oil free magnetic bearing chillers - solar installers | …€¦ · · 2016-07-07oil free...
TRANSCRIPT
Oil Free Magnetic Bearing Chillers
Lloyd DavisESTech Energy Ltd
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Agenda:
• Short History of Oil Free Magnetic Bearing Compressor
• Technical Details of the Magnetic Bearing Compressor
• Smardt History and Vision
• Smardt Products Development and Quality
• Refrigerant Economizer
• Heat Recovery Application
• Smardt Modularity Application
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Prototype 3 1999
Still only 55 TR capacity.
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Turbocor factory, Dorval, Quebec 2000
39,000 sf inc development labs and test facilities
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Manufacturing development 2002
Shaft construction and heat-shrink-fitting.
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THE TURBOCOR REVOLUTION Begins
• Sustainable energy efficiency
• Oil-free
• Variable speed
• Compact
• Quiet
• Less mechanical complexity
• Maintenance “free”
• Greater value, lowest LCC
Oil-free compressor technology
Centrifugal Compressors for Air
Conditioning and Process Cooling
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The first intelligent compressor
The TT300 is the world’s first digital compressor, with:
• Digitally controlled bearings,
• Digitally controlled power electronics,
• Digitally controlled compressor control,
• Digitally controlled chiller control,
• Digitally controlled expansion valve control
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INSIDE THE COMPRESSOR
Oil Free Magnetic Bearings
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INSIDE THE COMPRESSORTwo Stage, Direct
Drive, Centrifugal
Compressor
Stage One Impeller
Stage Two Impeller
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INSIDE THE COMPRESSOR
• 97% Efficient Permanent Magnet
Motor
• Small
• 140hp motor is the size of a
conventional 1hp induction
motor.
• High speed (18,000 to 48,000 RPM
• Refrigerant-cooled, enhancing
longevity.
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INSIDE THE COMPRESSORIntegral Variable Frequency Drive
Since the motor is driven by an
integral VFD, this compressor
requires very low starting
current, drawing less than 2
amps when first energized. No
in-rush.
Well suited for applications
with emergency back-up power
systems.
Reduces thermal stresses on
motor for long-life reliability.
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INSIDE THE COMPRESSOR
• Integral Microprocessor
• Inbuilt pressure and temperature transducers
• Motor and electronics cooling circuit
• Protected DC/DC power supply
• Open communications via modbus enable LON, BACNET and other BMS applications
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TT500
TT400
TT350
TT300
0 210 [kW] 316 [kW] 422 [kW] 522 [kW] 700 [kW]
0 60 [Ton] 90 [Ton] 120 [Ton] 150 [Ton] 200 [Ton]
Nominal Compressor Capacity
COMPRESSOR CAPACITY
Turbocor Family
of Products
~ 15,000SF ~22,500SF ~30,000SF ~37,000SF ~50,000SF
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COMPACT, LIGHTWEIGHT DESIGNWeighs less than 330 lbs. for up to 200 tons
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• Annually check
electronics for tight
and moisture-
sealed connections
• No oil service or oil
disposal
• Replace capacitors
once every ten
years
MAINTENANCE
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• Key aspects of the problem – Traditional “iceberg” model stresses
lowest first cost for chillers– Major ownership costs start after
warranty expires– Chiller companies harvest high
margins from after-market parts and labor pricing
• Oil testing is a major part of long term service contracts
– ENERGY COST another major component
– Chillers evaluated at full load rather than total cost of ownership
– Artificial separation of capex and opex – planning, management and reporting
Barriers to entry created a long lag to market acceptance 2001 - 2010
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OIL FREE TECHNOLOGYOil-free water-cooled chillerTypical screw water-cooled chiller
Fewer Connections
Higher Efficiency
Simplify application and reduce cost
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Oil Impact on Energy Efficiency
For the purpose of the Life Cycle
Cost, it is assumed that 3.5% oil
concentration occurs after 2 years of
operation for flooded evaporator
systems.
