improving Cold Chain Competitiveness With...

www.danfoss.com

Improving Cold Chain Competitiveness with

Danfoss Energy Efficiency Solutions

September 2013 | 2Danfoss Automatic Controls

Agenda

• Brief on Danfoss

• Danfoss Business Divisions / Areas

• Danfoss Drive Solutions for Energy Efficiency in HVAC & Refrigeration Systems

• Chiller Compressor Applications of Drives

• Fans and Pumps Applications of Drives

• Retrofit Applications of Drives in Various System Configurations

• Danfoss Drives Value Proposition

• Case Story on Screw Compressor Retrofit


Introduction to Danfoss

�www.danfoss.com


Danfoss Global in brief

� Global Company with Core Competencies in Solutions that sustain Climate and Energy

� 80 years of experience within energy-efficient technologies

� Solutions ready to combat climate challenge

� Global competence center for energy efficiency – rooted in Southern Denmark

� Danfoss Global Organization is Family owned Business


Facts in figures

Sales 34,007m DKK (6 b US$)

Number of employees globally

23,092

Factories, globally 56 in 18 countries

Global Presence >100 countries

Own sales companies, globally

in 51 countries

Top 3 Markets US, Germany & China


Danfoss India

�100% Subsidiary of Danfoss A/S

�Established in 1998

�Employs over 450+

�Corporate Headquarters – Chennai

�Turnover INR 4000 Million

�10 Offices & 60 Partner companies

�Major Investments on R&D, Manufacturing & Talent acquisition

�Engineered Panel Solution Facility

Global Management Meeting • 2010 | 7

Danfoss is recognised as a global trendsetter.

We passionately push boundaries on

results and reputation.

Our Aspiration

Road show • 2010 | 8

Our PromiseWe provide leadership

in our businessesthrough reliability,

excellence, and innovation

– driving truecustomer satisfactionand solutions withinClimate & Energy

Our Promise– to our customers and ourselves

Reliability Excellence Innovation

We commit – we deliver

On -Time delivery

Total quality Everywhere

Value for money

Easy to do business with

Continuous improvement

Value Creation

Focus on true customer needs

Trend-setting

Global Management Meeting • 2010 | 9

Our Behaviour

We will build our business on trust.

We will be innovative in

our ambition to exceed expectations.

We will be global

while respecting local cultures.

We will treasure sustainable results.

| 10Introduction to Danfoss 2013

Climate and energy

The solutions are ready!

� Danfoss is a global leader focusing on energy-efficiency solutions– Well-proven technologies that save energy and costs, and reduce CO2 emissions

� We have built up our competencies since 1933– Making modern living possible through climate and energy solutions used in areas such as cooling food, air conditioning, heating buildings, and controlling electric motors


Solutions ready going forward

� Utilize existing energy efficiency solutions to an optimum and boost economy

� Invest in new solutions based on core energyefficiency competencies, e.g.:

– Solar inverters

– Efficiency components for wind turbines

– Heat pumps

– Cooling systems based on natural refrigerants


Business areas – Danfoss Climate & Energy

� Danfoss Refrigeration & Air Conditioning Controls

� Danfoss Power Electronics

� Danfoss Heating Solutions

� Danfoss Commercial Compressors

� Danfoss District Energy


Climate & Energy

Danfoss Refrigeration & Air Conditioning Controls

� Danfoss Refrigeration & Air Conditioning Controls includes four product areas:

� Automatic Controls

� Electronic Controllers & Services

� Industrial Automation

� Heat Exchangers

� The division provides customers (e.g. OEMs, wholesalers and installers) with solutions on a global scale in the fields of commercial refrigeration, industrial refrigeration, air-conditioning, supermarket refrigeration and industrial automated systems.


Climate & Energy

Danfoss Power Electronics

� The Danfoss Power Electronics division includes three business units:

� Danfoss VLT Drives

� Danfoss Customised Power Electronics

� Danfoss Inverters for Solar and Wind

� The division has supply chain, research and development centers in China, Denmark, United States and Germany and a global network of sales offices offering customers high-quality energy-efficient power electronics solutions.


Climate & Energy

Danfoss Heating Solutions

� Danfoss Heating Solutions offers solutions within:

� Residential Heating

� Hydronic Balancing & Controls

� Burner Components

� Electrical Heating

� Heat Pumps

� Ventilation

� Through sales companies and agents, the division offers solutions for generating, distributing and adjusting heat for optimum indoor comfort and energy savings in residential heating all over the world.


