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 teachers 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 1.1 Salient Features of The Hospital 1.2 Scope of Work.. 1.3 Methodology.. 1.4 Instrumentation Support.. Chapter : 2 Base Line Data.. 2.1 Load Distribution 2.2 Connected Load in Pie Chart.. 2.3 CESC Billing History. 2.4 Power Factor Correction.. 2.5 TOD Metering Feasibility. 2.6 Energy Performance Assessment of Hospital.. Chapter : 3 Electrical Power Distribution 3.1 Rated Specification.. 3.1.1 Transformers. 3.2 Losses in Transformer. 3.3 Operational Load & Transformer Loading 3.3.1 Transformer 1... 3.3.2 Transformer 2 3.4 Recommendation.. 3.4.1 De-energization of Transformer. 3.5 Estimation of Energy Savings. Chapter : 4 Heating, Ventilation & Air Conditioning. 4.1 Rated Specification 4.1.1 Chiller. 4.1.2 Condenser Pumps 4.1.3 Chilled Water Primary Pumps 4.1.4 Chilled Water Secondary Pumps (Zone A)..... 4.1.5 Chilled Water Secondary Pumps (Zone B).. 4.1.6 Cooling Towers. 4.2 Measurements Made & Analysis 4.2.1 Chiller. 4.2.2 Cooling Towers. 4.3 Energy Conservation Opportunities 4.3.1 Chiller. 4.3.2 AHU & FCU Cooling Coil & Filters. 4.3.3 Cooling Towers. 2 3 3 3 4 5 5 6 6 7 7 8 9 9 9 9 9 9 10 11 11 12 13 13 13 13 14 14 15 15 15 15 16 17 17 17 17

Chapter : 5 Air Compressor. 5.1 Rated Specification 5.1.1 Air Compressor.. 5.2 Performance Evaluation 5.3 Energy Conservation Opportunities Chapter : 6 Water Treatment & Distribution. 6.1 Rated Specification. 6.1.1 Softener Water Pumps.. 6.1.2 Flushing Raw Water Pumps. 6.1.3 Flushing Treated Water Pumps 6.1.4 Hydro pneumatic Pumps 1 6.1.5 Hydro pneumatic Pumps 2 6.2 Performance Evaluation. 6.2.1 Softner Water Pumps. 6.2.2 Flushing Raw Water Pumps. 6.2.3 Flushing Treated Water Pumps Chapter : 7 Lighting.. 7.1 Lighting Loads... 7.2 Light Fittings Type. 7.3 Lux Level 7.4 LPD.. 7.5 Recommendations Chapter : 8 Elevators 8.1 Rated Specification. 8.1.1 Bed cum Passenger Elevator 8.1.2 Dumb Waiter. Chapter : 9 Hot Water Generation. 9.1 Rated Specification.. 9.1.1 Water Tank 9.1.2 Solar Collector.. 9.1.3 Water Circulation Motor.. 9.1.4 Performance Evaluation: Solar Plant 9.2 Estimation of Carbon Di Oxide Emission reduction

19 19 19 19 20 21 21 21 21 22 22 23 23 23 23 24 25 25 25 25 25 25 26 26 26 26 27 27 27 27 27 28 28

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

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.

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.

1.1 Salient Features of Hospital 1. 2. 3. 4. 5. Hospital Location Capacity Site area Built Up Area Climate Zone : 730, Anandpur, Kolkata-700107 : 400 Beds (As of now around 200 beds are operational) : 6026 sq m : 24143 sq m : 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 Develop a Base Line of the Energy systems. Consumption Pattern 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.
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

Measurements and monitoring with the Final Report Submission 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

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

Base Line Data

Power Supplier: CESC Ltd. Supply Voltage: 11kV Contract Demand: 800kVA Tariff Type: Flat 2.1 Load Distribution
SL NO CONNECTED LOAD(KW) OPERATING LOAD(KW) MAXIMUM DEMAND (KW) LOAD ON DG SET(KW) UPS LOAD(KW)

