A

Microproject report
On

“Collect information of district cooling”

SUBMITTED TO M.S.B.T.E., Mumbai

For the Award of
DIPLOMA IN MECHANICAL ENGINEERINGBY

Roll no. Name of Student Enrollment no.

16 Mr. Suraj Pampu Bansode 2210740397

UNDER THE GUIDANCEOF

( Mr. D. C. Jadhav )

DEPARTMENT OF MECHANICAL ENGINEERING

SVERI’s College of Engineering (Polytechnic), Pandharpur

Gopalpur Pandharpur-413304
2024-25
AFFILIATEDTO

M.S.B.T.E.
 Introduction to District Cooling

 Definition: District Cooling is a system that provides cooling services

to multiple buildings or districts from a central plant, distributing

chilled water through insulated underground pipes.

 Relevance: With the increasing urbanization and energy demands,

cooling accounts for a significant portion of energy consumption,

particularly in regions with hot climates. District cooling offers an

efficient, sustainable solution.

 How District Cooling Works

 Chilled Water Generation: The central cooling plant uses refrigeration

techniques to cool water, which is then circulated through a network of

insulated pipes to buildings.

 Cooling Process: The chilled water passes through a heat exchanger

inside each building, where it absorbs heat from the air conditioning

system. The cooled air is distributed throughout the building, providing

comfort.

 Efficient Energy Use: Centralized systems are more efficient because

they can be optimized for energy use and maintenance, unlike

decentralized air conditioning units.

 Key Components of a District Cooling System (DCS)

 Centralized Chiller Plant: The heart of the system, using technologies

like absorption or vapor compression chillers to cool water to the

desired temperature.

 Piping Infrastructure: A network of insulated, underground pipes that

carry the chilled water to each customer (building).

 User Station: A unit in each building that interfaces with the

centralized system and transfers the chilled water to the air handling
units inside the building.
 Types of Cooling Technologies Used in DCS

 Chilled Water Technology: Most common method, where water is

cooled to 4–7°C and circulated.

 Ice Storage Systems: Some systems use ice as the cooling medium,

freezing water during off-peak hours and using it to cool buildings

during peak hours.

 Seawater or Lake Water Systems: In some regions, cold water from

seawater or lakes is used for cooling, which is an environmentally

friendly approach.

 Benefits of District Cooling

 Energy Efficiency: Significant energy savings due to centralized

cooling plants, reducing the need for individual air conditioning units

in each building.

 Reduced Environmental Impact: Centralized cooling systems can use

environmentally friendly sources, such as seawater, solar power, or

even waste heat, thus lowering carbon emissions.

 Cost-Effective: Both operational and capital expenses are reduced by

sharing resources and infrastructure across multiple buildings.

  Maintenance and Scalability: Simplified and less costly maintenance

for the user; easier to upgrade or expand the system based on

demand.

 Case Studies of District Cooling

 GIFT City, Gujarat, India: A pioneering micro district cooling project in

India, focusing on sustainability, energy savings, and reduced peak

loads.

 University Campuses: Several universities around the world have

adopted district cooling as part of their green campus initiatives. This

reduces energy consumption and promotes sustainability.

 Residential Complexes: Many modern urban developments

implement micro district cooling to provide comfortable living

environments while reducing costs for developers and residents alike.

 Challenges and Considerations

 Capital Investment: Even micro systems require initial investments in

infrastructure and technology. While the long-term savings are

substantial, the upfront cost can be a barrier for some projects.

  Geographic Limitations: The feasibility of micro district cooling

systems depends on the geographical location, local climate, and

available resources (e.g., lake water, renewable energy sources).

 System Design: Ensuring that the system is designed to meet cooling

demands during peak times while remaining energy-efficient requires

careful planning and simulation.

 Regulatory and Operational Constraints: Local regulations regarding

energy usage, construction codes, and environmental considerations

need to be addressed.

 Future of District Cooling

Technological Innovation: Advancements in AI and IoT are making

district cooling systems more intelligent, optimizing performance and

lowering costs.

Smart Cities: As cities move toward "smart city" concepts, district

cooling systems are integral to managing urban energy consumption

efficiently.

Integration with Renewable Energy: More district cooling systems

are expected to integrate renewable energy sources such as solar,

wind, or geothermal energy to reduce their carbon footprint.
 Conclusion

District cooling systems, particularly micro projects, are an

innovative solution to the global challenge of urban cooling and
energy consumption. With benefits ranging from cost savings to
environmental impact reduction, these systems are a key part of
modern sustainable infrastructure.