Climate & Energy

Danfoss Commercial Compressors

� Danfoss Commercial Compressors offers efficient and energy-optimized compressor solutions such as scroll compressors, reciprocating compressors for air conditioning, commercial refrigeration and heat pumps as well as condensing units and variable speed solutions.

� The division has global manufacturing facilities spread across three continents, and customers can benefit from 40 years of experience within the development of hermetic compressors.

� The products are used in a variety of key customer applications such as cold rooms, supermarkets, milk tank cooling, residential air conditioners, rooftops applications, chillers, heat pumps and industrial cooling processes.


Climate & Energy

Danfoss District Energy� The Danfoss District Energy Division includes four business units

� Heat Exchangers

� Controls

� Heavy duty stations

� Small Duty Stations

� Danfoss District Energy offers solutions within the control and transfer of heat in district heating and cooling applications. District energy is energy-efficient, it capitalizes on economies of scale, and can be used with both renewable and fossil energy sources by providing an efficient green infrastructure which contributes to achieving individual comfort, while reducing energy consumption.

� Danfoss District Energy is a total supplier of substations and automatic controls for the district heating and cooling market and has sales companies and agents around the world.

Danfoss Energy Efficiency Solution for

HVAC and Refrigeration Systems

VLT® Refrigeration Drive

Danfoss

VLT® Refrigeration Drives

(VLT® FC 103)

For

� Compressors

� Condenser Pumps / Fans

� Evaporator Fans

� Liquid Feed Pumps

� Cooling Towers

�| 20

VLT® DRIVE APPLICATIONS IN REFRIGERATION SYSTEM

�| 21

What Savings VLT® Brings to the Refrigeration System

� Save Energy by System Capacity Modulation

(Reducing System Speed at Part Loads)

� Save Overall System Cost (DG Size/ Compressor

Size/ Cables etc.)

� Brings System Automation

� Safety and Protection

| Confidential/Property of Danfoss Drives A/S | Thursday, 21 August, 2008 | JSP-INSC | 22

Starting currents = FLC

� VFDs allow starting current equal to that of full load current of motor

� Lower Switchgear sizes

� Peak Demand under control

� Smooth start

� Reduction in DG Set capacity requirement


Chiller Compressor Application


Flow ∝ Speed

Energy ∝ Speed

20% Reduction in Speed of

Compressor saves 20% Energy

Physics Law governing Positive Displacement Devices

Law applicable for Reciprocating / Screw Compressors

�| 25

Drives Application on Compressors

�| 28

Reduced capacityMaximum capacity

Slide-Capacity

Slide stopSlide stop

Slide-

CapacitySlide stopSlide stopSlide stop

Active compression part

Screw Compressors with Slider Valve Capacity control

| Confidential/Property of Danfoss Drives A/S | Saturday, 14 September, 2013 | 29

Traditional Capacity Control Screw Compressor – Slide Valve Capacity Control

� Traditional Screw Compressor Capacity Control:• Slide Valve controls compressor capacity• Slide Valve position is determined by

suction pressure PID control• Slow system control due to 300s of dead

band • System delay causes energy losses –

lower temperature operation• Compressor COP decreases with its

capacity `

� 60% of Capacity demands 80% of Energy – 20% energy losses

0

20

40

60

80

100

10 20 30 40 50 60 70 80 90 100

Capacity %

Pow

er

%

Slide

Ideal

Slide valve

curve

Ideal curve

| Confidential/Property of Danfoss Drives A/S | Saturday, 14 September, 2013 | 30

Screw Compressor- VFD Capacity Control

� VFD Screw Compressor Capacity Control• Slide Valve & VFD actuate together for

Compressor Capacity control• VSD speed is determined by suction

pressure PID control• There is no dead band (Ramp up/down

time is max 30s)• Faster system response allows higher

temperature operation• Compressor COP is linear up to 60% of

the capacity• Minimum speed must be maintained

(Motor cooling, Oil pressure)0

20

40

60

80

100

10 20 30 40 50 60 70 80 90 100

Capacity %

Pow

er

%

Slide

VFD

Ideal

VFD Curve

� 60% of Capacity demands 60% of Energy – Linear Energy Consumption

VFD Capacity Control

�| 31

� No in-rush currents at start-up (Max. upto 200% of FLC).