DESCRIPTION

DIVERSITY

1 2 3

LIGHTING COMPUTER /PRINTER /HUB ROOM MEDICAL EQUIPMENTS UPS NON UPS

120 150 100 200

110 100 80 120

0.8 0.7 0.8 0.6

88 70 64 72

88 70 64 72

64 70 64

HVAC CHILLER # 3250 TR WATER COOLED SCREW PRIMARY PUMPS #3 SECONDARY PUMPS#5 CONDENSER PUMPS#3 COOLING TOWER#3 AHU/TFA VENTILATION 513 33 127 66 22 200 89 75 10 55 55 30 55 4.5 9 6 8 6 12 35 48 100 55 342 22 78 44 15 150 60 45 10 0 0 15 0 1.3 2.7 2.7 3.6 2.7 5.4 25 24 100 18.5 1 1 1 1 1 1 1 1 0.6 0.9 0.5 0.9 1 1 1 1 1 1 1 1 307.8 22 78 44 15 150 60 45 10 0 0 7.5 0 1.5 3 3 4 3 6 25 24 60 16.65 307.8 22 78 44 15 150 60 45 10 0 0 7.5 0 1.5 3 3 4 3 6 25 24 60 16.65 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

ELEVATORS BED ELEVATORS #5 DUMBWAITER #1

FIRE FIGHTING FIRE HYDRANT PUMP SPRINKLER PUMP JOCKEY PUMP STAND BY PUMP

PLUMBING LOADS HYDROPNUMATIC PUMP# 3 HYDROPNUMATIC PUMP# 3 BOREWELL FILTER PUMP#2 OVERHEAD TANK#2 RAW WATER TRANSFER PUMP#2 STORM &SEWAGEWATER SUMP#3 STP HOT WATER GENERATION

8 9

KITCHENADHOC MEDICAL GAS & PIPING SYSTEM TOTAL (APPRX)

2183.5

1086.9

1045

1045

200

2.2 Connected Load in Pie Chart

2.3 CESC Billing History (Source: CESC Bills)

YEAR MONT H 06-12 HRS 12-17 HRS 17-20 HRS 20-23 HRS 23-06 HRS CHARGEAB LE UNITS UNITS PER DAY

2010 2010 2010 2010 2010 2010 2010 2011 2011 2011 2011 2011 2011

JUN JUL AUG SEPT OCT NOV DEC JAN FEB MAR APR MAY JUN

7473 60403 78109 91419 79059 71676 74219 78269 97879 103742 122705 123252

6963 63773 71226 79356 70236 61746 71303 69936 92496 95096 111829 111436

4420 32473 37593 44923 38930 38853 39300 41673 52166 52453 61026 59493

4507 19806 31636 41603 32556 35723 35373 36170 47706 48113 50756 49230

9510 41390 68819 91656 64926 69316 67796 58256 84722 90622 94969 91832

32873 217845 287383 348957 285707 277314 287991 284304 374969 390026 441285 435243

1095.77 7027.26 9579.43 11256.68 9523.57 8945.61 9290.03 10153.71 12095.77 13000.87 14709.50 14508.10

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) Summer 468 Monsoon 465 Winter 462 Unit charge for TOD (paise/unit) Period Normal Peak Off-peak Summer 461 692 318 Monsoon 458 687 316 Winter 452 06:00-17:00& 20:00-23:00

683 17:00-20:00 314 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 Surcharg Rebate Surcharg Rebate Surcharg Rebate Surcharg in % e in % in % e in % in % e in % in % e in % 5 0 6 0 4 0 3 0

Load Factor Rebates Load Factor = Average Load / Maximum Demand

RANGE OF LOAD ABOVE 50 % UPTO 55% ABOVE 55 % UPTO 60% ABOVE 60 % UPTO 65% ABOVE 65 % UPTO 70% ABOVE 70 % UPTO 75% ABOVE 75 % UPTO 80% ABOVE 80 % UPTO 85%

PAISE/KWH 3 4 8 10 16 20 25

ABOVE 85 % ABOVE 90 % ABOVE 92 % ABOVE 95 %

UPTO 90% UPTO 92% UPTO 95%

30 35 37 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 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 Rs.264439

B.

