project : power & fuel consumption - an engineering initiative · nabh accredited hospital. ......
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Project : Power & Fuel consumption - an engineering initiative VPS Rockland, Qutab
VPS Rockland Qutab
VPS Rockland Qutab
Well-designed compact 200 bed Multi speciality hospitalPlot area of 4053 square meter, and build – up area of 20000 square meter, located in south west Delhi.Basement, G + 7 building.Consisting of 4 numbers of modular OT, Cath lab ICU, Radiology etc.NABH accredited Hospital.
Why did we choose this project :
To develop awareness on energy conservation among are 3 units.
Develop need of energy conversation pattern within team.
The power consumption was on higher side as compared to other hospitals in the network.
To spread awareness among staff and in the organization for global cause.
Equipment detail at Qutab
S.No Equipment Capacity UOM
1 Connected Load 1800 KW
2 Transformer - 1 2500 KVA
3 MDI 500 KVA
4 Chiller – 1 180 TR
5 Chiller – 2 180 TR
6 Chiller – 3 75 TR
7 Chiller – 4 75 TR
8 D G- 1 1010 KVA
9 D G - 2 630 KVA
10 UPS ( 06 no’s) 400 KVA
Root Cause Analysis [possible causes] :
High consumption of P&
U
People Process
Environment
Non Directional Approach
Non Availability of Trained resource Gaps between laid down and actual process
High expectations from users
Ineffective handing over
Government Regulation
Ineffective Managementof outsourced staff
Gaps in between technicalspecification and usage
Ineffective Documentation
Lack of proactive approach duringseasonal variation
Inconsistent work load dueto Seasonal variations
Lack of customized trainingto outsourced staff
Disparity amongst inventory
Lack of monitoring of process Indicators
Lack of communication To Patients
Machine
Lack of awareness for technology
Uncertainty in seasonal variation
Old technology
Adherence to preventive Maintenance Plan
Low efficiency of equipments
Electricity & Water Meter readings installed at various locations Monthly Electricity Bills Preventive & Breakdown data
• Vertically spread building with 1 basements & 7 floors.
• Terrace used for utility equipment's.
• There is no building on the back side, with view towards Qutab Minar forest area which allows easy cross ventilation.
• Building is made in “U” shape which allows direct sunlight and easy cross ventilation to all area.
• Separate “ 70 TR” chiller for winter season was installed which catered OT’s and ICU’s.
• Cooling tower is at Terrace with all side opened to air without any obstruction at any side.
• Centralized water cooled chilled water plant.
Merits at the Site
• Water quality is not good. TDS upto 3000 ppm, suspended particles also on the higher side.
• Water treatment plant was not available, filtered water with high TDS & hardness was used for utility operations.
• Infrastructure was very old.• Single glass building which increased the heat load of the building.• No standby cooling tower.• Manual Tap – changer in transformer.• No power saving gadgets like VFD etc weren’t installed to reduce
power consumption.• Getting the staff involved.
De - Merits at the Site
• Unable to measure basic parameters like cooling tower in & out temperature, running KW of chiller, approach temp etc.
• All electrical feeders did not have KWH consumption meters, no means to measure power consumption of critical equipment's and individual floors.
NO MEASUREMENT !!!!!
Golden Words :-If you can not fly, run.If you can not run, Walk.If you can not walk, crawl.but keep moving???..Santa:Oye Eh Ta Theek Aa, Per Jana Kithe Hai?
We spend in capex and replace our
chiller, cooling towers, install VFD’s etc..
Get an Energy audit done, higher
consultants for energy saving.
What to do???...
We deiced to avoid CAPEX and improve our operations, prevent leakages….
• Formed a core team consisting of shift supervisor, electrician & HVAC technician.
• Energy saving committee consisting of doctors, support staff, HK staff was formed.
• Gaps were identified ( as mentioned in Final root cause analysis) and closed on priority basis.
• Demerits and merits of the site were established.
• Each unit team audited other unit and shared there practices. Best practices were followed by each other
• Training was imparted to team and awareness for saving energy was spread.
Way forward
• Daily monitoring of power consumption was initiated, reading were taken in each shift and from all critical feeder.
• Temperature & pressure gauges were installed and reading monitored.
Team decided to take target of 5% reduction in power consumption.
The final root causes / improvement opportunities….
Problems Descriptions
Chiller approach temperature was on the higher side.
Cooling tower outlet temperature was on the higher side.