The trend towards more sustainable urban developments,

combined with technological advancements, ensures that micro district
cooling projects will continue to play a significant role in shaping
energy-efficient cities worldwide.
Evolution sheet for MicroProject

Academic Year:-2024-25 Name of Faculty:- Mr. D. C. Jadhav

Course:- MECHANICAL ENGINEERING Course code:-ME6I

Subject:-Emerging Trend In Mechanical Subject Code:-22652
Engineering
Semester:-6 Scheme:-I

Title of Project:- “Collect information of district cooling”

Comments/Suggestionsaboutteamwork/leadership/inter-personalcommunication(ifany)

Marks outof 4
Marks out of 6
for Total
for
performance in outof 10
performance in
group activity oral/
Presentation
Name of students
Name: Mr. Suraj Pampu Bansode
Name and
Signature of Mr. D. C. Jadhav
faculty
 SVERI’s COLLEGE OF ENGINEERING (POLYTECHNIC), PANDHARPUR.

This is to certify that the Project report entitled

“Collect information of district cooling”

Submitted by

Roll no Name of Student Enrollment no

Mr. Suraj Pampu Bansode 2210740397

16

Is a bonafide work carried out by above students, under the guidance of Mr. D. C. Jadhav and it is submitted
to words the fulfillment of requirement of MSBTE, Mumbai for the award of Diploma in MECHANICAL
ENGINEERING at SVERI’s COE (Polytechnic), Pandharpur during the academic year 2024-2025.

(Mr. D. C. Jadhav)
Guide

( Mr.S.V.Kulkarni ) (Dr.N.D.Misal)
HOD Principal

Place: Pandharpur

Date- / /
World-Class Industries Using Six Sigma Technique
Six Sigma is a set of techniques and tools for process improvement.
Industries across the globe have implemented Six Sigma to
enhance product quality, reduce defects, optimize processes, and
boost customer satisfaction. Here’s a list of world-class industries
that are using the Six Sigma technique:
Manufacturing Industry
Companies like General Electric (GE), Motorola, and Boeing have successfully utilized Six Sigma
methodologies to optimize their manufacturing processes and improve product quality.

Automotive Industry
Toyota, Ford, and General Motors have adopted Six Sigma to improve their production lines,
ensure consistency, reduce waste, and enhance the overall customer experience.

Pharmaceutical Industry
Pharmaceutical giants like Pfizer, Merck, and Johnson & Johnson have implemented Six Sigma to
streamline their production processes, improve product quality, and comply with regulatory
standards.

Healthcare Industry
Healthcare organizations, such as Cleveland Clinic and Kaiser Permanente, have utilized Six Sigma
to reduce patient wait times, improve operational efficiency, and ensure better healthcare
outcomes.

Retail Industry
Companies like Walmart, Amazon, and Target leverage Six Sigma techniques to optimize their
supply chain management, improve inventory control, and enhance customer satisfaction.

Financial Services Industry

American Express, Citigroup, and Bank of America have employed Six Sigma methodologies to
enhance their customer service, improve transaction processing, and reduce errors in financial
operations.
Telecommunications Industry
Telecom giants like AT&T, Verizon, and T-Mobile have adopted Six Sigma for improving network
performance, reducing service disruptions, and increasing customer satisfaction.

IT & Software Industry

Companies like IBM, Intel, and Microsoft use Six Sigma to improve software development
processes, reduce defects, and enhance customer experience with software products and services.

Aerospace & Defense

Lockheed Martin, Northrop Grumman, and Raytheon apply Six Sigma to improve the quality of
their products, streamline operations, and meet stringent defense industry standards.

Food & Beverage Industry

Coca-Cola, Nestlé, and PepsiCo use Six Sigma to improve the quality of their products, optimize
production processes, and enhance supply chain management.
Detailed Report on the Pharmaceutical Industry:
Pfizer
Introduction to Pfizer and Six Sigma Implementation
Pfizer is one of the world’s largest pharmaceutical companies,
renowned for its high-quality drugs, vaccines, and treatments
across various therapeutic areas. Given the complexity of the
pharmaceutical industry, including the need to maintain high
standards of quality, adhere to strict regulatory requirements, and
ensure the safety and efficacy of drugs, Pfizer adopted Six Sigma
methodologies to improve its processes.
Overview of Six Sigma in Pfizer:
 Objective: Improve operational efficiency, enhance product quality, minimize production
defects, ensure regulatory compliance, and enhance customer satisfaction.
 Strategy: Pfizer used Six Sigma to streamline its production processes, reduce variability,
eliminate inefficiencies, and minimize the risk of defects in pharmaceutical manufacturing
and packaging.