“An ASHRAE study determined
that the vast majority of installed
chillers have an excess amount
of oil in the cooling system.”
ASHRAE research study 601
3.5 % of oil in the refrigerant charge
reduces system efficiencies by 8 %
4.9
22.9
16.9
7.1
17.9
12.7
9
16.7
17.8
2.9
0 5 10 15 20 25
1
2
3
4
5
6
7
8
9
10
Percent Oil
Sa
mp
le N
um
be
rs
0
2
4
6
8
10
12
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1 2 3 4 5 6 7 8
%E
ffic
ien
cy L
oss
Percent Oil
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Performance standards have started to reflect the new market paradigm
• ASHRAE 90.1 – 2010:
– Shifts some emphasis away from the traditional “full load”
– Path A (full load) and Path B (slightly lower full load with substantially higher IPLV)
– Delivers 30% energy savings over 90-1-2004.
• New ASHRAE 90.1 – 2015
– Minimizes efficiency differences between screw and OFCC
• New whole-building standard ASHRAE 189 – in public draft Sep 2009 – reflects design approach aligned with LEED.
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• Variable speed and dual compressor control deliver
significant energy benefits, when applied to a wide range of
building types and climates.
• Oil-free design eliminates oil fouling of flooded heat
exchangers, which sustains energy efficiency over the life of
the system.
• Oil-free, magnetic bearing design has lower annual
maintenance and no periodic bearing inspections. Vibration
monitoring is built-in to the compressor as standard.
• Every project is unique, and Life Cycle Costing is a valuable
tool that can be used to look at the particular chiller options
available.
LCC of Oil Free Chillers vs. Conventional
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Oil Free Centrifugal Chillers (OFCC) represents a significant portion of the market
• OFCC represent over
50% of market share in
100 – 400 ton WCC
range
• OFCC represent about
20-25% of all WC
chillers
• Smardt has 1500 in NA
and 3500 total OFCC
chillers
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Lab testing 2001
Compressor mapping a major task for each design iteration.
Smardt have shared history and roots in Turbocor compressor and oil free chiller
development
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Global Smardt Footprint
Montreal,
Global HQ
Stuttgart,
European, HQ
Melbourne
Asia Pacific, HQ
Guangzhou,
ChinaDubai, Sales
Operation
Singapore, Sales
Operation
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Smardt Chillers innovate the Turbocor compressor into the widest variety of
configurations• Comprehensive manufacturing capability
• Most innovative controller
• Water Cooled
• Air Cooled
• Condenserless
• Heat Recovery
• Free Cooling
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Smardt has comprehensive and fully integrated manufacturing capability
Leading OFCC.
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Testing facility capable of performing load test up to 1200 tons.
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Smardt chiller controller graphics package leads the industry, for data acquisition,
intuition and flow
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Oil Free Magnetic Bearing Air Cooled Chillers Lead in Efficiency and Sound
• Full Load EER of 12
• IPLV EER over 22
•Quietest air cooled chiller – less than 85 DBa
• No additional sound wrapping or attenuation
needed
• Low flow condenser
• Free cooling, all air cooled models
• Single circuit
• Dual circuit for models with even qty of
compressors
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A quiet chiller means never having to shout about its performance
The traditional definition of noise is “unwanted or disturbing sound”. Sound becomes unwanted when it either interferes with normal activities such as sleeping, conversation, or disrupts or diminishes one’s quality of life.
Noise pollution adversely affects the lives of millions of people. Studies have shown that there are direct links between noise and health. Problems related to noise include stress related illnesses, high blood pressure, speech interference, hearing loss, sleep disruption, and lost productivity. Noise Induced Hearing Loss (NIHL) is the most common and often discussed health effect, but research has shown that exposure to constant or high levels of noise can cause countless adverse health affects.
