1 Transformer 1: Season Date Time Voltage

(Volts) Current (Amps)

Power Factor

Load (KW)

Load (KVA)

% load

Loss (KW)

Winter

16/11/10 17:20 412.6 428.2 0.91 278.46

306.00

30.60 3.14

17/11/10 07:35 422.2 309.7 0.93 210.62

226.47

22.65 2.71

03/12/10 13:20 420.5 461.9 0.98 329.68

336.40

33.64 3.33

23/12/10 00:15 416.2 324.5 0.963 225.26

233.92

23.39 2.75

04/01/11 16:45 420.6 431.3 0.999 313.88

314.19

31.42 3.19

11/02/11 00:05 424.6 360.9 0.998 264.88

265.41

26.54 2.90

Summer

17/03/11 08:30 426.5 454.2 0.995 333.84

335.52

33.55 3.33

17/03/11 12:30 425.3 457.1 0.999 336.37

336.71

33.67 3.33

17/03/11 00:10 445.6 366.2 0.991 280.08

282.63

28.26 3.00

10/04/11 08:30 424.4 344.7 0.999 253.12

253.38

25.34 2.84

10

10/04/11 16:30 412.7 248.5 0.997 177.09

177.63

17.76 2.52

10/04/11 21:00 431.9 280.2 0.983 206.04

209.60

20.96 2.64

09/05/11 08:00 410.8 458.0 0.991 322.94

325.87

32.59 3.26

09/05/11 14:00 410.9 489 0.991 344.88

348.01

34.80 3.41

09/05/11 21:00 418 465 0.993 334.29

336.65

33.66 3.33

21/06/11 07:20 416.1 555 0.998 399.18

399.98

40.00 3.80

21/06/11 12:30 417.4 544.8 0.998 393.07

393.86

39.39 3.75

21/06/11 22:00 427.2 367.8 0.999 271.87

272.14

27.21 2.94

3.3.2 Transformer 2: Season Date Time Voltage

(Volts) Current (Amps)

Power Factor

Load (KW)

Load (KVA)

% load

Loss (KW)

Winter

16/11/10

17:20 404.3 361.9 0.92 233.15

253.42

25.34 2.84

17/11/10

07:35 412.3 258.5 0.99 182.75

184.60

18.46 2.54

03/12/10

13:20 420.1 186.4 0.987 133.86

135.63

13.56 2.38

23/12/10

00:15 433.8 353.1 0.896 237.71

265.30

26.53 2.90

04/01/11

16:45 412.2 101.1 0.973 70.23 72.18 7.22 2.25

11/02/11

00:05 414.7 158.2 0.979 111.24

113.63

11.36 2.33

Summer

17/03/11

08:30 417.1 338.4 0.987 241.29

244.47

24.45 2.80

17/03/11

12:30 415.6 367.9 0.989 261.91

264.82

26.48 2.90

17/03/11

00:10 435.6 246.2 0.991 184.08

185.75

18.57 2.55

10/04/11

08:30 424.4 344.7 0.999 253.12

253.38

25.34 2.84

10/04/11

16:30 412.7 258.5 0.997 184.22

184.77

18.48 2.54

10/04/11

21:00 431.9 280.2 0.983 206.04

209.60

20.96 2.64

09/05/11

08:00 404.7 376.7 0.992 261.93

264.04

26.40 2.90

09/05/11

14:00 398.0 677.8 0.968 452.28

467.23

46.72 4.38

09/05/11

21:00 400.7 366.5 0.993 252.58

254.36

25.44 2.85

21/06/11

07:20 403.6 637.3 0.997 444.16

445.50

44.55 4.18

21/06/11

12:30 415.8 370.9 0.999 266.84

267.11

26.71 2.91

21/06/11

22:00 417.4 349.9 0.999 252.70

252.96

25.30 2.84

Source: Maintenance HT & LT log book

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Note: It can be observed from the collected & calculated data at different time throughout the year, that the loading pattern of transformers was quite low, may be because hospital is yet to be fully operational as it has been passing only a year since inception.

3.4 Recommendations

3.4.1 De-energization of Transformers So far contract demand is 800 KVA, which is 40% of cumulative capacity of two transformer of 1000 KVA.

So even when the operational monthly demand is maximum at 800 KVA or slightly more than that and is shared between the two transformers, the overall loading would not exceed 40%. Here it may be noted that transformers normally operate in the best efficiency range when the loading is at 50%.