Micro Project: "Improving the Drug Production Process in

Pfizer Using Six Sigma"
Project Objective:
The goal of this micro-project is to explore how Six Sigma
techniques are used to improve the drug production process, with
an emphasis on reducing defects and improving operational
efficiency. Specifically, this project looks at how Pfizer addressed
challenges in its manufacturing line and applied Six Sigma tools to
achieve measurable improvements.
Project Phases & Approach:
Define Phase:
Problem Statement: In the production of a specific pharmaceutical product (e.g., a tablet), Pfizer
experienced variation in tablet weight, causing the possibility of underdosing or overdosing.

Project Goals:

Reduce the variability in tablet weight.

Ensure the dosage is consistent across batches.

Comply with FDA regulatory standards for product quality.

Measure Phase:
Data Collection: Pfizer’s team collected data on tablet weight variability from multiple production
batches. The data included the weight of tablets, the number of defects in each batch, and the
production cycle time.

Key Metrics: Average tablet weight, variation in tablet weight, defect rate per batch, cycle time,
and waste generated during production.

Analyze Phase:
Root Cause Analysis: Pfizer utilized tools like Fishbone Diagram (Ishikawa), Pareto Analysis, and
Failure Mode Effects Analysis (FMEA) to identify potential causes of weight variation.

Causes Identified:

Inconsistent powder mixing.

Variability in machine calibration.

Human error during the formulation process.

Process Mapping: A flowchart was created to visualize the entire production process from raw
material input to the packaging of finished tablets.

Improve Phase:
Solution Implementation:

Process Standardization: Standard operating procedures (SOPs) were revised to ensure consistent
powder mixing and machine calibration.
Equipment Upgrade: New tablet compression machines with automated calibration features were
introduced.

Training & Empowerment: Operators were trained to handle equipment more effectively and were
empowered to report process deviations immediately.

Design of Experiments (DOE): A DOE was performed to test different formulation variables (e.g.,
powder flow properties) to find the optimal conditions for consistent tablet weight.

Pilot Run: A pilot run was conducted with the updated procedures and equipment. Results showed
a reduction in tablet weight variation and fewer defects.

Control Phase:
Monitoring: A control chart was set up to monitor tablet weight variation on a real-time basis.
Statistical process control (SPC) was employed to detect any process deviations quickly.

Sustaining Improvements: A continuous improvement team was established to review production

data monthly and ensure adherence to the new SOPs.

Documentation: All improvements were documented in the process guidelines to maintain

consistency across all production batches.

Results:
Reduction in Defects: The tablet weight variation was reduced by 40%, ensuring that each
tablet had a consistent weight within the allowable limits.

 Improved Efficiency: Production cycle time was reduced by 15% due to smoother
operations, fewer interruptions, and more consistent machine performance.
 Cost Savings: Waste generation was reduced by 20%, leading to a reduction in material
costs and an improvement in profitability.
 Regulatory Compliance: The enhanced quality control measures ensured that all batches
passed FDA inspection, meeting the required regulatory standards.
Conclusion:
Pfizer's implementation of Six Sigma resulted in significant
improvements in its pharmaceutical manufacturing process. By
systematically identifying problems, analyzing root causes, and
applying targeted improvements, the company was able to reduce
variability in tablet weight, increase production efficiency, and
maintain product quality. This approach not only ensured
compliance with regulatory standards but also contributed to the
company’s bottom line by reducing waste and improving
operational efficiency.

Future Considerations: Pfizer plans to extend Six Sigma

methodologies to other areas of production, such as the packaging
process and supply chain optimization. Additionally, the company
aims to leverage Six Sigma to improve customer satisfaction by
ensuring consistent product quality and enhancing delivery
timelines.
1. Introduction

Universal Testing Machine (UTM) is widely used in laboratories to test the

mechanical properties of materials, such as their strength, hardness, and elasticity.
The UTM applies loads to a material and measures its response under tension,
compression, bending, and shear forces.
A hydraulic system is a crucial component of the UTM, as it allows precise
control of the force applied during testing. It uses hydraulic fluid under pressure
to operate cylinders that apply the necessary forces to test specimens.

Importance of the Hydraulic System in UTM:

 The hydraulic system allows for the application of large forces in a

controlled manner.
 It ensures accurate and consistent loading during testing.

2. Objective

The objective of this micro project is to understand and analyze the hydraulic
system used in Universal Testing Machines. This report focuses on:

 The components of the hydraulic system.

 The working principle and operation of the hydraulic system.
 The role it plays in material testing.
 The advantages and challenges of hydraulic systems in UTM.
3. Components of the Hydraulic System in UTM

The hydraulic system in a UTM comprises several components that work

together to produce and control force. Below are the key components:

1. Hydraulic Pump:

 The hydraulic pump generates the fluid pressure necessary for the system to operate.
 It is typically driven by an electric motor and pressurizes the hydraulic fluid.

