EFFICIENCY SUSTAINABILITY IN CENTRIFUGAL CHILLERS...Magnitude™ WME Compressor Rotating Group...
Transcript of 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
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‘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
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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
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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
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Drive Train Losses – Full Load
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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?
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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
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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.
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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
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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
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0.6
0.8
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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
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0.6
0.8
1
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0 10 20 30 40 50 60 70 80 90 100 110
kW /
ton
Chiller percent load
30% energy reduction
Fixed speed
Traditional VFD
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0
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0.6
0.8
1
1.2
0 10 20 30 40 50 60 70 80 90 100 110
kW /
ton
Chiller percent load
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 . . .