Net Savings= Rs. (2378142-2113703) = Adverse Effects a. 2.6 2.6.1 2.6.2

Improper usage pattern in TOD metering may cause huge energy charges. Energy Performance Assessment of Hospital Energy Performance Index (kWh/annum/m): 184.98 Energy Performance Index (kWh/annum/bed): 19805.59

Electrical Power Distribution

3.1. Rated Specifications 3.1.1. Transformers Rating Make Type Voltage Ratio Current Ratio Type of Colling Frequency No of Transformer installed 3.2 = = = = = = = = 1000 KVA Crompton Greaves Ltd Dry 11 KV/433 V 52.48 A/1333.37 A AN 50 HZ 02

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) 10

Tr-1 & Tr-2 2.2 Source: Transformer Purchase order Copy 3.3 3.3.1 Operational Load & Transformer Loadings Transformer 1:
Season Date 16/11/10 Winter 17/11/10 03/12/10 23/12/10 04/01/11 11/02/11 17/03/11 17/03/11 Summer 17/03/11 10/04/11 Time 17:20 07:35 13:20 00:15 16:45 00:05 08:30 12:30 00:10 08:30 Voltage (Volts) 412.6 422.2 420.5 416.2 420.6 424.6 426.5 425.3 445.6 424.4 Current (Amps) 428.2 309.7 461.9 324.5 431.3 360.9 454.2 457.1 366.2 344.7

Power Factor 0.91 0.93 0.98 0.963 0.999 0.998 0.995 0.999 0.991 0.999

Load (KW) 278.4 6 210.6 2 329.6 8 225.2 6 313.8 8 264.8 8 333.8 4 336.3 7 280.0 8 253.1 2

Load (KVA) 306.0 0 226.4 7 336.4 0 233.9 2 314.1 9 265.4 1 335.5 2 336.7 1 282.6 3 253.3 8

% load 30.60 22.65 33.64 23.39 31.42 26.54 33.55 33.67 28.26 25.34

Loss (KW) 3.14 2.71 3.33 2.75 3.19 2.90 3.33 3.33 3.00 2.84

10/04/11 10/04/11 09/05/11 09/05/11 09/05/11 21/06/11 21/06/11 21/06/11

16:30 21:00 08:00 14:00 21:00 07:20 12:30 22:00

412.7 431.9 410.8 410.9 418 416.1 417.4 427.2

248.5 280.2 458.0 489 465 555 544.8 367.8

0.997 0.983 0.991 0.991 0.993 0.998 0.998 0.999

177.0 9 206.0 4 322.9 4 344.8 8 334.2 9 399.1 8 393.0 7 271.8 7

177.6 3 209.6 0 325.8 7 348.0 1 336.6 5 399.9 8 393.8 6 272.1 4

17.76 20.96 32.59 34.80 33.66 40.00 39.39 27.21

2.52 2.64 3.26 3.41 3.33 3.80 3.75 2.94

3.3.2

Transformer 2:
Season Date 16/11/1 0 17/11/1 0 03/12/1 0 23/12/1 0 04/01/1 1 11/02/1 1 17/03/1 1 17/03/1 1 17/03/1 1 10/04/1 1 10/04/1 1 10/04/1 1 09/05/1 1 09/05/1 1 09/05/1 1 21/06/1 1 21/06/1 1 21/06/1 1 Time 17:20 07:35 13:20 00:15 16:45 00:05 08:30 12:30 00:10 08:30 16:30 21:00 08:00 14:00 21:00 07:20 12:30 22:00 Voltage (Volts) 404.3 412.3 420.1 433.8 412.2 414.7 417.1 415.6 435.6 424.4 412.7 431.9 404.7 398.0 400.7 403.6 415.8 417.4 Current (Amps) 361.9 258.5 186.4 353.1 101.1 158.2 338.4 367.9 246.2 344.7 258.5 280.2 376.7 677.8 366.5 637.3 370.9 349.9 Power Factor 0.92 0.99 0.987 0.896 0.973 0.979 0.987 0.989 0.991 0.999 0.997 0.983 0.992 0.968 0.993 0.997 0.999 0.999 Load (KW) 233.1 5 182.7 5 133.8 6 237.7 1 70.23 111.2 4 241.2 9 261.9 1 184.0 8 253.1 2 184.2 2 206.0 4 261.9 3 452.2 8 252.5 8 444.1 6 266.8 4 252.7 0 Load (KVA) 253.4 2 184.6 0 135.6 3 265.3 0 72.18 113.6 3 244.4 7 264.8 2 185.7 5 253.3 8 184.7 7 209.6 0 264.0 4 467.2 3 254.3 6 445.5 0 267.1 1 252.9 6 % load 25.34 18.46 13.56 26.53 7.22 11.36 24.45 26.48 18.57 25.34 18.48 20.96 26.40 46.72 25.44 44.55 26.71 25.30 Loss (KW) 2.84 2.54 2.38 2.90 2.25 2.33 2.80 2.90 2.55 2.84 2.54 2.64 2.90 4.38 2.85 4.18 2.91 2.84

