Project : Power & Fuel consumption - an engineering initiative VPS Rockland, Dwarka.
VPS Rockland Dwarka Well-designed compact 103 bed Multi speciality hospital Plot area of 1250 square meter, and build up area of 4058 square meter, located in south west Delhi. Double Basement, G + 6 building. Consisting of modular OT s, 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 Dwarka S.No Equipment Capacity UOM 1 Connected Load 650 KW 2 Transformer - 1 1000 KVA 3 MDI 450 KVA 4 Chiller 1 100 TR ( 25TR x 4 no s) 5 Chiller 2 100 TR ( 25TR x 4 no s) 6 Boiler 400 KG/hr. 7 D G- 1 350 KVA 8 D G - 2 350 KVA 9 UPS ( 02 no s) 400 KVA
Root Cause Analysis [possible causes] : Electricity & Water Meter readings installed at various locations Monthly Electricity Bills Preventive & Breakdown data People Non Directional Approach Lack of awareness for technology Lack of communication To Patients Non Availability of Trained resource High expectations from users Ineffective handing over Uncertainty in seasonal variation Lack of proactive approach during seasonal variation Environment Process Lack of customized training to outsourced staff Ineffective Documentation Government Regulation Inconsistent work load due to Seasonal variations Machine Gaps between laid down and actual process Lack of monitoring of process Indicators Disparity amongst inventory Ineffective Management of outsourced staff Gaps in between technical specification and usage Old technology Low efficiency of equipments Adherence to preventive Maintenance Plan High consumption
Merits at the Site Vertically spread building with 2 basements & 7 floors. Terrace used for utility equipment's. There is no building on all 3 side which allows easy cross ventilation. Cooling tower is at Terrace with all side opened to air without any obstruction at any side. Have complete water supply of DJB ( Delhi Jal board) with 100% treated water is available at site. Cooling tower fills and chiller condenser were maintained in healthy condition Centralized water cooled chilled water plant. Cohesive team, ready to accept changes.
De - Merits at the Site Old infrastructure. Building with single glass windows. Centralized chilled water plant was very basic model with no key indicators and scroll compressors. No standby chillers. No standby cooling tower No VFD etc. were installed to reduce power consumption. High water cost ( DJB water is 4 times more expensive than in-house RO water)
NO MEASUREMENT!!!!! 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.
What to do???... We spend in capex and replace our chiller, cooling towers, install VFD s etc.. Get an Energy audit done, higher consultants for energy saving. We deiced to avoid CAPEX and improve our operations, prevent leakages.
Way forward Formed a core team consisting of shift supervisor, electrician & HVAC technician. 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. 5 R s principle was adopted.
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 Power Factor Power Factor at different end users was on lower side Maintaining chiller approach temperature Chiller approach temperature was on the higher side. Maintaining chiller & Cooling tower temperature No provision to maintain cooling tower temperature Low efficiency of chiller To increase chiller efficiency. Excessive running of chiller. To install separate DX unit for critical area so that chiller running hours. can be reduced in winter Converting CFL into LED Old CFL were replaced by LED light of Lesser wattage Dashboard on daily service level and complaints Daily dashboard put in place
Electricity Consumption analysis: 60% 50% 55% Key Consumption Areas 40% 30% 20% 10% 18% 12% 8% 7% 0% HVAC Lighting Equipments Motor and Pumps Others Our focus area was on HVAC, Lighting and Motor & Pumps as they constitute around 85% of total consumption.
Actions Taken Power Factor Increase Power Factor power factor at HT panel was 0.99 but at end user was on lower side. Individual P.F cum KWH/KVAH meter was installed at chiller plant. Initial power factor was 0.90 at chiller room and HVAC panel. Plant room is at terrace and electrical substation in Basement. Separate capacitor bank was installed at above area panel. Load trial was done with power factor of 0.90 and then with power factor of 0.99. Load was reduced at main LT panel by 12 KWH when PF of 0.99 was maintained at chiller panel. Daily power consumption was reduced by 100KWH.
Power Factor Pics Initial P.F of 0.90. With P.F of 0.90 the load went upto 211 KW.
Power Factor Pics P.F. increased to 0.99 Chiller plant load was reduced to 198 KW with P.F of 0.99
Innovating and improving P.F. P.F. increased to 0.99 at chiller also increased P.F at LT panel from 0.95 to 0.99. Earlier we had to turn on 3 capacitors bank in LT plant to maintain PF of 0.99 but now we maintain 0.99 with 2 capacitor banks. This resulted in reduction of power consumption by 6 %.
