EFFICIENCY SUSTAINABILITY IN CENTRIFUGAL CHILLERS...Magnitude™ WME Compressor Rotating Group...

© DAIPL – October 2012

Jayesh Deshpande

DAIKIN AIRCONDITIONING INDIA PVT. LTD .

EFFICIENCY SUSTAINABILITYEFFICIENCY SUSTAINABILITYEFFICIENCY SUSTAINABILITYEFFICIENCY SUSTAINABILITY

IN CENTRIFUGAL CHILLERSIN CENTRIFUGAL CHILLERSIN CENTRIFUGAL CHILLERSIN CENTRIFUGAL CHILLERS

© DAIPL – October 2012 2

‘Sustainability’ of Efficiency

�No loss of Efficiency due to wear & tear throughout the life cycle

�No Maintenance

Same efficiency on the 1 st day of operation and the last day of operation


Factors which add inefficiency

� Frictional losses in Bearings• Typically Frictional losses in bearings account to about 2 ~3%

additional power

• Bearing wear & tear add to inefficiency & maintenance

� Drive Train Losses:•Includes Motor Inefficiency & Gear Losses

�Oil• Efficiency loss due to oil presence in heat exchangers is between

3 ~ 12% depending on the quantity of oil & type of heat exchanger

• Oil contamination also add up to system in-efficiency

• Oil related accessories such as oil pump, oil heaters add to thepower and also the maintenance.

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0

5

10

15

20

25

30

35

0 2000 4000 6000 8000 10000 12000 14000 16000 18000

frict

iona

l pow

er lo

sses

(%)

speed (rpm)

Speed vs Frictional Power Loss

Loss of Efficiency due to Bearings

Hydrodynamic Bearings

4


Drive Train Losses – Full Load

5


Loss of Efficiency due to oil

Source: The News, 04/15/04, by Jack Sine

Oil-free design would eliminate the performance degradation due oil contamination of the refrigerant

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Impact of oil on heat transfer in the system

•Oil adheres to the tubes

•Reduced surface area therefore less heat transfer and less cooling of the water inside the tubes.

•Reduced cooling therefore reduced system efficiency.

•An oil-free system provides more surface area for boiling enabling more heat transfer and better efficiency.

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Oil accessories & Related Maintenance Standard Centrifugal

Oil YES

+ Oil Heater YES

+ Oil Cooler YES

+ Oil Pump/Starter YES

+ Oil Reservoir YES

+ Oil Filter YES

+ Oil Piping/Valving YES

+ Oil Sensors/Controls

YES

= More things to break, more maintenance,more $

On a standby chiller Oil Heater needs to be kept “ON”

Consumes about 1 KW i.e , 8760 KW.Hrsin a year without running.

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Efficiency? What about it’s sustainability

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Possible loss of efficiency with your high COP chiller after few years of operation

3 years � 3~5% efficiency Loss

5 years � 7~9% efficiency Loss

10 Years � 12 ~ 15% efficiency Loss

NEED TO EMPHASISE ON SUSTAINABILITY OF EFFICIENCY?


Frictionless Magnetic Bearing - Oil free Compressor Technology

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Innovative Compressor Design• Magnetic bearings

– No contact = No frictional losses

• Oil-free design– No contact surfaces– No oil or oil handling

equipment – No loss of efficiency due to oil

contamination

• Permanent Magnet DC motor - Less Drive train losses

VFD

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The Simplicity of Being Oil-FreeStandard Centrifugal Magnetic Bearing

Centrifugal

Oil YES NO

+ Oil Heater YES NO

+ Oil Cooler YES NO

+ Oil Pump/Starter YES NO

+ Oil Reservoir YES NO

+ Oil Filter YES NO

+ Oil Piping/Valving YES NO

+ Oil Sensors/Controls

YES NO

= More things to break, more maintenance,more $

No concerns, no cost

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What is a magnetic bearing?

• A bearing that can hold a load using magnetic attraction forces without requiring lubrication

• Magnetic forces come from coils of wire similar to a motor( electromagnet)

Radial Magnetic Bearing StatorWorld wide uses:

•Mag-lev trains

•Turbo-molecular pumps

•Compressors – natural gas pipelines, HVAC

•Power generation

•Military applications13


Magnetic Bearings

Introduction

Thermodynamics

Fluid Movement

Compressors

VFD / Motors

Bearings

Drive Train

Summary

Questions

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Magnetic bearings and sensors keep the shaft properly centered and positioned at all times.


Magnitude™ WME Compressor Rotating Group

Magnetic bearingsand sensors(front/rear)

Permanent magnet brushless DC motor(refrigerant-cooled)

Suction gas

Discharge Port

Inlet GuideVanes

Single StageImpeller

Compressor controlintegrated

VFD and unit controlcontained in

external panel

Rotor – shaft assembly

HOW DOES IT WORK?

Magnetic bearing compressor


Magnetic Bearing Controls

• High speed controls– Measure position 12,000+

times per second

– High speed power switching to adjust the magnets ( SCR, IGBT)

– Pulse width modulation similar to a fuel injector

•Bearing health data:• Temperature, • Position, • Sensor status

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Industry-Leading Performance• Far exceeds ASHRAE 90.1 guidelines

• LEED Energy and Atmosphere Credit 1 (EAC1), Optimize Ene rgy Efficiency for 1 to 19 points

• RebatesModel Capacity

tonsFull load,

kW/tonIPLV

WME700S 700 0.532 0.306

WME500S 570 0.570 0.335

WME500S 500 0.532 0.312

WMC400D 390 0.604 0.330

WMC400D 360 0.576 0.327

WMC290D 290 0.634 0.328

WMC250D 250 0.633 0.357

WMC150D 150 0.619 0.358

WMC145D 145 0.638 0.370

WMC145S 145 0.668 0.364

14% EnergySavings OverComparableStandard CentrifugalChiller w/ VFD

39% EnergySavings OverFixed SpeedCentrifugalChiller

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Designed for efficiencyChillers are usually used at their maximum power for only a limited period of time in a year.

performance and efficiency in partial load conditions are much more representative parameter for the evaluation of unit energy consumption per year.

IPLV / ESEER – Seasonal energy efficiency ratio

Time

Mar AprJan

JunSep

OctNov Dec

May

kWh

cool

ing

load

Feb

Jul Aug

Example Maximum power

Part Load efficiency holds the key

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Fixed Speed Centrifugal Compressor

0

0.2

0.4

0.6

0.8

1

1.2

0 10 20 30 40 50 60 70 80 90 100 110

kW/to

n

Chiller percent load

Fixed speed

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Induction Motor Vs. VFD Compressor

0

0.2

0.4

0.6

0.8

1

1.2

0 10 20 30 40 50 60 70 80 90 100 110

kW /

ton


30% energy reduction

Fixed speed

Traditional VFD

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0

0.2

0.4

0.6

0.8

1

1.2

0 10 20 30 40 50 60 70 80 90 100 110

kW /

ton


PM Motor / VFD / Magnetic Bearings

14% energy reduction

Fixed speed

Traditional VFD

Magnetic Bearings

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+ + =Reduced

MaintenanceHigh

Efficiency

Sustainability(Performance

&Environmental)

Lower TotalCost of

Ownership

What does a Magnetic bearing Frictionless centrifu gal provide to the owner ?

SUMMARY

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Thank you . . .Thank you . . .

EFFICIENCY SUSTAINABILITY IN CENTRIFUGAL CHILLERS...Magnitude™ WME Compressor Rotating Group...

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