Virtual Gas Network (VGN), a division of CNG Holdings, recently partnered with the Gauteng Department of Infrastructure Development (GDID) and the Gauteng Department of Health (GDOH) to reduce the carbon footprint of 10 state-owned hospitals, which forms part of government’s Green Initiative. By converting their coal-burning boiler systems to cleaner natural gas systems, the hospitals not only reduce their CO 2 emissions but the new systems are more economical to maintain than their coal-burning predecessors.

The government’s Green Initiative seeks to reduce Gauteng’s carbon footprint on a municipal and industrial level. As state hospitals operate on coal-burning energy – the largest contributor to CO 2 – the GDID contracted VGN to convert four state hospitals to compressed natural gas. Once their efficiency had been proven, an additional six hospital contracts were awarded to the company.

A move towards the ‘fuel of the future’
Compressed natural gas is a cleaner, more environmentally friendly energy source that emits less CO 2 , NOX, HC and PM than other fossil fuels. It is a naturally occurring gas that consists of 90% methane, has an ignition temperature of 600° C and is lighter than air which eliminates fuel pooling at ground level – making it one of the safest transport fuels on the market. Furthermore where the quality of coal often varies, natural gas is a consistent and efficient energy source that provides consistent output levels.

From a maintenance perspective, natural gas is a cleaner burning fuel and reduces residue, stench and carbon build up. This will significantly lower the hospitals’ maintenance requirements, extend service intervals and prolong overall equipment life.“When you compare this to dirty and labour-intensive coal-burning processes that require extensive maintenance and cleaning, converting the hospitals to natural gas is not only an environmentally sound decision, but a business one too,” comments Stephen Rothman, Chief Executive Officer, CNG Holdings.

Taking the hassle out of the conversion process
Hospitals typically operate two or three boilers, and as they simply cannot shutdown, VGN is converting one boiler at a time for each hospital. The conversion process includes refurbishing the boilers for gas burning; as well as civil construction to lay manifold high- and low-pressure piping, create bays for on-site trailers and the installation of a containerised pressure regulating plant (PRP).

“We were initially contracted for the gas supply only, but in order to lower the conversion process timeframe we ended up supplying a turnkey solution that included design, boiler conversion, civil works, piping and equipment installation, gas supply as well as the required MHI and SAGA certifications,” adds Rothman. “We also sourced new boilers for the hospitals that were operating outdated ones.” By managing the entire conversion supply chain, VGN was able to convert the hospitals in three to four months. The company has also committed to lower this timeframe to just five weeks for future
conversions with its recently increased equipment stockholding.

A guaranteed supply, delivered to the hospitals
VGN transports its rich source of compressed natural gas via its road-based distribution network to the hospitals in pressurised modular, mobile tube trailers that store between 200 to 240 gigajoules of gas. From there, the 250-bar compressed natural gas is decompressed to the hospitals’ required one-bar pressure in the two-stage PRP that is stationed at each hospital. This ready-for- use gas is then piped directly into the hospital’s energy network to heat its various boilers where the operations personnel merely need to monitor boiler operation, as opposed to its labour-intensive coal-burning counterpart.

VGN’s unique PRP also monitors and controls the hospitals’ gas usage with its sophisticated SCADA system. “What this means for the hospitals is that we undertake the responsibility of a guaranteed gas supply. The intelligent system automatically alerts our team at our Langlaagte-based motherstation who, in turn, transport more trailers of gas to the hospital,” comments Rothman. “Some of the larger hospitals require a new trailer every day, so by placing the onus on us it is a massive benefit for the hospitals, and it also allows us to uphold our guarantee of a constant supply of gas.” The PRP is also equipped with a flow meter to ensure that the hospitals only pay for the gas they use.

Maintaining the new systems
All supplied equipment is controlled by VGN, and so the company undertakes the responsibility of equipment service and maintenance. A certified technician conducts routine inspections on every trailer re-fill to ensure equipment is being operated correctly and efficiently. This on-going preventative maintenance also benefits the hospitals with regards to downtime savings – where its coal counterpart often clogged the boilers and required extensive maintenance.

Government leads the way with its Green Initiative
South Africa has access to large volumes of natural gas, but our usage is much lower that it should be. “By converting these 10 state-owned hospitals to compressed natural gas, and with the inevitable carbon tax looming, the GDID and the GDOH are now setting the example by using more environmentally friendly fuel sources – and are benefitting from the maintenance and cost implications thereof,” concludes Rothman.

VGN was initially contracted to convert Tembisa, Kopanong, Yusuf Dadoo and Discoverers hospitals. After these successful installations, the company was later contracted to convert Steve Biko, George Mukhari, Dunswart Laundry, Pretoria West, Far East Rand and Pholosong hospitals. All will be completed by the end of 2017.

Virtual Gas Network is a division of CNG Holdings – a leading driver and supplier of compressed natural gas for the country’s private and public sector. Industrial Development Corporation (IDC) is a shareholder of CNG Holdings.