Winter

Summer

Source: Maintenance HT & LT log book

10

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 3.4.1 Recommendations 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 Load (KVA) 306.00 226.47 336.40 233.92 314.19 265.41 335.52 336.71 282.63 253.38 177.63 209.60 325.87 348.01 336.65 399.98 393.86 272.14 Loss (KW) 3.14 2.71 3.33 2.75 3.19 2.90 3.33 3.33 3.00 2.84 2.52 2.64 3.26 3.41 3.33 3.80 3.75 2.94 Load (KVA) 253.42 184.60 135.63 265.30 72.18 113.63 244.47 264.82 185.75 253.38 184.77 209.60 264.04 467.23 254.36 445.50 267.11 252.96 Loss Total (KW) Loss(KW) 2.84 5.98 2.54 5.25 2.38 5.71 2.90 5.65 2.25 5.44 2.33 5.23 2.80 6.13 2.90 6.23 2.55 5.55 2.84 5.68 2.54 5.06 2.64 5.28 2.90 6.16 4.38 7.79 2.85 6.18 4.18 7.98 2.91 6.66 2.84 5.78 De-energisation of one Transformer & operation of other Load % Loss Possible (KVA) load (KW) Savings(KW) 559.42 55.94 5.33 0.65 411.07 41.11 3.89 1.36 472.03 47.20 4.43 1.28 499.22 49.92 4.69 0.96 386.37 38.64 3.69 1.75 379.04 37.90 3.64 1.59 579.99 58.00 5.56 0.57 601.53 60.15 5.82 0.41 468.38 46.84 4.39 1.16 506.76 50.68 4.77 0.91 362.40 36.24 3.51 1.55 419.20 41.92 3.96 1.32 589.91 58.99 5.68 0.48 815.24 81.52 8.85 -1.06 519.01 59.10 5.69 0.49 845.48 84.55 9.35 -1.37 660.97 66.10 6.57 0.09 525.10 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(%) 100 75 50 Efficiency(%) 98.75 98.96 99.06

11

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 : Working hours during which transformer can be de-energised Minimum Energy Savings /Per annum (0.09 X 8760) KWh Maximum Power Savings : Working hours during which transformer can be de-energised Maximum Energy Savings /Per annum (1.75 X 8760) KWh Overall Purchased Power Rate Monitory Benefit per annum Estimated Investments Simple Payback Period = = = = 0.09 KW 8760 788.4 KWh 1.75 KW 8760 15530 KWh

Average 4.65 per KWH Rs 0.03Lacs to Rs 0.72Lacs Nil Immediate

12

Heating, Ventilation & Air-Conditioning (HVAC)

4.1 4.1.1 Rated Specifications Chiller Make Model Compressor Model No Evaporator Water Side Pressure Condenser Water Side Pressure Refrigerant Power Capacity Average Working Hours No of Chiller Installed 4.1.2 Condenser Water Pumps Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Make Head Flow Pump Input Full Load Efficiency Speed = = = = = = = = Pump = = = = = = Grundfos Ltd 30.1 m 177.1 m3/hr 20 KW 78 % 1455 rpm 01 Nos Grundfos Ltd 30 HP (22 KW) 1460 rpm 90.5 % 415 V (3 Phase) 43 A 50 Hz 0.89 = = = = = = = = = = Trane Ltd RTHD UC2U XA0X AF2A 3LAL F3A2 LALA VXXX CHHC1C2C2FOAO 150 psi 150 psi R 134a 415 V, 3 Phase, 50 Hz 250 TR 24 hrs/day 03

Number of Pumps normally in Operation =

13

4.1.3

Chilled Water Primary Pumps Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Make Head Flow Full Load Efficiency Speed = = = = = = = = Pump = = = = = Grundfos Ltd 18.1 m 148 m3/hr 72% 1460 rpm 01 Nos Grundfos Ltd 15 HP (11 KW) 1460 rpm 88.4% 415 V (3 Phase) 22.6 A 50 Hz 0.85