� Drastic Reduction in Backup DG Sets

� Less Power Bills with lower Peak Demand (Improved power factor and Low Inrush Current)

� At least 20% Extra capacity available with the compressor (60 Hz operation)

� Smooth start and low wear and tear of Compressor

� 10% -30 % Energy Savings with Capacity Modulation as per requirement

� Motor Protection and Safety

� Reduced risk of liquid refrigerant in compressor at start-up through use of ”crankcase heater” function

Advantages of Drives on Chiller Compressors

�| 32

Other Benefits

Better System Performance:

� Precise Temperature Conditions maintained by capacity modulation

Flexibility and system simplification:

� Easy to Retrofit

� Smaller Compressors can be used with increased Capacity


Fan & Pump Applications


Flow ∝ Speed

Pressure ∝ (Speed)2

Energy ∝ (Speed)3

20% Reduction in Speed of Pumps /

Fans saves 50% Energy

Physics Laws governing Centrifugal Devices including Centrifugal Compressors

Basic Centrifugal laws applicable for Centrifugal Devices

�| 35

VLT Drives Application On Fans

| 36

Laws of Affinity - Applicable on Centri Compressors /

Fans / Pumps

If Fan Speed is reduced thru VFD to 80% = 0.8

Then

Air Flow Rate ∝∝∝∝ (0.8) = 80%

Pressure Developed by Fan ∝∝∝∝ (0.8 x 0.8) = 64%

Power Consumed by Fan ∝∝∝∝ (0.8 x 0.8 x 0.8) = 51%

Therefore with 20% Speed Reduction, the Power Consumption

is reduced to 50%

| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 37

�Speed Control thru Temp Sensor or RH

Sensor

�Speed Reduction upto 50%

�Automatic Temp. Control thru PID

Controller

�One Drive can run multiple fans (One

drive for One Chamber)

� Precise Temp. conditions maintained

with substantial Energy savings

� Evaporator sync with Compressor to

have capacity Modulation for whole

system

Evaporator Pump Applications


�Speed Control thru Refrigerant Outlet

Temp.


�Automatic Speed Control thru PID

Controller

�One Drive can run multiple fans (One

drive for all Condenser Fans Units)

�Uniform Condenser performance with

substantial Energy savings

�Condenser in sync with Compressor /

Evaporator achieves maximum Energy

Savings

Condenser Fans Applications


�Speed Control thru Condenser Water

Outlet Temp.



