WELCOME TO PRESENTATION ON ACS DEPARTMENT & OVERVIEW

BY

V. SUGUNAKARA RAO AGM (MECH.) / ACS

TEMPERATURES : T2 > T1

SINK (ATMOSPHERE)

T2

35o

SOURCE (ROOM)
25o C AC

T1

REFRIGERATION
REFRIGERATION DEALS WITH THE TRANSFER OF HEAT FROM A LOW TEMPERATURE LEVEL (HEAT SOURCE) TO HIGH TEMPERATURE LEVEL (HEAT SINK) BY USING LOW BOILING REFRIGERANTS.

AIR CONDITIONING
AIR CONDITIONING RELIES ON REFRIGERATION FOR COOLING AND DEHUMIDIFICATION (MOISTURE REMOVAL). THE LIQUID REFRIGERANT DURING ITS CYCLE OF FLOW THROUGH THE EVAPORATOR ABSORBS HEAT FROM THE SURROUNDING.
4

PROCESS CHART

TON OF REFRIGERATION

Q
0
o

C WATER 0
o

C ICE

24 HOURS

1000 Kg ICE

1 TR = 3024 K Cal/Hr. = 12000 BTU/Hr. = 3.51 KW7

ROLE OF ACS DEPARTMENT

TO MAINTAIN / REPAIR THE AC EQUIPMENT / CHILLING UNITS

TO TECHNOLOGICAL UPKEEP OF AC EQUIPMENT

TO REPLACE THE OUTLIVED AC EQUIPMENT TO STUDY AND STANDARDIZATION OF AC EQUIPMENT TO STUDY AND IMPLIMENT ENERGY CONSERVATION PROJECTS TO TRAIN THE EMPLOYEES FOR CONTINUAL IMPROVEMENT

TYPES OF AC EQUIPMENT
S.N
01

EQUIPMENT
CENTRAL AC PLANTS

CAPACITY RANGE
30 TR 120 TR

QUANTITY
26

02
03 04 05 06 07 08 09 10 11 12

AIR HANDLING UNITS

FAN COIL UNITS PACKAGE ACS CRANE ACS WINDOW ACS SPLIT ACS WATER COOLERS DUCTABLE SPLIT ACS PANEL / PENDANT ACS OIL CHILLERS DEEP FREEZERS

10 TR 72 TR
1.0 TR, 1.5 TR, 2.0 TR 5.0 TR, 7.5 TR, 10.0 TR 3.0 TR 1.0 TR, 1.5 TR, 2.0 TR 1.5 TR, 3.0 TR 40 L 3.0 TR, 5.0 TR 250 W, 1000 W, 1500 W 3.0 TR - 100 OC

183
224 284 53 1150 106 340 30 133 5 1
10

13

PRECISSION ACS

15.0 TR

APPLICATIONS

OPERATION THEATERS/ICU/MBU/OPD ROOMS MOVING MACHINES OF COKEOVEN BATTERIES HOT METAL HANDLING CRANES PULPIT CANTROL ROOMS CONFERENCE HALLS ELECTRICAL CONTROL ROOMS IBM COMPUTER CENTRE PLC PANELS CNC LATHE MACHINES DEEP FREEZER FOR BEARING FIXING/STORAGE DATA CENTRES TELEPHONE EXCHANGES COOL DRINKING WATER HUMAN COMFORT

11

AC EQUIPMENT OVERVIEW
A B TOTAL NUMBER OF EQUIPMENTS TOTAL INTSTALLED CAPACITY 2537 Nos. 10, 000 TR

C
D

TOTAL CONNECTED LOAD TOTAL INSTALLED QUANTITY OF REFRIGERANT

7.1 MW
6,500 Kg

CRITICAL LOCATIONS

VISAKHA STEEL GENERAL HOSPITAL ERP DATA CENTRE ADM DIRECTORS OFFICES & DOCUMENTATION ROOMS COCCP / SMS & OTHER DEPARTMENTS IBM COMPUTER CENTRE AUDITORIUMS AT T&DC, STEEL CLUB AND UKKU CLUB
13

CENTRAL AC

14

CHILLED WATER PUMPS

15

CONDENSOR WATER PUMPS

16

COOLING TOWERS

17

PACKAGE AC
INDOOR UNITS OUTDOOR UNITS

18

AIR HANDLING UNIT

19

WINDOW AC

20

SPLIT AC

21

WATER COOLER

22

PANEL AC

23

EXECUTIVES

THE EMPLOYEE PROFILE

Nos.