Number of Pumps normally in Operation = 4.1.4 Chilled Water Secondary Pumps (Zone A) Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Make Head Flow Full Load Efficiency Speed = = = = = = = = Pump = = = = =

Grundfos Ltd 25 HP (18.5 KW) 1460 rpm 90% 415 V (3 Phase) 33.5 A 50 Hz 0.87 Grundfos Ltd 31.7 m 136.8m3/hr 76.5% 1455 rpm 01 Nos

Number of Pumps normally in Operation =

14

4.1.5

Chilled Water Secondary Pumps (Zone B) Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Make Head Flow Full Load Efficiency Speed = = = = = = = = Pump = = = = = Grundfos Ltd 39.7 m 213.7 m3/hr 72% 2930 rpm 01 Nos Grundfos Ltd 40 HP (30 KW) 2960 rpm 91.4% 415 V (3 Phase) 57.5 A 50 Hz 0.91

Number of Pumps normally in Operation =

4.1.6

Cooling Towers Number of Cooling Towers Installed Number of Fans per Cooling Tower Make of CT fan Motor Rating Voltage Type of Blades = = = = = = 03 Nos 01 Nos Paharpur Cooling Tower 10 HP (7.5 KW) 415 V (3 Phase) Aluminium

4.2 4.2.1

Measurements Made & Analysis Performance Evaluation: Chiller Plant 27/07/11@11:00 Chiller Panel Operating Voltage Chiller 1 Drawing Current Chiller 3 Drawing Current Condenser Motor 1 Drawing Current Condenser Motor 3 Drawing Current Primary Motor 1 Drawing Current : : : : : : 402 V 240 A 245 A 38 A 39 A 21 A 06/07/11@14:30 411 V 230 A 240 A 38 A 38 A 18 A

15

Primary Motor 3 Drawing Current : Secondary Motor (A Zone) Drawing Current : Secondary Motor (B Zone) Drawing Current : Cooling Tower Motors Drawing Current : Evaporator Leaving Water Temperature : Evaporator Entering Water Temperature : Secondary Pump Water Flow Rate : Condenser Leaving Water Temperature : Condenser Entering Water Temperature : TDS in Make Up Water : TDS in Circulating Water :

22 A 12.2 A 36.8 A 19 A 10.44 C 7.22 C 775.76 GPM 36.44 C 39.33 C 933 PPM 6630 PPM

20 A 17 A 38 A 20 A 12.67 C 9.27 C 898.12 GPM 36.45 C 39.34 C

Based on above values collected, following calculations are donePower Drawn by Chiller 1 & 3 : 300.55 KW Power Drawn by Condenser Motor 1 & 3 : 47.71 KW Power Drawn by Primary Motor 1 & 3 : 26.01 KW Power Drawn by Secondary Motor (Zone A & B): 31.68 KW Power Drawn by CT Motors : 11.64 KW Tons of Refrigeration : 187.34 TR Specific Power Consumption (KW/TR) : 2.22 Cycles of Concentration : 7.10 Condenser Water Flow : 311 m/hr Evaporative Loss : 1.37 m/hr Blow Down Loss : 0.22 m/hr Make up Water Requirement : 1.59 m/hr

297.76 KW 47.06 KW 22.98 KW 35.68 KW 12.52 KW 228.31 TR 1.82 305 m/hr 1.34 m/hr 0.21 m/hr 1.55 m/hr

Note: To meet high cooling load it is observed that two chillers are being running simultaneously. So as per design parameters chiller plants 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 CT out Water temperature Ambient Wet Bulb temperature Range Approach Effectiveness Tim e 11:0 0 12:3 5 09:3 0 CT in Water Temp (C) 31.61 31.55 34.83 CT out Water Temp (C) 29.16 29.0 31.11 Ambient WB temp(C) 19 19 25.5

: : : : : : Range( C) 2.44 2.55 3.72

37.7C 32.2C 28.3C 5.5C 3.9C 58.51% Approac h (C) 10.16 10.0 5.61 Effectivene ss (%) 19.38 20.35 39.89