Controller

�Uniform Condenser performance with


�Condenser in sync with Compressor /

Evaporator achieves maximum Energy

Savings

Condenser Pump Applications


�Speed Control thru Temp Sensor on

Return Temp. to Heat Exchanger



Controller

� Precise Temp. maintained at inlet of

Evaporator Coils / Receiver with


Brine / Glycol Pumps Applications


�Speed Control thru Temp of Water

Sump



Controller

� Precise Temp. maintained at Water

Outlet from Cooling Tower leading to

stable inlet Condenser Temp. resulting

in substantial Energy savings

Cooling Tower Fan Applications

�| 42

Typical Load Profile of a Refrigeration System & Savings Potential

� Energy Consumption Profile of System components

�Compressor Consumption Is Highest : 60% ~90%

�Typical Savings With VLTs – 10-20%

�Evaporator Fans Consumption is 5~15%


�Condenser is 3~5%


�Brine Pump is 2 ~3%


Compressor

Evap Fans

Condensor PumpsSecondary Pumps

Compressor Evap Fans

Condensor Pumps Secondary Pumps


VFD Retrofit Solutions on Compressors connected in Common Header

� Both the compressor contribute to the

Refrigeration load

� Suction Header is also common for both

Compressors

� Single Suction Pressure sensor is

sufficient

� Cascade Control / Master Slave systems

can be proposed


VFD Retrofit Solutions on Controlled Atmosphere Cold Stores

� VFD Retrofit possible on Compressor

Application

� Evaporator Fans in a chamber can be

fitted with Single Drive for Speed Control

� Inside Temp of the Chamber to be the

feedback for Speed Control


VFD Retrofit Solutions on Cold Stores Chambers

� Single VFD Drive for Multiple Fan Cooler

Units (FCUs) in one Chamber




VFD Retrofit Solutions on Multi-Purpose Cold Stores

� VFD Retrofit possible on Compressor

Application

� Evaporator Fans in a chamber can be

fitted with Single Drive for Speed Control



www.danfoss.com

Danfoss Value Proposition


Easy to Install / Retrofit IP 55 / IP 54 / IP 66 enclosures

�Reliable operation in harsh

environments

�No need for cabinets

� Fast and easy wall mounting


Pack controller for Multiple Compressor Operation

�Minimum energy consumption over a wide

load range

�No external controller requiredCompressor variable speed

Compressor fixed speed



Cascade Control and Master Slave Control

�Cascade Control and Master Slave Control

for Multiple Compressors

�System Optimization in a cost effective

manner

Compressor variable speed




Built-in Cascade Controller

�Replace external controllers

�Multiple Compressor optimized to

save maximum energy


4 PID controller

� Independent closed loop applications

without external controller


ADAP KOOL® Electronic Controls

�Complete and integrated system from fully

Automated Refrigeration Plant

�Customised Control Solutions to suit the

specific application and requirement

� Pre-Loaded Applications provide flexible

control schemes

�Can be extended to provide Web based

Remote Monitoring and Control


Communication via bus systems

� Integration with System Manager / BMS

systems on commonly used Communication

Protocols

�RS485 Port for Communication Protocol

ADAP KOOL®


Inbuilt Dry run and end of curve pump protection

�Additional safety without external

components

80% heat can

be taken

out of Panel

Room

Innovative Design Back Channel Cooling

� Lowest Heat Loss with Efficient Cooling System

� No need for Special Inverter Grade Motors

� Runs the standard Squirrel Cage Induction Motors

� Safe for all Retrofit applications

No need for Special or Inverter Grade Motors

VVCVVC

Conventional PWM Output

VVCPLUS OutputVVC+ TECHNOLOGY OUTPUT RESULT:

•Increased motor life- motor gets 100%

fundamental voltage

•Less heat generation

•Motor works as if it is working on Mains

•No need of inverter grade motor

PWM VFD OUTPUT RESULT:

•Motor does not get 100% fundamental voltage

•Stress on motor insulation and winding

•High heat generation

•Need for higher frame or inverter grade motor

Danfoss drives offer Patented VVC+ technology-Motor friendly


� Danfoss VLT® HVACR Drives Family

� VLT FC 102 – VLT® HVAC Drive

� VLT FC 101 – VLT® HVAC Basic Drive

� VLT FC 103 – VLT® Refrigeration Drive

� VLT FC 051 – VLT® Micro Drive

60

Confidential / Property of

Danfoss Drives A/S

14 September, 2013

JSP/INSC/MKTG

Local Service – Global Expertise

Dedicated HVAC sales organisation in India with skilled specialists

• Spare parts

• Hotline suppport

• Preventative service

• Service around-the-clock

• Global service network

| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 61Presenting Power Electronics

Case Story - VFD Retrofit on Screw Compressor

Successful Integration of VLT FC 102 Drive with Screw Compressor


Installation – Brewery Plant in North India

� Brewery Plant in India

� Screw Compressor Application in Chiller Water / Ammonia Refrigeration System

� Motor KW – 315 KW & Danfoss Drive - 315 KW

� Combined - Primary Ammonia + Chilled Water Application

• Application – Screw Compressor on Process Chilled Water Refrigeration System


Test Results and Energy Savings Calculations

Compressor with Slide Valve without VFD

KW consumed to produce 1 Ton of Refrigeration = 0.94 KW

Compressor with Slide Valve With VFD

KW consumed to produce 1 Ton of Refrigeration = 0.69 KW


Energy Savings Calculations - Conclusion

KW/TR WITHOUT VFD 0.94

KW/TR WITH VFD 0.69

%age DIFFERNECE IN KW/TR WITH VFD 26.51%

AVERAGE SAVINGS IN POWER CONSUMPTION / TR. OF REFRIGERATION LOAD 26.51%

Comparison of Energy Savings for Corresponding Refrigeration Load

173.14

203.93

210.02

225.40

254.75

160.75

176.00

193.69

221.26

239.87

127.25

149.87

154.35 16

5.65

187.22

118.14 12

9.35 14

2.35

162.61

176.28

45.90 54.06

55.67

59.75 67.53

42.61

46.65

51.34 58.65

63.58

0.00

50.00

100.00

150.00

200.00

250.00

300.00

184.73 217.57 224.07 240.47 271.79 171.50 187.78 206.65 236.07 255.91

Refrigeration Load TR

KW Consumption.

KW Consumption without VFD KW Consumption with VFD Savings in KW


Calculated Energy Savings Projections - ROI

Parameters Calculations Formulae Values

AE Calculated Average Savings per Hour Rs. 436.60

AE Assuming power saving to be Rs 300 considering the load and season variation. Rs 300.00

RD Running Hours / day (Assumed) 16

Y Running Days / Year (Assumed) 300

H Total Running Hours per year RD x Y = H 4800

D Total Average Savings H x AE = D 1440000

C Cost of VFD System 1000000

ROI Return on Investment in Years ROI = D / C 0.69 Years


Energy Savings Projections (Return on Investment)

Important Points

� Even if the calculated ROI Projection is doubled, it is close to one year for the VFD system to pay back for the investment

� All in all, a very good case of enhanced Energy Savings using the Drive on Compressor Motor and very high return on Investment.

| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 67

�Questions

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