S.No. DESIGNATION

1
2 3

DGM (E-7)
AGM (E-6) MANAGER (E-4)

02
03 02

4
5 6 7 8

Dy. MANAGER (E-3)

ASSISTANT MANAGER (E-2) JUNIOR MANAGER (E-1) MANAGEMENT TRAINEE (E-0) JUNIOR OFFICER TOTAL

02
12 01 01 01 24
24

ACS ORGANISATION CHART

DGM (ACS)I/C
DM (Staff)

DGM (ACS)
AGM (E)
AGM (ACS)
MANAGER-01
MANAGER-01
DEPUTY MANAGER-01 ASSISTANT MANAGER-07 MTT-01

ASST. MANAGER-04

AGM (M)

ASSISTANT MANAGER-01 JUNIOR MANAGER-01 JUNIOR OFFICER-01

THE EMPLOYEE PROFILE

S.No. 1 2 3 DESIGNATION NON EXECUTIVES CONTRACT MAN POWER EXPANSION CONTRACT MAN POWER Nos. 42 99 75

26

MAINTENANCE ZONES

PLANNING STEEL MELTING SHOP ZONE LMMM ZONE WRM ZONE COCCP ZONE WORK SHOP CRMP ZONE SINTER PLANT ZONE TOWN SHIP ZONE EXPANSION: SMS, RMHP, BF&SP & WRM
27

28

HIGHLIGHTS
1. HCFC GAS CONSUMPTION LIMITED TO 0.164 Kg/TR AGAINST THE TARGET OF 0.17 Kg/TR 2. CFC CONSUMPTION NIL 3. CFC EQUIPMENTS REPLACED 20 Nos. PANEL AIR CONDITIONERS & 7 CRANE AIR CONDITIONERS 4. 20 Nos. PACKAGE AIR CONDITIONERS REPLACED WITH ENERGY EFFICIENCIENT SYSTEMS. POWER SAVING 3 Lakh UNITS 5. 4 Nos. AIR HANDLING UNITS UPGRADED, POWER SAVING 1 Lakh UNITS

6. 25 Nos. SAFETY DOOR INTERLOCKS PROVIDED

29

HIGHLIGHTS
1. 51 Nos. QUALITY IMPLIMENTED CIRCLES PROJECTS

2. 72 Nos. SUGGESTIONS GENERATED. 3. 6.54 TRAINING ACHIEVED MAN DAYS PER EMPLOYEE

4. ZERO ACCIDENT AWARD FOR THE CALENDOR YEAR

5. 2 MILLION ACCIDENT FREE MAN HOURS AWARD

6. 2nd PRIZE FOR QUALITY CIRCLE ACTIVITIES
30

31

QUALITY CIRCLE: FOR THE YEARS 2003-04, 2004-05, 2005-06, 2006-07, 2007-08, 2010-11 & 2011-12 TRAINING: FOR THE CALENDER YEARS 2004, 2005, 2006, 2007, 2008, 2009, 2010 SAFETY AND HOUSEKEEPING : FOR THE YEARS 200304, 2005-06, 2006-07, 2008-09, 2010-11 2 MILLION ACCIDENT FREE HOURS: DURING THE YEAR 2011 5-S : FOR THE YEARS 2006, 2009, 2010

ZERO ACCIDENT : FOR THE YEARS 2006, 2007,2008, 2009, 2010, 2011
ENERGY PERFORMANCE AWARD : FOR THE YEAR 2007
32

33

ZERO ACCIDENTS FOR THE CALENDER YEAR FOR 2011

2 MILLION ACCIDENT FREE MAN HOURS 2nd PRIZE FOR BEST QUALITY CIRCLE IMPLIMENTATION DEPARTMENT FOR 2011-12

34

35

36

38

QSHE OBJECTIVITIES

TO IMPLEMENT QUALITY CIRCLE PROJECTS 31 Nos. TO GENERATE SUGGESTIONS 66 Nos.