Date 27/2/1 1 28/2/1 1 31/3/1 1

16

31/3/1 1 31/3/1 1 31/5/1 1 31/5/1 1 27/6/1 1 29/6/1 1 30/6/1 1 4.3 4.3.1

13:3 0 22:3 0 08:4 0 13:0 0 10:4 0 23:3 0 10:3 0

35.27 36.55 40.78 41.16 39.45 36.44 39.11

32.33 33.22 37.45 37.95 36.22 36.33 36.39

25 25 26.5 25 26.5 27 24

2.95 3.33 3.33 3.22 3.22 3.11 2.72

7.33 8.22 10.95 12.95 9.72 6.33 12.39

28.64 28.85 23.34 19.94 24.90 32.95 18.01

Energy conservation opportunities Chiller: It is the main source of power consumption; hence efforts should be made to minimize power consumption with little effortsA) Evaporator: Fouled evaporators result in increased power consumption as contact area between chilled water and refrigerant increases. Due to this heat transfer also didnt 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 (32.2C) during peak hours and this could be main reason of higher power consumption as a reduction of 0.55C temperature in water returning from the cooling tower reduces compressor power consumption by 3.0 % . Lack of cooling attributed to non-effectiveness of followingA) Water Distribution System: CT uses Target nozzles which supposed to rotate

17

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 5.1.1 Rated Specifications Air Compressor Number of Air Compressor Installed Number of Cylinder per Air Compressor Make of Air Compressor Discharge Air Rating No of Stages of compression Piston Displacement Max Discharge Air Pressure Model Type Compressor Speed Type of Cooling Motor Rating Voltage Make of Motor Full Load Current Speed Full Load Efficiency Type = = = = = = = = = = = = = = = = = = 03 Nos 03 Nos Anest Iwata 60 CFM 02 57.18 CFM 8.5Kg/cm TFT 150-9 Reciprocating Oil-free 1125rpm Air-cooled 11 KW (15 HP) 415 V (3 Phase) Crompton Greaves 21 A 1460 rpm 89% 3 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/cm Cut out Pressure : 9.3 Kg/cm Motor Pulley Diameter : 38.5 cm Compressor Pulley Diameter : 50 cm Atmospheric Pressure : 1.03 Kg/cm Based on above mentioned measured values, following calculations doneCompressor Speed : 1125 rpm Percentage Leakage : 20.1 % System Leakage Quantity : 0.33m Free Air Delivery : 1.37m

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5.3

Energy conservation opportunities A) Cool Air Intake: As a thumb rule, Every 4C 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) 10 15.5 21.1 26.6 32.2 37.7 43.3 Source: BEE Relative Air Delivery (%) 102.0 100.0 98.1 96.3 94.1 92.8 91.2 Power Saved (%) +1.4 Nil -1.3 -2.5 -4.0 -5.0 -5.8

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) 0 200 400 600 800 Source: BEE Increase in Power consumption(%) 0 1.6 3.2 4.7 7.0

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/cm which is much more than high pressure delivery at 7.2 kg/cm. 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. 6.1.1 Rated Specifications Softener Water Pumps Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Pump Make Head Flow Full Load Efficiency Speed = = = = = Grundfos Ltd 33.2 m 17 m3/hr 72% 2902 rpm = = = = = = = = Grundfos Ltd 4 HP (3 KW) 2900-2920 rpm 87.5% 415 V (3 Phase) 6.8A 50 Hz 0.87

6.1.2

Flushing Raw Water Pumps Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Pump Make Head Flow Full Load Efficiency = = = = Grundfos Ltd 33.2 m 17 m3/hr 72% = = = = = = = = Grundfos Ltd 4 HP (3 KW) 2910-2920 rpm 88% 415 V (3 Phase) 6.8A 50 Hz 0.87

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Speed

2902 rpm

6.1.3

Flushing Treated Water Pumps Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Pump Make Head Flow Full Load Efficiency Speed = = = = = Grundfos Ltd 44.8 m 17 m3/hr 72% 2917 rpm = = = = = = = = Grundfos Ltd 5.34 HP (4 KW) 2910-2930 rpm 89% 415 V (3 Phase) 8.8A 50 Hz 0.88

6.1.4

Hydro Pneumatic Pumps (7.5 bar) Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Pump Make Head Flow Full Load Efficiency = = = = Grundfos Ltd 64.8 m 10 m3/hr 72% = = = = = = = = Grundfos Ltd 4 HP (3 KW) 2900-2920 rpm 87.5% 415 V (3 Phase) 6.8A 50 Hz 0.87