The following table illustrates the change in the transformer losses under different loading conditions at energization of both TR and at de-energisation of one TR.

Both Transformer operational De-energisation of one Transformer & operation of other

Load (KVA)

Loss (KW)

Load (KVA)

Loss (KW)

Total Loss(KW)

Load (KVA)

% load

Loss (KW)

Possible Savings(KW)

306.00 3.14 253.42 2.84 5.98 559.42 55.94 5.33 0.65 226.47 2.71 184.60 2.54 5.25 411.07 41.11 3.89 1.36 336.40 3.33 135.63 2.38 5.71 472.03 47.20 4.43 1.28 233.92 2.75 265.30 2.90 5.65 499.22 49.92 4.69 0.96 314.19 3.19 72.18 2.25 5.44 386.37 38.64 3.69 1.75 265.41 2.90 113.63 2.33 5.23 379.04 37.90 3.64 1.59 335.52 3.33 244.47 2.80 6.13 579.99 58.00 5.56 0.57 336.71 3.33 264.82 2.90 6.23 601.53 60.15 5.82 0.41 282.63 3.00 185.75 2.55 5.55 468.38 46.84 4.39 1.16 253.38 2.84 253.38 2.84 5.68 506.76 50.68 4.77 0.91 177.63 2.52 184.77 2.54 5.06 362.40 36.24 3.51 1.55 209.60 2.64 209.60 2.64 5.28 419.20 41.92 3.96 1.32 325.87 3.26 264.04 2.90 6.16 589.91 58.99 5.68 0.48 348.01 3.41 467.23 4.38 7.79 815.24 81.52 8.85 -1.06 336.65 3.33 254.36 2.85 6.18 519.01 59.10 5.69 0.49 399.98 3.80 445.50 4.18 7.98 845.48 84.55 9.35 -1.37 393.86 3.75 267.11 2.91 6.66 660.97 66.10 6.57 0.09 272.14 2.94 252.96 2.84 5.78 525.10 52.51 4.56 0.82

It is evident from above table de-energisation of one transformer would help savings considerable energy as at above 50% loading, transformer will be most efficient.

As Per design parameter, efficiency of transformer at unity power factor :

Load(%) Efficiency(%) 100 98.75 75 98.96 50 99.06

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Therefore, from the energy conservation point of view, distribution transformers should be loaded at around 50%.

So it is suggested that instead of sharing load on two transformer throughout the year , only one transformer should be energized at a time especially in winter season when TR-2 load came down to as low as 7.22%.

3.5 Estimation of Energy Savings Minimum Power Savings : 0.09 KW

Working hours during which transformer can be de-energised 8760 Minimum Energy Savings /Per annum – (0.09 X 8760) KWh 788.4 KWh

Maximum Power Savings : 1.75 KW Working hours during which transformer can be de-energised 8760

Maximum Energy Savings /Per annum – (1.75 X 8760) KWh 15530 KWh

Overall Purchased Power Rate = Average 4.65 per KWH

Monitory Benefit per annum = Rs 0.03Lacs to Rs 0.72Lacs

Estimated Investments = Nil

Simple Payback Period = Immediate

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Heating, Ventilation & Air-Conditioning (HVAC)

4.1 Rated Specifications

4.1.1 Chiller

Make = Trane Ltd

Model = RTHD UC2U XA0X AF2A 3LAL F3A2 LALA VXXX

Compressor Model No = CHHC1C2C2FOAO

Evaporator Water Side Pressure = 150 psi

Condenser Water Side Pressure = 150 psi

Refrigerant = R 134a

Power = 415 V, 3 Phase, 50 Hz

Capacity = 250 TR

Average Working Hours = 24 hrs/day

No of Chiller Installed = 03

4.1.2 Condenser Water Pumps

Motor

Make = Grundfos Ltd

Rating = 30 HP (22 KW)

Speed = 1460 rpm

Full Load Efficiency = 90.5 %

Voltage = 415 V (3 Phase)

Full Load Current = 43 A

Frequency = 50 Hz

Full Load Power Factor = 0.89

Pump

Make = Grundfos Ltd

Head = 30.1 m

Flow = 177.1 m3/hr

Pump Input = 20 KW

Full Load Efficiency = 78 %

Speed = 1455 rpm

Number of Pumps normally in Operation = 01 Nos

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4.1.3 Chilled Water Primary Pumps

