Works/Results

Heating

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Works/Results

Heating

Asur Area V1. Asur Area Vasta No.3 ZT9, San Severino Marche (MC)
Hospital Complex in San Severino Marche
Regeneration of the Heating System and boiler replacement performed for the San Severino Marche Hospital Complex (MC)
Customer

ASUR AREA VASTA No.3 ZT9 – Hospital Complex in San Severino Marche

Specific problems

The structure in question required a moderate quantity of primary energy throughout the year to fulfil various types of energy requirements, including heating, refrigeration and electricity. In particular, heating was produced by three hot water generators equipped with gas burners, two of which were outdated and inefficient, as was the fourth steam boiler. This meant high fuel consumption to produce the necessary heating to guarantee the correct environmental comfort during the months in which the heating system was in use, and generally throughout the year as the boilers also operated in summer. Furthermore, the two carbo-fuel boilers and the steam boiler, although in working order, could not guarantee an appropriate useful life and furthermore were not environmentally and ecologically very reliable. The boiler technology dated back to the early 90s, when environmental pollution was not of prime importance in the design of heat generators. The modest production performance (i.e. the ratio between the energy provided for the liquid heat transfer and the energy for the heating system) also had an impact on fuel consumption and pollution emissions. With the exception of the new refrigerated water circuits, all the plant engineering in the sub-station was obsolete, as were the three boilers. Boiler maintenance and servicing was poor, insulation was incomplete and incorrectly installed, so it was unable to guarantee adequate performance. The maintenance and servicing of the control valves was not compliant. The electrical control panels of the power plant and sub-station were outdated and inadequate, due to the precarious conditions of the protective equipment. Thus, the systems clearly did not comply with current legislation. In the event of a fault, there would have been a high risk that a widespread interruption would have occurred to numerous activities, as the various circuits were all linked to just a few protective switches. The control panels were roughly divided into a light circuit and a utility power circuit and the switches showed the following failures:

  • lack of protection against indirect contact;
  • lack of line protection coordination;
  • lack of selectivity between upstream and downstream protective devices;
  • outdated protective devices and, therefore, the possibility that in the event of a fault, the protective switch would not trigger, with subsequent risk of damage to the electrical control panel or worse still, to the system.

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Reply from C.P.M.

The intervention was designed to dismantle the two “CARBOFUEL” heat generators together with their burners and hydraulic circuits. The heat meters were reinstalled on new generators. Once the existing equipment had been removed, two new, highly efficient (three-star) Riello RTQ 1100 3S boilers were installed, each of which with a water load power of 1049 kW. Modulating gas burners were installed on the boilers and new safety and shut-off equipment was installed to connect them to the existing pipe network. The open-cup expander system was retained and the safety connections were attached to the existing piping system; special care was taken over the height of the joints which could not be modified (1.6 m from the floor). For this purpose the heat generators were equipped with safety connections and a max height of 1.55 m including the masonry base.  A primary “open” circuit, above the boilers, was connected to the existing collecting head on which the electric circulating pumps for the generators and the electric pumps were fitted to supply the power sub-station. The intercooler supplied by the co-generator was connected to the same circuit. The heating fluid was transported from the power plant to the substation via electro-pumps connected to the existing piping from the power plant. The new heating fluid distribution manifold, supplied via the existing piping from the power plant, was installed in the power sub-station. The new, electronically controlled electro-pumps to supply the existing circuits were installed on the collector head.  Cross valves to control the delivery temperature according to the outside temperature were installed on the radiator circuits. To avoid complete shutdown of the heating system, the new collector head was placed parallel to the refrigerated water head. The existing collector head was kept in operation until all existing circuits had been completely disconnected. Furthermore, new domestic hot water distribution collector heads replaced the current heads in the substation near the boilers. Two separate collector heads now provide domestic hot water: one at a high temperature and the other at a mixed temperature for domestic utilities. A cross valve placed between the high temperature (60°C) and the mixed temperature (45°C) collector heads controls the temperature supply.

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Results

Regeneration of the system by replacing the boilers gave the following advantages:

  • Functional benefits;
  • energy-saving benefits;
  • technical-economic benefits;
  • ecological benefits.

This translates into

  • Increased system efficiency and reliability;
  • Reduced maintenance costs.

The presence of new generators enables optimum use, thanks also to the pre-mixing, modulating burners, with a subsequent reduction in mandatory maintenance.

The energy benefits obtained are due to the reduction in thermal energy and electricity consumption. The achievable figures show 20,645 TOE/year, 240.062 kWh, which corresponds to a reduction in primary energy of 7.31%/year.

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Energy Diagnosis Before/After Work
Annual Data
  • Ante operam
  • Post operam

kWh/year
-7.3 %

mcCH4/year
-7.3 %

Eco-energy outline
Annual Data


0
TCO2/year


0
TEP/year