To increase chiller efficiency
To increase cooling tower efficiency.
500 TR chiller & 500 TR cooling tower.
High hardness and TDS of water used for utility
Process for regular PM & service was not laid down,
Maintaining chiller approach temperature
Cooling tower outlet temperature was not maintained
Low efficiency of chiller
Low efficiency of cooling tower
Cooling tower & chiller capacity of same capacity
Water quality not maintained
Regular PM & service of equipment's not done
Electricity Consumption analysis:
55%
18%
12%8% 7%
0%
10%
20%
30%
40%
50%
60%
HVAC Lighting Equipments Motor and Pumps Others
Our focus area was on HVAC, Lighting and Motor & Pumps as theyconstitute around 85% of total consumption.
Key Consumption Areas
• 4 chillers were installed.• 180 TR x 2 no’s for Basement to 5th floor• 75 TR x 2 no’s for OT and 6th floor ( ICU area.)• During peak summer seasons all 4 Chillers were running during
day time.• During winters one chiller each ( 180 TR chiller for operated for
Radiology area and 75 TR for OT & ICU)• 2 cooling tower ( with common header for all 4 plants ) of 300
TR & 200 TR were installed.• With 500 TR cooling tower capacity & 500 TR chiller capacity it
was difficult to maintain head pressure during peak summer season
Actions Taken
Chiller
• All 4 chillers were running on approx 80% load.
• As OT’s were hardly operational in night which reduced load on 75 TR chillers, the same way OPD area was not operational in night which reduced the load on 180 TR Voltas chiller.
• Team decided to interconnect both chiller headers.
• Header of both Chillers were interconnected and chilled water supply was provided to whole building from all chillers.
• OT and ICU AHU are installed on terrace, when we tried to operate building with 2 x 180 TR and 1x 75 TR we were unable to get required chilled water GPM in OT no. 3 & 4 as they were on other side of the terrace.
• One of the 400 GPM pump of 15 KW was replaced with 600 GPM pump of same motor capacity ( 15KW.)
• During day 75 TR chiller was shutdown, this also helped in maintaining cooling tower temperature.
• During night hours when OT was not running, the whole building load was shifted on 180 TR x 2 chillers.
• Chiller approach temp was on higher side.
• There was no mechanism for direct measurement of chiller approach temp, cooling tower outlet temp gauge were installed for measuring approach temp.
• Separate Softener plant was installed for cooling tower water.
• RO reject from Dialysis and CSSD was ( with TDS less than 200 ppm) was used for cooling tower.
• Online TDS meter was installed for monitoring of TDS.
• Chemical dosing of cooling tower was initiated.
• Grey area for which we had to run chiller at low temperature were identified. Normally the chiller was operated at 8°C but on some occasions due to requirement and some problematic area we had to run chiller at 6°C.
• OT and other area where low temp was required, the AHU were modified.
• These AHU had 2 coil system, second coil was for hot water was converted into chilled water and hot water, when low temperature ( like 16deg C ) was required chilled water was used in both coils.
• Separate Softener plant was installed for cooling tower water.• RO reject from Dialysis and CSSD was ( with TDS less than 200
ppm) was used for cooling tower.• Grey area for which we had to run chiller at low temperature
were identified. Normally the chiller was operated at 8°C but on some occasions due to requirement and some problematic area we had to run chiller at 6°C.
• OT and other area where low temp was required, the AHU were modified.
• These AHU had 2 coil system, second coil was for hot water was converted into chilled water and hot water, when low temperature ( like 16deg C ) was required chilled water was used in both coils.
• Earlier we were running the building with 500 TR chiller.
• After making the above changes, now the building is running on 430 TR.
• Earlier 4 chilled water pumps were running, after making changes 3 chilled water pumps were running.
INNOVATION
2016- 17 2017 - 18
Month KWH Month KWH Saving in KWH%
Increase
Apr 52855 Apr 67752 14896 28
May 74533 May 91890 17358 23
Jun 79762 Jun 79259 -504 -1
Jul 95126 Jul 76503 -18623 -20
Aug 102465 Aug 78760 -23705 -23
Sep 89212 Sep 66484 -22728 -25
Oct 72198 Oct 49904 -22294 -31
Nov 49595 Nov 29004 -20591 -42
Dec 48724 Dec 29098 -19627 -40
Jan 41142 Jan 30982 -10160 -25
Feb 46622 Feb 35000 -11622 -25
Mar 55878 Mar 44534 -11344 -20
Chiller Plant KWH comparison FY 16/17 VS FY 17/18
Chilled water plant power reduced by
17%.
