LATEST TRENDS IN CHILLER TECHNOLOGIES

By: Arif Hussain, National Product Manager

•Falling Film Evaporator

•Microchannel Condenser

•Current scenario

•Future Scenario

•Elimination of oil circuit

•Elimination of Gears

•Speed Control

• Improved Power factor

Power electronics operational

savings

Levitation and

magnetic bearings

Advancements in Heat exchanger Technology

Change in refrigerant

scenario

Latest Trends in Chiller Technologies

YVAA – YORK Variable Speed Air Cooled Screw ChillerAll these benefits flow from our key technology elements

VSD application can differ significantly:Screws need constant torque w/speed change

5

There are several benefits (beyond efficiency and sound performance) that

come with using a VSD design

VSD provides Soft start with no inrush.

Starting current never exceeds full load amps.

Lowest maximum electricity

demand costs

Eliminates starting thermal

and electrical stress

No motor heating at start

allows for quicker re-start

after power failure

Stand by generator size reduced

% Full-Load

Amps

600

500

400

300

200

100

0

0 10 20 30 40 50

Time (milliseconds)

Solid State Starter

Star Delta Starter

YVAA Chiller

Electrical Benefits

Soft Starting

The VSD in chiller provides 0.95

displacement power factor as standard

Power factor is constant at all loads

Non VSD systems will have reduced

power factor at part load operation – j

or 99% of the operating hours

Many electric rate structures charge

consumer based on power factor or

offer incentives for high power factor

These are based on the average

over the billing cycle

They will be affected by part load

operation

Electrical Benefits

Power Factor

Power

Factor

1

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

20 30 40 50 60 70 80 90 100

Chiller Load (%)

YVAA

Ordinary A/C Screw Chiller

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How can power factor affect the retrofit market?

Power factor influences the total unit current draw (amps)

Lower amps = smaller electrical wire sizes

More importantly … when replacing equipment, the ability to install

more cooling capacity without replacing electrical service

Electrical service retrofit can be a major contributor to cost

Electrical BenefitsPower Factor

8

Compressor & VSD

More than 15,000 YORK compressors operating on VSD in air-cooled chiller applications –All in YCAV & YCIV models shipped since 2004

We use a dedicated VSD platform

Eliminates slide valve and associated inefficiencies, and reduces compressor moving parts by 50% - going to a dedicated VSD design improved reliability

Competitor’s with “add on” VSD stillmust maintain unloading componentsin their compressor design

Our motor is purpose designed foroperating in a VSD system, allowing for maximum reliability and efficiency

1 Circuit per compressor, protectscompressor from oil and liquidmanagement issues

Proven Compressor & VSD

VSD application can differ significantly:Torque varies proportionately to square of speed

Basic Centrifugal Machines Laws

Fan Laws

CFM ~ RPM

Static head ~ RPM 2

HP ~ St Head*CFM

HP ~ RPM 3

Centrifugal Compressor

Refri Flow Rate ~ RPM

Lift ~ RPM 2

HP ~ Lift * Refri Flow Rate

Input Power ~ RPM 3

%RPM %Power

100 100

90 73

80 50

70 34

Major savings driven by application head (p-discharge minus p-suction) reduction

Energy SavingsH

ea

d

Power

Throttling (riding the curve)VFD (varying the speed)

Hea

d

Power

Speed 1

Speed 2

DX Evaporator:

Water outside the tubesRefrigerant inside the

tubesWater connection at sides

Flooded Evaporator:

Water inside the tubes

Refrigerant outside the

tubes

Water connection at ends

Full Load EfficiencyEvaporator

1

3

Hybrid Falling Film Evaporator:

Water is inside the tubes; Refrigerant is outside the tubes

Two bundles of water tubes

Upper bundle is covered in a film of refrigerant

Lower bundle is flooded in the refrigerant

Effi

cie

ncy HIG

H Falling Film

Flooded

LOW DX

LOW HIGHRefrigerant Qty

Full Load EfficiencyFalling Film Evaporator. Best elements of DX and Flooded.

1

4

Hybrid Falling Film Evaporator:

Water is inside the tubes; Refrigerant is outside the tubes

Two bundles of water tubes

Upper bundle is covered in a film of refrigerant

Lower bundle is flooded in the refrigerant

Full Load EfficiencyFalling Film Evaporator. Best elements of DX and Flooded.

“Patented Falling Film design provides the best combination of performance

& refrigerant charge”

Images courtesy

All Aluminum tubes, fins, and header

Higher heat transfer per volume of coil

Increased heat transfer without adding chiller length or weight

Full Load EfficiencyMicrochannel Coils. Lightweight, robust and easily cleaned.

Microchannel Coil Round Tube Plate Fin Coil Tube Cross Section

Microchannel

Round Tube

1

6

Microchannel maintains the high efficiency of your chiller over time All aluminum construction minimizes the opportunity for galvanic (dissimilar metal

corrosion)

The fins do not extend past the tubes making it easier to clean with water spray

Microchannel coils are less deep, allowing more complete dirt removal when

washing

Full Load EfficiencyMicrochannel Coils. Lightweight, robust and easily cleaned.

1

7

Full Load EfficiencyMicrochannel Coils. Lightweight, robust and easily cleaned.

Why microchannel coils?