2. Hydraulic Cylinder:

 The hydraulic cylinder converts the hydraulic fluid’s pressure into mechanical force.
 It is the main actuator that applies force to the specimen.
 The cylinder consists of a piston and a barrel. The piston moves in response to the pressurized
fluid.

3. Hydraulic Fluid:

 Hydraulic fluid is the medium through which force is transmitted in the system.
 It lubricates the system and ensures smooth operation.
 Common hydraulic fluids include mineral oils or water-based fluids.

4. Control Valve:

 The control valve directs the flow of hydraulic fluid.

 It is responsible for controlling the movement and speed of the hydraulic cylinder.
 It can vary the direction of fluid to extend or retract the cylinder.

5. Pressure Gauges:

 Pressure gauges are used to monitor and measure the pressure applied in the system.
 They ensure that the forces applied are within safe and accurate ranges during the test.
6. Reservoir:

 The reservoir stores the hydraulic fluid.

 It ensures a continuous supply of fluid and also allows for fluid cooling and filtration.

7. Actuators:

 These are devices that apply force to the specimen. They could be in the form of a gripping or
clamping mechanism.
 The actuator might be a hydraulic clamp or jaw used to hold the material during the test.
4. Working Principle of the Hydraulic System

The hydraulic system in the UTM operates based on Pascal’s Law, which states
that when pressure is applied to a fluid in an enclosed system, it is transmitted
undiminished to all parts of the system.

Working Steps:

1) Pump Operation:

The hydraulic pump is activated, pressurizing the fluid in the system. The fluid is forced
through the pipes into the hydraulic cylinder.

2) Force Application:

The pressurized fluid enters the hydraulic cylinder, causing the piston inside to move.
This movement applies force to the specimen in the form of tension or compression.

3) Force Measurement:

Pressure gauges measure the pressure of the fluid, which directly corresponds to the
force applied on the specimen.

4) Control Valve:

The control valve regulates the flow of fluid, allowing the operator to control the force

applied during testing. The valve ensures that the force can be adjusted precisely.

5) Cyclic Operations:

For tests that involve loading and unloading, the hydraulic system can operate in cycles,
allowing for the testing of fatigue and other mechanical properties.
5. Importance of Hydraulic Systems in UTM

The hydraulic system in a Universal Testing Machine is essential for performing

various material tests, such as:

 Tensile Testing: The hydraulic system applies a pulling force to a material, measuring its
tensile strength and elongation.
 Compression Testing: The system applies compressive forces to materials to test their
resistance to crushing or buckling.

 Bending and Shear Tests: The hydraulic system can apply forces at specific points to test
the material’s resistance to bending or shear.

Why Hydraulic Systems are Important:

 High Precision: Hydraulic systems can apply controlled and accurate forces, ensuring
reliable test results.
 Large Force Application: They can generate large forces required for testing strong
materials.
 Smooth Operation: The system operates smoothly at different speeds, allowing for
detailed analysis.
6. Advantages and disadvantages of Hydraulic Systems in UTM

Advantages:

1. High Force Generation: Capable of generating large forces with compact machinery.
2. Precision and Control: Allows for fine control over force and displacement, ensuring accurate test
results.

3. Smooth Operation: Operates with minimal noise and vibration, ensuring stable performance.
4. Flexibility in Force and Speed Control: Easily adjustable force and speed, suitable for different test
types.

5. Energy Efficiency: Efficient transmission of energy through hydraulic fluid, reducing energy loss.
6. Versatility: Suitable for various types of material tests (tensile, compression, bending, etc.).
7. Self-contained System: Minimal external power requirements, reducing mechanical complexity.

Disadvantages:

1. Maintenance Requirements: Regular checks for leaks, fluid contamination, and component wear.
2. High Initial Cost: Expensive setup due to the cost of hydraulic components.
3. Fluid Contamination and Disposal Issues: Hydraulic fluid can degrade, and proper disposal is
necessary.

4. Potential for Leaks: Seals and hoses can wear over time, leading to fluid leaks and performance
issues.

5. Complex Setup and Calibration: Requires technical expertise for proper setup and calibration.
6. Limited Speed of Response: Slower response times compared to electromechanical systems.
7. Environmental Concerns: Risks of fluid spills and environmental damage if not managed properly.
8. Size and Weight: Larger and heavier compared to other systems, requiring more space.
7. Conclusion

In conclusion, the hydraulic system plays a crucial role in the Universal Testing
Machine, providing precise force application and control for testing the
mechanical properties of materials. The hydraulic system’s ability to generate
large forces, along with its smooth and controlled operation, makes it
indispensable for material testing in engineering and research. Despite challenges
such as maintenance and cost, hydraulic systems are highly effective in ensuring
the accuracy and reliability of tests.