Chiller Plant KWH load percentage FY 16/17 VS FY 17/18
2016/17 2017/18
Month KWH Chiller KWHChiller load
%ageKWH Chiller KWH
Chiller load %age
Apr 224916 52855 23.50 274632 67752 24.67
May 300777 74533 24.78 329592 91890 27.88
Jun 327701 79762 24.34 321276 79259 24.67
Jul 373042 95126 25.50 338508 76503 22.60
Aug 395770 102465 25.89 346044 78760 22.76
Sep 356492 89212 25.03 309228 66484 21.50
Oct 285739 72198 25.27 231036 49904 21.60
Nov 192377 49595 25.78 145020 29004 20.00
Dec 181943 48724 26.78 144048 29098 20.20
Jan 170784 41142 24.09 151872 30982 20.40
Feb 187314 46622 24.89 166668 35000 21.00
Mar 226777 55878 24.64 200154.6 44534 22.25
Total 3223632 808112 25 2958079 679169 22
• In basement there were 2 AHU of 16000 CFM and motor of 15 KW each.
• During night hours and off peak season the area was more chilled than requirement.
• The AHU were also very old and body was partially damaged.
• Instead of installing 2 AHU of 16000 CFM with VFD and temp controller we installed 4 AHU of 8000 CFM each with each motor of 7.5 KW.
S.No System unit
1 Existing AHU 15 KW
2 Running hours 24 Hours
3 Total KWH per day 360 KWH
4 New AHU 7.5 KW x 2 no's 15 KW
5 AHU running for 24 hours 7.5 KW
6 Running hours 24 Hours
7 Total KWH consumption 180 KWH
8 AHU running for 12 hours 7.5 KW
9 Running hours 12 hours
10 Total KWH consumption 90 KWH
11 Total KWH consumption with both AHU 270 KWH
12 Saving per AHU per day 90 KWH
• There are 10 AHU for OT & 6th floor which are installed in terrace, separate console was installed for temperature monitoring ( only temp view) and switching AHU ON/OFF. Earlier technician had to go to respective area now it was controlled from plant room.
• Chilled water pump and cooling tower pump were also connected with the same.
• There were 4 areas which were modified ( room area was reduced) but AHU was same. As these AHU became of higher capacity, there were regular complaints of low temperature in these area. 2 way valve were installed along with temperature controller & indicator.
• Temp indicator was installed in the room and nursing staff controlled temp as per requirement.
• Converted CFL into LED lights.
48 watt CFL were replaced with 36 Watt LED.
36 watt down lighter were replaced with 12 Watt LED.
Daily power saved 340 KWH.
S.No Discription Unit
1 Existing CFL ( 2x 18 watt) 36 watt
2 Proposed LED 12 watt
3 Saving in load 24 watt
4 Daily running hours 18 hour per day
5 Daily saving in KWH per light 0.43 KW
6 Total number of ( 2x18 watt) CFL replaced 800 no's
7 Daily saving in KWH for ( 2x18 watt) CFL 340 KWH
LED LIGHTS
Result Year Month KWH KWH Saving
2016-17
Apr 224916
2017-18
274632 -49716
May 300777 329592 -28815
Jun 358910 321276 37634
Jul 373042 338508 34534
Aug 412978 346044 66934
Sep 340288 309228 31060
Oct 285739 231036 54703
Nov 192377 145020 47357
Dec 181943 144048 37895
Jan 170784 151872 18912
Feb 187314 166668 20646
Mar 226777 200154.6 26623
Total 3255845 Total 2958079 297766Total power saved in 9%.
• Recycle paper. Re – use paper and take print om both sides.
• Conducted classes for staff to spread awareness about energy conservation.
• Avoid usage plastic bags. Encouraged staff to not to use plastic bags and use jute bags instead.
• Switch off lights, AC and Fans when not in use.• Switch of computer instead of “log off”.• Proper disposal of garbage in bin bags.• Use water saving aerator in taps.
Environmental awareness….
Environment benefits
Reduce Carbon footprint by 222 metric ton.This equal to green house gas emission from 47 passenger vehicles in year…
• Replacement of old 180 TR Voltas chiller with new screw chiller of 250 TR with VFD, so that we operate only one chiller during most of the year.
• Converting pending CFL into LED lights.
• Installing VFD on high capacity motors.
Future plan.
Thanks You.!!!