Post on 10-Apr-2018
transcript
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“Efficiency Sustainability in
Centrifugal Chillers”
“SUSTAINABILITY IN PRACTICE”
Presented by:
Shailesh Nigam
Daikin Airconditioning India Pvt. Ltd.
AIC Tech 2016
Global Economic Scenario
Energy intensity :Energy consumed for each unit of GDP,
India is:
• 3.7 times that of Japan
• 1.55 times that of US
• 1.47 times that of Asia
• 1.5 times that of World
* (Source – BEE)
Others
5%
Machinery
20%
Lighting
15%
Air Conditining
60%
Average load Distribution in
Industry
A significant part of the
available energy is consumed
by air-conditioning systems.
Need to Act . . . . . .
This is high time we increase our efforts to
2016/2/9
3
Daikin, Globally No. 1 HVAC Co, has been pioneering the
movement with a large array of energy efficient products
• Strengthen Green Building
Movement
• Have more energy efficient methods
of operations
• Have high energy efficient machines
• Have a habit of Energy
Conservation
• Have best utilisation of available
Energy Resources.
green & sustainable Frictionless wonder ……
…….Magnetic Bearing Centrifugal Chiller
5
„Sustainability‟ of Efficiency
No loss of Efficiency due to wear &
tear throughout the life cycle
No Maintenance
Same efficiency on the 1st day of operation
and the last day of operation
Factors which add Inefficiency
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 the
power and also the maintenance.
Frictional losses in Bearings
•Typically Frictional losses in bearings account to about 2 ~3%
additional power
•Bearing wear & tear add to inefficiency & maintenance
6
7
Factors for Inefficiency – Full Load
7
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
8
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.
9
10
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 per Hr. i.e.
8760 kWH in a
year without
running.
10
Efficiency? What about it‟s sustainability
11
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
12
13
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
13
14
The Simplicity of Being Oil-Free
Standard 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 14
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 Stator
World wide uses:
• Maglev trains
• Turbo-molecular pumps
• Compressors – natural gas pipelines, HVAC
• Power generation
• Military applications 15
Magnetic Bearings
Introduction
Thermodynamics
Fluid Movement
Compressors
VFD / Motors
Bearings
Drive Train
Summary
Questions
16
Magnetic bearings and sensors keep the
shaft properly centered
and positioned at all times.
Shaft
Coil
Coil
Coil
Coil
Sensor
Sensor
Sensor
Sensor
How does it work?
• Drive 97% Efficient Synchronous Motor and integrated VFDs
• Magnets Levitate Shaft and Impeller
• Dual Two Stage Impellers and Inlet Guide Vanes
• 5 axis sensors monitor the shaft position consistently.
• Electromagnets Position Shaft 100,000 times/s
• Position held within 0.00002 inches
• Capacitors Provide Coast Down Protection
Touchdown bearing
Magnitude™ WME Compressor Rotating Group
Magnetic bearings
and sensors
(front/rear)
Permanent
magnet brushless
DC motor
(refrigerant-
cooled)
Suction gas
Discharge
Port
Inlet Guide
Vanes
Single Stage
Impeller
Compressor control
integrated
VFD and unit control
contained in
external panel
Rotor – shaft
assembly
HOW DOES IT WORK? Magnetic bearing compressor
Designed for efficiency
Chillers 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 Apr Jan
Jun Sep Oct Nov Dec
May
kW
h c
oolin
g load
Feb
Jul Aug
Example Maximum power
Part Load efficiency holds the key
19
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
20
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
/ t
on
Chiller percent load
30% energy reduction
Fixed speed
Traditional VFD
21
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
/ t
on
Chiller percent load
PM Motor / VFD / Magnetic Bearings
14% energy reduction
Fixed speed
Traditional VFD
Magnetic Bearings
22
Simply “WOW”
In addition to having a significant full and part load
efficiency advantage and being Oil-Free, this compressor:
• Is so quiet, that with typical background noise, you
can’t hear it run.
• Redefines soft-start, pulling only 2 amps vs. the 500
to 600 amps of a typical screw compressor.
• Only weighs 1/5 that of a typical screw compressor
• Because of its Integrated Compressor Design (ICD), it
inherently has a built in VFD - not one that is added on
after the fact.
Daikin Magnitude Chillers
• Two model series, from 100 to 1500 tons
• Magnetic bearing compressor system eliminates the
efficiency losses inherent with traditional compressors
• DAIKIN - First in the chiller industry to utilize
magnetic bearing technology, in 2004.
Magnitude WMC
100 to 400 tons
Magnitude WME
400 to 1500 tons
©2
014
Dai
kin
Ap
plie
d
For
Co
nfi
den
tial
Us
e
Onl
y –
Do
Not
Dis
trib
ute
25
26
Industry-Leading Performance
• Far exceeds ASHRAE 90.1 guidelines
• LEED Energy and Atmosphere Credit 1 (EAC1), Optimize Energy
Efficiency for 1 to 19 points
• Rebates
Model Capacity
tons
Full load,
kW/ton
IPLV
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
For Fixed Speed
Centrifugal Chiller
IPLV 0.44 – 0.51,
VFD Chillers 0.35 –
0.38
39% Energy
Savings Over
Fixed Speed
Centrifugal
Chiller.