Fins are secured and recessed

between channels

No galvanic corrosion keeps the

fins attached to the channels

Microchannel coils with R134a are

being used in automobiles for over

a decade

Photo courtesy of Danfoss

Aerodynamic Condenser Inlet Diffuser

Eliminate Losses at Exit of the Discharge Pipe

Uniform Distribution of Refrigerant over Condenser Tubes Better Utilization Condenser Tubes

Efficiency Improvement

Centrifugal Chiller Design Enhancements

Evaporator Spray Header

Spray Header

Hybrid Falling Film Components

Around 100 “spray slots”

Spray Header in Operation

Proprietary V-pattern spray design.

Spray pattern design was tested down to a minimum system head and lift of 1 psid and still delivered good spray performance.

Picture represents spray at minimum pressure (1 psid.)

Centrifugal Chillers

Specify Superior Sustainability

90/10 Copper/ Nickel tubes for Condenser

Heat Exchanger Tube Design

Tube Actual Tube Thickness

Gage Enhanced Section Plain Section (land)

23 0.025" 0.050 - 0.053"

22 0.028" 0.053 - 0.056"

20 0.035" 0.059 - 0.063"

Water

Flow

Tube

Sheet

Tube

Support

Magnetic Centrifugal Chillers

Employ Superior Efficiency

Proven aerodynamic designs from our flagship

YK product line

Permanent magnet motor with active magnetic

bearings

Proven aerodynamics combined with efficient motor technology

“YK Aero” Section

Permanent Magnet Motor

Magnetic Centrifugal Chillers

Driveline Design -- Permanent Magnet Motor

Motor Rotor

Motor Stator

Motor Stator

During operation the rotor is suspended (levitated) and there is no mechanical contact

between the rotor and the bearings

Radial Bearing

Axial Bearing

Touchdown Bearing

The YMC²’s motor rotor is supported on magnetic bearings with “touchdown” ball bearings

for backup

Magnetic Centrifugal Chillers

Driveline Design -- Permanent Magnet Motor

Magnetic Centrifugal Chillers

Acquire Superior Attenuation

73 dBA

YMC²

Telephone dial tone

80 dBA

90 dBAMost centrifugal chillers

140 dBAJet aircraft

Chainsaw

110 dBA

50 dBAAverage home

Conversational speech

60 dBA

Achieved through the use of:• Permanent magnet motor with

active magnetic bearings• OptiSound™ Control

Lowest sound levels on the market. Selections available for all tonnages at 73 dBA

or less (AHRI 575 Rating)

In Paris, parties agreed to hold global temp. rise below 2°C by the end of the century

• 195 countries agreed in Dec. 2015 to develop plans to mitigate global temperature rise – required 5 year review cycle

• Monitoring, reporting and verification of emissions

• Submitted plans include reduction of energy use in buildings and HFCs

• Verification will require energy monitoring of buildings

• $100B to be used for climate mitigation—significant portion will be towards reducing buildings energy consumption

• Potential for “carbon market” with 3rd party verified energy efficiency projects

• 196 countries agreed to phase-down targets for HFC refrigerants (all equipment, not just chillers)

• Final goal is 85% global CO2 equivalent reduction from now to 2047

• Individual countries and regions to decide on specific plans to meet targets

Oct. 2016 agreement in Rwanda to manage reduction of HFCsunder the governance of the Montreal Protocol

Not a phase-out, no impact to existing equipment, servicing or sales today

Montreal Protocol amendment agreementHFC phase down schedule

"Developing Countries - Faster Track"China, African Group, GRULAC (Latin American and

Caribbean Group*), Thailand, Malaysia, Indonesia,

Cambodia, West Asian Countries (except those in

Group 2), Turkey, Pacific Islands, Maldives, Sri

Lanka

"Developing Countries"GCC (Bahrain, Kuwait, Oman, Qatar, Saudi Arabia,

United Arab Emirates), India, Iran, Pakistan, Iraq

"Developed Countries"Andorra, Australia, Azerbaijan, Belarus, Canada,

European Union with its 28 members, Iceland, Israel,

Japan, Kazakhstan, Liechtenstein, Monaco, New

Zealand, Norway, Russian Federation, San Marino,

Switzerland, Tajikistan, Ukraine, United Kingdom of

Great Britain and Northern Ireland, United States of

America, Uzbekistan

Year Total % of Base Line Remaining

2024 100%

2029 90%

2035 70%

2040 50%

2045 20%

Year Total % of Base Line Remaining

2028 100%

2032 90%

2037 80%

2042 70%

2047 15%

Year Total % of Base Line Remaining

2019 90%

2024 60%

2029 30%

2034 20%

2036 15%

The Impact of different refrigerantsB

en

efi

cia

l

Beneficial

smaller

Components

Larger Components

Energy consumption, and the CO2 emissions resulting from power production, accounts for over

95% of a chiller’s lifetime carbon footprint.

95%from electricity consumption

5%

from refrigerant GWP

Greenhouse gas emissions or carbon footprint can be measured through equipment life-cycle climate performance

TOTAL equivalent

greenhouse gas

emissions

Leakage of

refrigerant over

the life of the

equipment

(direct impact)

Energy

consumption

driven by burning

of fossil fuels

(indirect impact)

+ =

Annual kWh used CO2 emissions /

kWh generated

Leaks Escape during service Refrigerant not recovered

at end-of-life

>95% <5%

• Most electricity consumed by the chiller is produced by burning fossil fuels

Global greenhouse gas emissions(Source: US EPA)

When low-GWP provides the best environmental option…GWP is an inadequate measure of impact

Website: www.york.com.sa

YORKKSACustomer Care Center: 920003588

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