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Speed 6.1.5 Hydro Pneumatic Pumps (3.5 bar) Motor Make Rating Speed Full Load Efficiency Voltage Full Load Current Frequency Full Load Power Factor Pump Make Head Flow Full Load Efficiency Speed 6.2. 6.2.1 Performance Evaluation Softener Water Pumps Motor Drawing Current Motor Operating Voltage Water Flow Rate

2902 rpm

= = = = = = = = = = = = =

Grundfos Ltd 2 HP (1.5 KW) 2890-2910 rpm 85.5% 415 V (3 Phase) 3.45A 50 Hz 0.87 Grundfoss Ltd 49.8 m 5.8 m3/hr 72% 2896 rpm

: 4.7 A : 412 V : 5.5 m/hr

Based on above measured values, following calculations doneInput 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 Motor Operating Voltage Water Flow Rate : 4.4 A : 413 V : 3.5 m/hr

Based on above measured values, following calculations doneInput 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 Motor Operating Voltage Water Flow Rate : 4.03 A : 412 V : 2 m/hr

Based on above measured values, following calculations doneInput 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 7.2 The lighting load constitutes about 10% of the electricity consumption in the building. Light Fittings Type The major light fittings types are: a) b) c) d) e) 1 x 36W F/L Fixture. 2 x 36W F/L Fixture. 2 x 18W CFL, Wall mounted fixture. 4 x 18W HF CFL, Recessed Fixture. 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.

25

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 Make of Elevators Capacity Speed Type Control Motor Rating Voltage Full Load Amps Speed Type Make 8.1.2 Dumb Waiter Number of Dumb Waiter Installed Make of Dumb Waiter Capacity Speed Control Motor Rating Voltage Frequency Type = = = = = = = = = 01 No Omega Elevators 250 Kg 0.5 mps Microprocessor based V3F 2.25 KW 415 V 50 HZ Single speed Squirrel cage motor = = = = = = = = = = = = 05 Nos. ETA MELCO Elevators Co LLC. 1000 Kg 1.75 mps EM -2471 AC V3F 15 KW,4 pole 250 V 52 A 1380 rpm 3 Induction Motor Mitsubishi Electric Corporation

All the elevators are energy efficient V3F (variable voltage variable frequency) controlled. Hence, there is no scope of further energy consumption reduction.

26

Hot Water Generation

9.1 9.1.1 Rated Specification Water Storage Tank Number of storage tank installed Model Make Peak DHW flow rate Max Working Pressure Cold Water Supply Pressure Min/Max Electric boost Full Load Amps No of Coils Coil Rating Voltage Heating Capacity 9.1.2 Solar Collector Number of Collector installed Make Type Glazing Gross Collector Area Collector Volume Mildly Cloudy day rating Thermal Performance rating 9.1.3 Water Circulation Pump Motor Make Rating Voltage Full Load Current Frequency = = = = = Grundfos Ltd 1.17 KW 240V (1 Phase) 3.12 A 50 Hz = = = = = = = = 95 No Solahart Industries Pvt Ltd. Solahart BT Collector Flat Plate 3.2 mm Low Iron Solar Glass 1.98 m 2.1 L 17 MJ/day 20.3 MJ/day = = = = = = = = = = = = 01 No 7000 DB Solahart Industries Pvt. Ltd. 180 Ltr/min 1 Kg/cm 1.4/12 Kg/cm 57.6 KW 100 A 12 4.8 KW 415 V(3 phase) 1237 l/hr at 40C

27

Pump Make Head Flow 9.1.4 Performance Evaluation: Solar Plant Solar Insolation Rate Effective Absorber Surface Area Water temperature before experiment Water temperature after experiment Duration of experiment : 200 W/m (63.39 Btu/ft) : 1.86 m : 30 C (86F) : 40 C (94F) : 2 hours = = = Grundfos Ltd 55 m 4 m3/hr

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 (Considering 11 sunny hour per day) : (41.20 X 1.468 X 11 X 365)/1000ton = 242.84 ton

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Annexure: 1

Energy Consumption Variation

140000

120000

100000

No of Units

80000

60000

40000

20000

0 Jun'10 Jul'10 Aug'10 Sep'10 Oct'10 Nov'10 Dec'10 Jan'11 Feb'11 Mar'11 Apr'11 May'11

Monthly KWH Consumption

500000 450000 400000 350000 300000

KWH

250000 200000 150000 100000 50000 0 KWH