Motor

Make = Grundfos Ltd


Speed = 1460 rpm

Full Load Efficiency = 88.4%


Full Load Current = 22.6 A

Frequency = 50 Hz


Pump

Make = Grundfos Ltd

Head = 18.1 m

Flow = 148 m3/hr

Full Load Efficiency = 72%

Speed = 1460 rpm


4.1.4 Chilled Water Secondary Pumps (Zone A)

Motor

Make = Grundfos Ltd

Rating = 25 HP (18.5 KW)

Speed = 1460 rpm




Frequency = 50 Hz


Pump

Make = Grundfos Ltd

Head = 31.7 m

Flow = 136.8m3/hr


Speed = 1455 rpm


15

4.1.5 Chilled Water Secondary Pumps (Zone B)

Motor

Make = Grundfos Ltd


Speed = 2960 rpm




Frequency = 50 Hz


Pump

Make = Grundfos Ltd

Head = 39.7 m

Flow = 213.7 m3/hr


Speed = 2930 rpm


4.1.6 Cooling Towers

Number of Cooling Towers Installed = 03 Nos

Number of Fans per Cooling Tower = 01 Nos

Make of CT fan = Paharpur Cooling Tower

Motor Rating = 10 HP (7.5 KW)


Type of Blades = Aluminium

4.2 Measurements Made & Analysis

4.2.1 Performance Evaluation: Chiller Plant 27/07/11@11:00 06/07/11@14:30

Chiller Panel Operating Voltage : 402 V 411 V Chiller 1 Drawing Current : 240 A 230 A Chiller 3 Drawing Current : 245 A 240 A Condenser Motor 1 Drawing Current : 38 A 38 A Condenser Motor 3 Drawing Current : 39 A 38 A Primary Motor 1 Drawing Current : 21 A 18 A

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Primary Motor 3 Drawing Current : 22 A 20 A Secondary Motor (A Zone) Drawing Current : 12.2 A 17 A Secondary Motor (B Zone) Drawing Current : 36.8 A 38 A Cooling Tower Motors Drawing Current : 19 A 20 A Evaporator Leaving Water Temperature : 10.44 °C 12.67 °C Evaporator Entering Water Temperature : 7.22 °C 9.27 °C

Secondary Pump Water Flow Rate : 775.76 GPM 898.12 GPM Condenser Leaving Water Temperature : 36.44 °C 36.45 °C

Condenser Entering Water Temperature : 39.33 °C 39.34 °C TDS in Make Up Water : 933 PPM TDS in Circulating Water : 6630 PPM Based on above values collected, following calculations are done- Power Drawn by Chiller 1 & 3 : 300.55 KW 297.76 KW Power Drawn by Condenser Motor 1 & 3 : 47.71 KW 47.06 KW Power Drawn by Primary Motor 1 & 3 : 26.01 KW 22.98 KW Power Drawn by Secondary Motor (Zone A & B): 31.68 KW 35.68 KW Power Drawn by CT Motors : 11.64 KW 12.52 KW Tons of Refrigeration : 187.34 TR 228.31 TR Specific Power Consumption (KW/TR) : 2.22 1.82 Cycles of Concentration : 7.10 Condenser Water Flow : 311 m³/hr 305 m³/hr Evaporative Loss : 1.37 m³/hr 1.34 m³/hr Blow Down Loss : 0.22 m³/hr 0.21 m³/hr Make up Water Requirement : 1.59 m³/hr 1.55 m³/hr Note: To meet high cooling load it is observed that two chillers are being running simultaneously. So as per design parameters chiller plant’s specific power consumption is 0.956.Present operating specific power consumption is much more than design value. Hence there is opportunity of power savings.

4.2.2 Performance Evaluation: Cooling Tower Design Parameters: CT in Water temperature : 37.7°C

CT out Water temperature : 32.2°C Ambient Wet Bulb temperature : 28.3°C Range : 5.5°C Approach : 3.9°C Effectiveness : 58.51%

Date Time

CT in Water Temp (°C)

CT out Water Temp (°C)

Ambient WB temp(°C)

Range(°C)

Approach (°C)

Effectiveness (%)