14% Energy
Savings Over
Comparable
Standard
Centrifugal
Chiller w/ VFD
26
Efficiency with Standard Centrifugal Chillers
WSC 250 – 1500 TR
WDC 320 – 3000 TR
WCC 1200 – 3000 TR
• Green Refrigerant R134a
• Entire Range ASHRAE 90.1 Compliant
• Positive Pressure Design
• No Purge Unit: No contamination to
environment
• Unique Surge Guard feature
• Unique 3 Tier Control Architecture
• Quiet Operation, Quieter at part loads
• Close Control: + 0.1 oC
• Unique Power Loss Damage Protection
Centrifugal Chillers
• Magnetic Centrifugal : WMC :100 – 400 TR
• Magnetic Centrifugal : WME :400 – 1500 TR
• Two stage Centrifugal : WTC : 600 – 1500 TR
• COP 6.7
• Two stage Centrifugal : WCT : 3000- 6200 TR
Centrifugal Chillers
Chilled Water Control Band
Keeping tight control on “Leaving” chilled water ( maintaining
narrow control band) contributes to energy saving in long term.
Microprocessor controls & Expansion devices play major
role.
Types of Expansion Devices
Float Valve
Orifice plate
Thermostatic Expansion Valve
Electronic Expansion valve
Float Valves & Orifice Plate :-
Have high inertia & can not react quickly to the
changing needs of evaporator. Hence normally
controls the temp. within + / - 0.3 deg C range
Mainly designed for Full Load operation, hence
impart in-efficiencies at part loads.
Chilled Water Control Band
Thermostatic Expansion Valve
•Superior refrigerant flow control
•Superheat taken as feedback
allows precise chilled water control
Up to +/- 0.1 deg C
Electronic Expansion Valve :
• Gives very close control.
• Size limitation limits the use up to
600 TR Competition
Daikin
Set
point
Chilled Water Control Band
Dual advantage
2 Compressors
2 Oil pumps & oil separators
2 Expansion valves
2 Compressor controllers
1 Unit Controller
1 Operator Interface Touch Screen
DUAL COMPRESSOR CENTRIFUGAL CHILLER
Excellent Redundancy
IPLV of 0.43 - excellent part load performance
0.4730.442 0.425
0.363
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
WSC WDC WSC-VFD WDC-VFD
kW/ton
UNIT
IPLV @ ARI - 1000 TONS
Using VFD - Excellent Part Load Efficiency
If Speed of motor is reduced then its lift decreases to square root of actual load.
At the same time there is cubic reduction in power consumption.
innovation Two stage advantage
WTC – 2 Stage Centrifugal
Energy efficiency positioning:
• COP : 6.1 to 6.7
• 600-1500RT
Features:
• AHRI certification
• Highest efficiency Centrifugal chiller in industry
• R134a
WTC centrifugal chiller
Two-stage compressor
Motor
Motor terminals
Suction
Discharge
Interstage suction
(piping connection to the economizer)
Motor driven variable diffuser
(DDC)
Motor driven inlet guide vanes
(IGV)
1° compression stage
2° compression stage
WTC centrifugal chiller
Two-stage compressor
Unique innovative ‘back-to-back’ impeller design, resulting in:
Thrust load reduction by 67%
Improved reliability
Longer bearing life
Conventional 2-stage impeller New back-to-back 2-stage impeller
WTC centrifugal chiller
No extra efforts for a higher cooling effect!
Same power input for 10% more cooling capacity!
Cooling
effect
Flash economizer
Entalpy P
ress
ure
Economized cycle
Conventional cycle
High Efficiency
Mono – Screw chillers
Water Cooled Screw Chiller
• Mono - Screw Technology
• Ultra Low Sound Levels
• Symmetrical Compression Cycle
• Balanced system: More reliable
• Multi Compressor: Built-in Redundancy
• Reliable Bearing Design: Lower Maintenance
• Green Refrigerant R134a
• Multi Compressor technology: Higher Efficiency
•Entire range ASHRAE 90.1 Compliant
Product
Air Cooled Chiller with
new single screw
compressor
Refrigerant R-134a
Cooling
Capacity
Up to 2000 kW ( 570 TR)
(Referred to: water evaporator 12/7°C --- inlet air condenser 35°C)
Circuits 2-3 truly independent circuits (2-3 compressors)
Versions
SE Standard Efficiency
XE High Efficiency
PR Premium Efficiency
Noise
Configurations
ST Standard Noise
LN Low Noise
XN Extra Low Noise
New Range Overview
AWS Series – Air Cooled Chiller
AWS: Capacities and Full load
Efficiencies
500 650 800 1100 1250 1400 1550 1700
Cooling Capacity (kW) 2000 350 950 1850
EER = 2.87
EER = 3.23
EER = 3.50
EER = Cooling Capacity (kW)
Total Power Input (kW)
Total PI= (PI Compressor + PI Fan)
Data referred to:
- evap: in/out water temp.
12/7°C
- cond: inlet air temp. 35°C
CC = 647 CC = 1714
3 C
3 Compressors 2 Compressors
EER = 2.75
EER = 3.00
STANDARD
EFFICIENCY
(AWS SE)
CC = 756 CC = 1858
3 Compressors
2 Compressors
EER = 3.15
EER = 3.30
HIGH EFFICIENCY
(AWS XE)
CC = 821 CC =1390
2 Compressors
EER = 3.35
EER = 3.65
PREMIUM EFFICIENCY
(AWS PR)
The Journey to excel
continues …