LED LIGHTS 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 200 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 500 no's 7 Daily saving in KWH for ( 2x18 watt) CFL 216 KWH
CHILLER Chiller make is Voltas and it did not have features like inlet outlet cooling tower inlet temperature, Chilled water inlet temperature, approach temp etc. Temperature and pressure gauges were installed in cooling tower inlet outlet, condenser inlet & outlet and chiller inlet & outlet. During day time in peak summers the cooling tower temperature was observed at higher side and at around 12:00 noon it was above 36deg C which was on the higher side. The cooling tower temperature was maintained till 11:00 but it suddenly shooted at around 12:00 and went on the higher side..
CHILLER Site observation was done and observed :- Kitchen exhaust duct outlet was just next to cooling tower. During day time at around 11:30 lunch preparation started and it was peak heat time. The exhaust from kitchen duct cooling tower. This drastically increased the cooling tower outlet temp. Kitchen outlet duct was modified direction of the outlet was changed. With one chiller one cooling tower was operated, to reduce condenser inlet temperature we started to operate 2 cooling towers.
CT fan blades were adjusted and service of the cooling tower was done. By operating 2 cooling towers this resulted in wastage of energy as sometimes CT outlet temperature would go below 26deg C. To overcame wastage we installed was Online temperature controller and it was synchronized with CT fan. Cooling tower temperature was maintained between 28 30 deg C This resulted in reduction of Chiller power consumption by 10 %.
S.No Description Unit 1 Chiller load at 36 deg C CT temperature 250 KW 2 Chilled load at 28-30 Deg C temperature 220 KW 3 Cooling tower fan load 5 KW 4 Total load after reducing CT temperature 225 KW 5 Reduction in chiller load with low CT temperature 25 KW 5 percnetage reduction in chiller load 10 %age During day time at 12:00 to 17:00 for 5 hours chiller was running at high discharge and load went upto 250 KW.
Inlet temp as 36 deg C. Inlet temp as 28 Deg C
HVAC Separate team was formed for cleaning of filters, coil cleaning, chiller descaling, AC service and schedule was prepared for the same. Condenser tube brushing was done by in- house team. Damaged AHU coils were replaced with new one. Monitoring of HVAC temp with regard to out door conditions. Earlier we use to set the chiller temperature at 44 deg F, now we started to increase the chiller temperature to 46 48 deg F during night hours, sundays or when ambient temperature was on lower side. Reduced our daily power consumption by 100 KWH ( average per day )
Filter cleaning process initiated by in-house team
Chiller descaling done by in-house team
Water Saving Get a kick to initiate changes when money in involved. DJB water is 3-4 times more expensive than In house RO.
Water Water saving aerators were used in taps and water flow was regulated by partially closing the plumbing line valves. ( earlier water flow speed was approx 8 liter per minute which was reduced to 4 liter per minute.) Re use of RO reject water from Dialysis and CSSD. Daily 5KL to 8 KL of reject water of TDS less than 500 ppm was reused in cooling towers. STP plant was modified by adding extra diffusers and increasing aeration flow in the tanks. STP treated water was used for partial cooling tower inlet and partial for gardening purpose. Separate tank of 5 KL was installed for cooling tower make up in which water blending was done, by mixing DJB water, RO reject and partial STP treated water. Water consumption was reduced by approx. 5 KL per day. Previous daily avg. water consumption was 5LD.
Result Year Month KWH KWH Saving 2016-17 Apr 100008 106224-6216 May 114120 127450-13330 Jun 135960 131592 4368 Jul 144072 143592 480 Aug 138924 134076 4848 Sep 138156 2017-18 128376 9780 Oct 125736 103644 22092 Nov 107520 74076 33444 Dec 80153 49356 30797 Jan 59340 56460 2880 Feb 61073 75096-14023 Mar 88752 69828 18924 Total 1293814Total power Total saved 1199770 in 7%. 94044
Environmental awareness. 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.
Environment benefits Reduce Carbon footprint by 70 metric ton. This equal to green house gas emission from 15 passenger vehicles in year Power saved at VPS ROCKLAND, DWARKA in a year equals power consumed by 10 Indian families in a year. Water saved at VPS ROCKLAND, DWARKA in a year equals power consumed by 10 Indian families in a year.
It is due to hardwork done by many engineers in saving power that our country has become power surplus.. Besides generating power we need to conserve power to reduce electricity short fall and to make our nation a power surplus one. Mr. Arvind Kejriwal has reduced power tariff in delhi from Rs 8.40 per unit to Rs 8.0 per unit.
Future plan. Replacement of Cooling tower ( non- clog fills.) Replacement of chillers. ( existing chillers are scroll compressor of 25 TR x 4 no s) Converting pending CFL into LED lights. Installing VFD on high capacity motors.
Thanks You.!!!