27/2/11

11:00

31.61 29.16 19 2.44 10.16 19.38

28/2/11

12:35

31.55 29.0 19 2.55 10.0 20.35

31/3/11

09:30

34.83 31.11 25.5 3.72 5.61 39.89

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31/3/11

13:30

35.27 32.33 25 2.95 7.33 28.64

31/3/11

22:30

36.55 33.22 25 3.33 8.22 28.85

31/5/11

08:40

40.78 37.45 26.5 3.33 10.95 23.34

31/5/11

13:00

41.16 37.95 25 3.22 12.95 19.94

27/6/11

10:40

39.45 36.22 26.5 3.22 9.72 24.90

29/6/11

23:30

36.44 36.33 27 3.11 6.33 32.95

30/6/11

10:30

39.11 36.39 24 2.72 12.39 18.01

4.3 Energy conservation opportunities 4.3.1 Chiller: It is the main source of power consumption; hence efforts should be made to

minimize power consumption with little efforts-

A) Evaporator: Fouled evaporators result in increased power consumption as contact area between chilled water and refrigerant increases. Due to this heat transfer also didn’t take place properly.

An increase in leaving chilled water temperature also leads to energy savings and at least it could be applied in winter season. B) Condenser: Fouled condenser tubes also force the compressor to work harder to attain the desired capacity. For example, a 0.8 mm scale build-up on condenser tubes can increase energy consumption by as much as 35 %. To avoid this soft water should be used instead of raw water which is so far used in condenser. PPM level found in circulating water is 6630 PPM which is much more than normal value.

4.3.2. AHU cooling coil and filter: Scaling on cooling coil and choked filter would be cause of time delay to attain certain set point temperature and because of this delaying chilled water requirement would be same for longer period. Non-regulation of chilled water in turn keep loaded the compressor for longer period. Periodic Maintenance of cooling coil and filter will help the compressor to be unloaded as soon as possible.

4.3.3. Cooling Tower: It is clear from above table so far Cooling Towers’ effectiveness never attains design value. This leads to lack of cooling of hot water coming into, hence temperature of water going into condenser never attains design value (32.2°C) during peak hours and this could be main reason of higher power consumption as a reduction of 0.55°C temperature in water returning from the cooling tower reduces compressor power consumption by 3.0 % . Lack of cooling attributed to non-effectiveness of following- A) Water Distribution System: CT uses “Target ” nozzles which supposed to rotate

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New Nozzle Present Nozzle condition

to make water flows into sprays for better contact with air as well as effective heat transfer.But the physical condition of the nozzles are poor. These nozzles need to replace with new for proper heat transfer and effective utilisation of CT. B) PVC film-type fill: The fill sheets have integral louvres and drift eliminators and these prevents costly nuisance of drift spotting on the surrounding environment. It has observed water drifting to surrounding has been taking place since commisioning. Factory Assembled Condition Present Conditions

Either maintenance or replacement of fill is required to prevent drifting of water.

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Air Compressor

5.1 Rated Specifications

5.1.1 Air Compressor

Number of Air Compressor Installed = 03 Nos

Number of Cylinder per Air Compressor = 03 Nos

Make of Air Compressor = Anest Iwata

Discharge Air Rating = 60 CFM

No of Stages of compression = 02

Piston Displacement = 57.18 CFM

Max Discharge Air Pressure = 8.5Kg/cm²

Model = TFT 150-9

Type = Reciprocating Oil-free

Compressor Speed = 1125rpm

Type of Cooling = Air-cooled

Motor Rating = 11 KW (15 HP)


Make of Motor = Crompton Greaves

Full Load Current = 21 A

Speed = 1460 rpm


Type = 3 ø Induction Motor

5.2 Performance Evaluation Compressor Average Loading Duration : 252.67 Sec Compressor Average Unloading Duration : 972.67 Sec Cut in Pressure : 6.4 Kg/cm² Cut out Pressure : 9.3 Kg/cm² Motor Pulley Diameter : 38.5 cm Compressor Pulley Diameter : 50 cm Atmospheric Pressure : 1.03 Kg/cm²

Based on above mentioned measured values, following calculations done- Compressor Speed : 1125 rpm Percentage Leakage : 20.1 % System Leakage Quantity : 0.33m³

Free Air Delivery : 1.37m³

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5.3 Energy conservation opportunities

A) Cool Air Intake: As a thumb rule, “Every 4°C rise in inlet air temperature results in a higher energy consumption by 1% to achieve equivalent output”. So intake air temperature should be as low as possible for efficient compression.