TO MAINTAIN MOU RATINGS MORE THAN 95% WITH CUSTOMER DEPARTMENTS TO TRAIN EMPLOYEES ON CASE STUDIES RELATED TO CONTINUAL IMPROVEMENT IN QUALITY AND ENVIRONMENTAL PERFORMANCE 60 Nos.

39

QSHE OBJECTIVITIES

TO RESTRICT ODS SUBSTANCE CONSUMPTION - 0.17 Kg/Ton OF INSTALLED QUANTITY TO TRAIN EMPLOYEES ON OZONE DEPLETING AND GLOBAL WARMING - 141 Nos.

TO PROVIDE METAL CLAD PLUG & SOCKETS FOR WINDOW AC- 100 Nos.
TO PROVIDE DOOR INTERLOCKS IN AIR HANDLING UNITS 15 Nos. TO TRAIN EMPLOYEES ON SAFETY CONCIOUSNESS 40 AND FIRST AID 141 Nos.

ISO 50001

ENERGY SAVING 8% BY REPLACING AHUs 03 Nos. ENERGY SAVING 13% BY PROVIDING VFD 11 Nos. ENERGY SAVING 12% BY REPLACING PACKAGE ACs 10 Nos. ENERGY SAVING 6.5% BY REPLACING 2 STAR RATING WINDOW ACs 50 Nos. REDUCTION 71% GWP, 98% ODP BY REPLACING NON CFC UNITS 73 Nos.
41

42

SUGGESTIONS

43

QUALITY CIRCLES

44

TRAINING MAN DAYS

45

MOU RATINGS

46

CFC CONSUMPTION

47

48

REFRIGERANTS
S.No. 1 2 3 4 5 6 REFRIGERANT R-12 R-22 R-13 R-114 R-124 R-134 A CHEMICAL FORMULA CCl2F2 CHClF2 CF3Cl C2F4Cl2 CHClF-CF3 CF3-CH2F YEAR OF PHASE OUT 2010 2040 2010 2010 2040 ODP 1.0 0.055 1.0 1.0 0.04
49

Alternative Refrigerants
CFC

Cl
F

R-12

Cl C
R-22 /R-124

HCFC

HFC R-134a

HC
R-600a

Cl

F C F

H
50

Cosmic Rays Gama Rays X - Rays

UV-C

S U N

Ultraviolet Light Infra-red Radio waves Microwaves

Absorbed in the Stratosphere by Ozone UV-B

Partially absorbed by Ozone UV-A

51

52

CFC - 12

The chemical chain reaction of ozone destruction is shown. O3 + Cl ClO + O2 ClO+O3 2O2 + Cl

1 Atom of Cl break 1,00,000 molecules of O3

53

ODSs & Global Consumption

Halon 23% Refrigeration 28%

Foam 25%

Solvent 12% Others Aerosol 0% Global Consumption 12%

of ODS = 110, 667 Tones

54

EFFECTS OF DAMAGED OZONE LAYER

Moderate exposure to sunlight in daily life not harmful, given vitamin D. UV-B radiation that damages ozone layer from filtration ultimately reaches earth causing damage to life. Eye Damage Skin Cancer

Aqua Life & Animals

Plant life / Crops Air Quality Deterioration of Some Synthetics etc.

Suppresses Body Immune System

55

REFRIGERANT CONSERVATIVE INITIATIVES

56

REFRIGERANT RECOVERY UNIT

ENERGY CONSERVATIVE INITIATIVES

58

SCROLL COMPRESSORS

BACKWARD CURVED FANS

DOUBLE SKIN AIR HANDLING UNITS

MICROPROCESSOR BASED THERMOSTATS

63

S.No.

BUDGET HEAD(12-13)
INDENTING BUDGET MECHANICAL ELECTRICAL EXPANSION CONSUMPTION BUDGET MECHANICAL ELECTRICAL CONTRACTUAL BUDGET EXISTING EXPANSION CAPITAL BUDGET (AMR)

AMOUNT (Lakhs)
50.0 5.0 10.0
65.0 8.0 170 120 155

01

02

03

04

64

5 S CERTIFICATION

65

Thank you

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