Source – US EPA
As a reference ASHARE Fundamentals
Handbook lists various sound power
sources, a voice shouting has a sound
power of 90 dBA
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Smardt Nano coated condenser is another innovation in achieving the lowest total
cost of ownership for Smardt air cooled chillers.Smardt provides an optional nano-polymer coating. This innovative nanotechnology lowers the surface energy of aluminum fins protecting them from corrosion and water damage. Nano coating is only 5µ thin with high heat transfer capabilities. It resists corrosion, salt water, and dust; Salt Spray test results are superior achieving over 3,000 hours resistance and counting.
Repelling water and dirt is a key factor in keeping your air cooled chiller as efficient as the first day it was installed.
Nano coating prevents the adhering of the water droplets on the fin surface, keeping the fin from accumulating dust and water.
On uncoated fins, water droplets accumulate which can restrict air flow, cause pitting, corrosion and produce water spray.
Smardt performed side by side exposure testing in the harsh environment aircraft environment at a local municipal airport to demonstrate the difference in benefits of Nano condenser coatings. After 7 months the Nano coated fin was as clean as the first day, while the uncoated fin showed clear evidence of pitting, corrosion and dust accumulation.
Nano Coated fin Uncoated fin
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Another Innovation - Refrigerant Economizer for Water Cooled
• Only design with multiple compressors and flash economizer
• This feature provides advantages of capacity and efficiency improvement of 5% and 7% at full load respectively when an economizer is installed
• Lower the operating costs
• Available from 200 Tons to 500 Tons capacity now, and up to 1100 TR in the future
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Economizer improvement in efficiency in two typical sizes.
Smardt Model
Eff Max Cap
Additional Features
WA 096.2H 0.643 290 Previous non-econ performance
WA 096.2H ECON
0.606 310 New Econ Performance-Most efficient, stretches capacity above 300 tons
WA 130.2L .618 390 Previous non-econ performance
WA 130.2L ECON
.578 400 Most efficient with econ, 4% more efficient than
WMC 400
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Refrigerant Economizer for Air cooled chiller
• This feature provides advantages of capacity and efficiency improvement of 9% to 12 % at full load respectively when an economizer is installed
• Inexpensive and more reliable than over sizing the unit in order to maintain a lower kw/ton at full load.
• Available from 80 ton to 455 TR air cooled units Tons capacity
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Innovation Continues –Largest Multiple Compressor Heat
Recovery
• Smardt has built chillers
using Turbocor for heat
recovery starting in 2009
• Single and Dual vessel
designs
• Maximum hot water
temperature 110-115F
• Latest project to be
delivered in Mar 2014
• 8 compressors
• 1100 TR Cooling
• 400 TR Heat Recovery
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Smardt Air Cooled Chillers with Heat Recovery
Available in sizes up to 300 tons
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• Integrated pump package
• Single Source Power
• Dual pump design
• Integrated VFD
• Sensorless VFD: no need
to wire any sensor back to
the pump
• Automatic variable flow
control
• Chiller sizes up to 400 TR
• Available Feb 1SmardtModels
GPM Range
Head Range
AC028.1B.4A 90 – 192 25 - 125
AC040.1E.8A 150 – 275 25 - 125
AC054.2B.8A 225 – 384 25 - 125
AC065.2E.10A 270 – 432 25 - 125
AC080.2E.12A 300 – 480 25 – 125
AC086.3B.12A 330 – 528 25 – 125
AC120.3E.16A 360 – 576 25 – 125
AC 150.3E.20A 600 – 960 25 - 125
48”
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Multiple Compressors, no risk
of cross contamination
Multiple Serviceable Expansion
Valves
Multiple circuits, controls and
electrical systems, vessels
Simplified Designs using Oil Free Chillers – N+1 is achieved without adding another chiller.
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Level control chamber directly measure refrigerant in vessel
• Not provided, use a calculated superheat value to determine liquid level
Smardt Competitors
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1800 Trans Canada Highway
Dorval, Quebec H9P 1H7
Phone: (514) 426-8989
Fax: (514) 416-5757
www.smardt.com
•Very Efficient
•Low Maintenance
•Flexible Design
•Extremely Quiet