Inlet Air temperature(°C)

Relative Air Delivery (%)

Power Saved (%)

10 102.0 +1.4 15.5 100.0 Nil 21.1 98.1 -1.3 26.6 96.3 -2.5 32.2 94.1 -4.0 37.7 92.8 -5.0 43.3 91.2 -5.8

Source: BEE

B) Dust free Air Intake: Dust in inlet air will be causing of choked filters which will interrupt smooth air intake, hence increased power consumption for equivalent output. As a thumb rule “For every 250 mmWC pressure drop in air suction path due to choked filters, power consumption increase by 2 % for same output”.

Pressure drop across Air filter(mmWC)

Increase in Power consumption(%)

0 0 200 1.6 400 3.2 600 4.7 800 7.0

Source: BEE C) Reducing Delivery Pressure: A reduction in the delivery pressure by 1 bar would reduce power consumption by 6-10%.So pressure switches must be adjusted for compressor cut-in and cut-out at optimum levels as cut-out pressure is set at 9.3 kg/cm² which is much more than high pressure delivery at 7.2 kg/cm². D) Arrest leakage: Leakage in the system will keep the compressor loaded most of the time. So to reduce power consumption leakages need to be arrested. Leakage in the system is found 20%.

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Water Treatment & Distribution

6.1. Rated Specifications

6.1.1 Softener Water Pumps

Motor

Make = Grundfos Ltd


Speed = 2900-2920 rpm



Full Load Current = 6.8A

Frequency = 50 Hz


Pump

Make = Grundfos Ltd

Head = 33.2 m

Flow = 17 m3/hr


Speed = 2902 rpm

6.1.2 Flushing Raw Water Pumps

Motor

Make = Grundfos Ltd


Speed = 2910-2920 rpm




Frequency = 50 Hz


Pump

Make = Grundfos Ltd

Head = 33.2 m

Flow = 17 m3/hr


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Speed = 2902 rpm

6.1.3 Flushing Treated Water Pumps

Motor

Make = Grundfos Ltd

Rating = 5.34 HP (4 KW)

Speed = 2910-2930 rpm




Frequency = 50 Hz


Pump

Make = Grundfos Ltd

Head = 44.8 m

Flow = 17 m3/hr


Speed = 2917 rpm

6.1.4 Hydro Pneumatic Pumps (7.5 bar)

Motor

Make = Grundfos Ltd


Speed = 2900-2920 rpm




Frequency = 50 Hz


Pump

Make = Grundfos Ltd

Head = 64.8 m

Flow = 10 m3/hr


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Speed = 2902 rpm

6.1.5 Hydro Pneumatic Pumps (3.5 bar)

Motor

Make = Grundfos Ltd

Rating = 2 HP (1.5 KW)

Speed = 2890-2910 rpm




Frequency = 50 Hz


Pump

Make = Grundfoss Ltd

Head = 49.8 m

Flow = 5.8 m3/hr


Speed = 2896 rpm 6.2. Performance Evaluation 6.2.1 Softener Water Pumps Motor Drawing Current : 4.7 A Motor Operating Voltage : 412 V Water Flow Rate : 5.5 m³/hr Based on above measured values, following calculations done- Input Power : 2.9 KW Hydraulic Power : 0.49 KW

Motor-pump Set Efficiency : 17.14% Note: As per design value system efficiency is 62% but present operating efficiency level not goes above 20%.That is why motor usually run continuously during peak hours and also a cause of high power consumption.

6.2.2 Flushing Raw Water Pumps Motor Drawing Current : 4.4 A Motor Operating Voltage : 413 V Water Flow Rate : 3.5 m³/hr Based on above measured values, following calculations done- Input Power : 2.73 KW Hydraulic Power : 0.31 KW

Motor-pump Set Efficiency : 11.01%

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Note: Design value of efficiency is 63% but present operating efficiency level not rises above 20% and this is a cause of high power consumption.

6.2.3 Flushing Treated Water Pumps Motor Drawing Current : 4.03 A Motor Operating Voltage : 412 V Water Flow Rate : 2 m³/hr Based on above measured values, following calculations done- Input Power : 2.53 KW Hydraulic Power : 0.24 KW

Motor-pump Efficiency : 9.09%

Note: Design value of efficiency is 61% but present operating efficiency level reaches only 9% and this is also cause of more power consumption.

