1. WELCOME Presentation on Co-Generation Installation at
Deenanath Mangeshkar Super Speciality Hospital
Pune
Date: 15th November 2017

2. Building Description: The Building consists of total 14 Floors.
Project Description
Building Description:
The Building consists of total 14 Floors.
Ground & First Floor – OPD’s, Pharmacy, Blood Bank, Canteen and Diagnosis Areas.
First to Fourth Floor – NICU, ICU’s Dialysis, Dormitories.
Fifth Floor – OT’s
Sixth Floor – Service Floor (AHU’s for OT’s).
Seventh Floor to 14th Floor – Patients Rooms.

3. Building Description:
Project Description
Building Description:
The Utility Building is located at the rear end of the premises, it is planned to be separate from the main Hospital Building.
The Ground Floor has the Gas Engines 2 x 1.2 MW & Control Room.
Mezzanine Floor – Ventilation AHU’s for Gas Engines, Air Compressor, Vacuum Pumps.

4. Building Description:
First Floor – Vapour Absorption Machines & Water Cooled Screw Chillers.
First Floor Mezzanine – Primary, Secondary, Condenser Pumps.
Terrace – Cooling Towers.

5. Building Description:
Service Floor (6th Floor) in Main Building – AHU for OT’s and other supporting areas.

6. Project Description HVAC Installation Description:
The Project consists of 2 Nos. 1.2 MW Natural Gas Fired Engines from MWM each generating 1.2 MW of Electricity.
Each 1.2 MW Engine is connected to 1 No. 352 TR Vapour Absorption Chillers from Thermax, total 2 Nos. 352 TR VAM. These VAM are fired with engine hot gas exhaust and Engine Jacket Hot Water.
To augment the VAM installation, we have installed 2 Nos. 180 TR Water Cooled Screw Chillers from Daikin.
The entire project has been designed with Primary and Secondary Variable Pumping system installed in the Utility Building.
The total requirement of the project is 1064 TR in Phase 1 + Phase 2. Presently the installation is (2W + 1S) – 2 Nos. VAM as working & 2 Nos. Screw Chillers as Standby and also as backup augmentation.
The Total installation is 1064 TR, with provision of adding another 1.2 MW engine and another 353 TR VAM as Working &, taking the total installation to 1416 TR. All 3 VAM as working & Screw Chillers as Standby and augmentation.

7. Project Description
HVAC Installation Description:
The Ground Floor to First Floor are covered with Floor Mounted & Ceiling Suspended AHU’s, and Chilled Water Cassette Units are used for small Conferences, Offices etc.,
The OT Floor are designed for Class 10,000 with HEPA Filters and Laminar Air Flow. The OT’s are as per NABH requirements.
The Server Rooms located on the Service Floor are provided with Precision Airconditioners.
All areas are provided fresh air and are sized as per ASHRAE 62.1 – 2007.
The Service Building purpose kept outside to have minimum disturbances to the Hospital functioning, during operation and major maintenance, and all noisy equipment's are kept away from the silent zone.

8. Project Description
HVAC Installation Description:
Reasons why a Co-Generation Plant was opted for.
The cost of bringing the required electrical connection from the nearest sub station was 6.0Crores.
Natural Gas was made available by MNGL at the gate without any extra cost.
The overall cost of generation of electricity at site is Rs.7.50 / Per KWH including the cost of Natural Gas, and the cost of electricity available from electricity board is Rs.15/- Per KWH being a Commercial Establishment as per Electricity Board.
Hence it was cheaper to generate the electricity at site using Natural Gas fired Engines, considering the initial cost and the Interest cost on the same.

9. Project Description
HVAC Installation Description:
Reasons why a Co-Generation Plant was opted for.
The total cost of HVAC works was Cr. Including cost of VAM, Screw Chillers, Ancillary works. The cost without VAM machines was 9.76 Cr.
The overall saving in reducing the connected load using a VAM machine was 211 KW for each chiller x 3 Nos. = 633 kW in final phase. First Phase 211 kW x 2 Nos. = 422 kW
Hence saving on the running cost of chillers = 422 kW x 15/- KWH x 24 Hrs x 365 day x 0.6 Div. = 3,32,70,480 / Per Year. Say 3.32 Cr.
The investment done for Engines + VAM + Balance of Plant + Utility Building = Rs.12.0 Cr. Hence additional investment of 6.0 Cr. Compared to the cost of bringing the electricity from nearest sub station.
Hence the Payback on the additional investment was – 6.0 Cr/ 3.32 Cr. = 1.8 Years. Considering only the saving of the energy cost of running screw chillers.

10. Project Description
HVAC Installation Description:
Reasons why a Co-Generation Plant was opted for.
If the cost of saving in electricity units is considered the savings annually are further more.
The total generation of electricity annually is 84,86,400 KWH/annum, hence the total savings in electrical cost is 84,86,400 x (Rs.15 – Rs.7.50 = Rs.7.50 per KWH) = 6,36,48, Annually.
The total saving is Rs.6.36 Cr. (electrical) Cr (Chillers) = Rs.9.68 Cr. – Estimated.
Actually Saved Rs.8.18 Cr. Due to less running hours of the chillers. Refer Excel sheet.
Hence the Payback on the investment was Cr/ 8.18 Cr. = Years. i.e. 8.5 Months.

11. Project Description
HVAC Installation Description:
Other Salient Feature of the Project.
Why screw Chillers have been introduced? Well if the Gas Engines are not loaded above 70% to 80%, the temperature of exhaust gases is lower, and hence the generation of cooling capacity is lesser. This typically happens during night time when the demand load is less. Hence in such a scenario the Screw Chillers are used to get the desired temperature of Chilled Water, and meet the cooling requirements.
The HVAC project has been designed as per LEEDS standard, however no certification has been taken.
The Chilled Water Connection between the Utility Building and the main building is through MS Class ‘C’ piping taken through concrete trenches, and it enters the main building in the level 1 underground parking, and then further taken up vertically through 2 shaft.

12. Project Description
HVAC Installation Description:
Other Salient Feature of the Project.
The Vertical chilled water piping are designed with reverse return in the shaft.
All further distribution of Chilled Water on every floor is done using standard SCHEDULE 80 PVC Pipes using Solvent Cement as joining process. The advantage of using the PVC piping are as under:
Advantages of PVC Pipe.
Lighter pipe, hence faster Installation.
Lesser thickness of pipe insulation.
Lesser frictional drop, saving some pump energy.
Lesser cost of installation of piping.

13. Project Description
HVAC Installation Description:
Some disadvantages of PVC piping.
As the material is totally corrosion resistant, there are inherent properties of water to corrode, hence the water starts attacking other component's of the system for corrosion. Hence it is necessary that you introduce a SACRIFICING Agent in the system. Which we have done by using a MS Class ‘C’ Header.
The PVC Piping needs proper and more supporting, specifically at joints and elbows, bends etc.,
The PVC piping is prone to physical damages easily, if not protected properly.
PVC piping needs very skilled workers to carry out the piping.

14. Project Description
HVAC Installation Description:
SUCCESS OF THE PROJECT:
Customer already in process of installation of the 3rd Gas Engine and the 3rd VAM, after analysing the system running from 2014, and recovering the earlier investment on the system.
The Project has been running successfully since 15th June 2014.
The challenge was also having a economic design keeping the capital costs under control without compromising the final requirements and the final out come. In order to have the shortest payback period, and actually save money to be used to add additional Engine and VAM.

15. Thank You!