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Lighting

7.1 The lighting load constitutes about 10% of the electricity consumption in the building.

7.2 Light Fittings Type

The major light fittings types are:

a) 1 x 36W F/L Fixture. b) 2 x 36W F/L Fixture. c) 2 x 18W CFL, Wall mounted fixture. d) 4 x 18W HF CFL, Recessed Fixture. e) 2 x 18W CFL Fixture.

7.3 The lux levels are measured randomly in different rooms to check the lux level as per IS: 3646. The lux level & uniformity level of most of the places are found as per standards. Everywhere efficient light fittings were installed with some application of sensors too.

7.4 LPD (Lighting Power Density)

Total Connected Lighting Load= 120kW

Built-up Area= 24143sqm

So, LPD= (120X1000)/24143

= 4.97Watt/sqm

7.5 Recommendations

To reduce the energy consumption against lighting load following steps may be taken care of:

a. Applications of solar energy in out-door lighting. b. Replacement of 36W F/L lamp by 28W T-5 lamp, after expiry of lifecycle.

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Elevators

8.1 Rated Specification The hospital has total 6nos. (5 nos Bed cum Passenger & 1 no Dumb Waiter) Elevator. 8.1.1 Bed cum Passenger Elevators

Number of Elevators Installed = 05 Nos.

Make of Elevators = ETA MELCO Elevators Co LLC.

Capacity = 1000 Kg

Speed = 1.75 mps

Type = EM -2471

Control = AC V3F

Motor Rating = 15 KW,4 pole

Voltage = 250 V

Full Load Amps = 52 A

Speed = 1380 rpm

Type = 3Ø Induction Motor

Make = Mitsubishi Electric Corporation

8.1.2 Dumb Waiter

Number of Dumb Waiter Installed = 01 No

Make of Dumb Waiter = Omega Elevators

Capacity = 250 Kg

Speed = 0.5 mps

Control = Microprocessor based V3F

Motor Rating = 2.25 KW

Voltage = 415 V

Frequency = 50 HZ

Type = Single speed Squirrel cage motor All the elevator’s are energy efficient V3F (variable voltage variable frequency) controlled. Hence, there is no scope of further energy consumption reduction.

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Hot Water Generation

9.1 Rated Specification 9.1.1 Water Storage Tank

Number of storage tank installed = 01 No

Model = 7000 DB

Make = Solahart Industries Pvt. Ltd.

Peak DHW flow rate = 180 Ltr/min

Max Working Pressure = 1 Kg/cm²

Cold Water Supply Pressure Min/Max = 1.4/12 Kg/cm²

Electric boost = 57.6 KW

Full Load Amps = 100 A

No of Coils = 12

Coil Rating = 4.8 KW

Voltage = 415 V(3 phase)

Heating Capacity = 1237 l/hr at 40°C 9.1.2 Solar Collector

Number of Collector installed = 95 No

Make = Solahart Industries Pvt Ltd.

Type = Solahart BT Collector

Glazing = Flat Plate 3.2 mm Low Iron Solar Glass

Gross Collector Area = 1.98 m²

Collector Volume = 2.1 L

Mildly Cloudy day rating = 17 MJ/day

Thermal Performance rating = 20.3 MJ/day

9.1.3 Water Circulation Pump Motor

Make = Grundfos Ltd

Rating = 1.17 KW

Voltage = 240V (1 Phase)


Frequency = 50 Hz

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Pump

Make = Grundfos Ltd

Head = 55 m

Flow = 4 m3/hr

9.1.4 Performance Evaluation: Solar Plant Solar Insolation Rate : 200 W/m² (63.39 Btu/ft²) Effective Absorber Surface Area : 1.86 m² Water temperature before experiment : 30 °C (86°F) Water temperature after experiment : 40 °C (94°F) Duration of experiment : 2 hours

Based on above values and Technical data sheet of solar collector, efficiency of the collectors calculated –

Efficiency : 0.55% - 0.60%

Note: This experiment done on a 5th July, which was cloudy day. The efficiency of solar collector would be high on a sunny day.

9.2. Estimation of Carbon-die-oxide Emission Reduction: Total heat utilized to supply hot water : 35000 Kcal/hr (41.20 KWh) Carbon-die-oxide Emission to generate 1 KWh : 1.468 Kg

(Considering 50% carbon present in 0.8 Kg Coal) Hence Carbon-die-oxide emission reduction : (41.20 X 1.468 X 11 X 365)/1000ton

= 242.84 ton (Considering 11 sunny hour per day)

Annexure: 1

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