Oil Free Magnetic Bearing Chillers. Lloyd Davis ESTech Energy Ltd

Transcription

1 Oil Free Magnetic Bearing Chillers Lloyd Davis ESTech Energy Ltd

2 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 3

3 Prototype Still only 55 TR capacity. 5

4 Turbocor factory, Dorval, Quebec ,000 sf inc development labs and test facilities 6

5 Manufacturing development 2002 Shaft construction and heat-shrink-fitting. 7

6 THE TURBOCOR REVOLUTION Begins Oil-free compressor technology Centrifugal Compressors for Air Conditioning and Process Cooling Sustainable energy efficiency Oil-free Variable speed Compact Quiet Less mechanical complexity Maintenance free Greater value, lowest LCC 9

7 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 10

8 INSIDE THE COMPRESSOR Oil Free Magnetic Bearings 11

9 INSIDE THE COMPRESSOR Stage One Impeller Two Stage, Direct Drive, Centrifugal Compressor Stage Two Impeller 12

10 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. 13

11 INSIDE THE COMPRESSOR Integral 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. 14

12 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 15

13 COMPRESSOR CAPACITY Turbocor Family of Products TT500 TT400 TT350 TT [kw] 316 [kw] 422 [kw] 522 [kw] 700 [kw] 0 60 [Ton] 90 [Ton] 120 [Ton] 150 [Ton] 200 [Ton] ~ 15,000SF ~22,500SF ~30,000SF ~37,000SF ~50,000SF Nominal Compressor Capacity 16

14 COMPACT, LIGHTWEIGHT DESIGN Weighs less than 330 lbs. for up to 200 tons 17

15 MAINTENANCE Annually check electronics for tight and moisturesealed connections No oil service or oil disposal Replace capacitors once every ten years 18

16 Barriers to entry created a long lag to market acceptance 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 21

17 OIL FREE TECHNOLOGY Typical screw water-cooled chiller Oil-free water-cooled chiller Fewer Connections Higher Efficiency Simplify application and reduce cost 22

18 %Efficiency Loss Sample Numbers Oil Impact on Energy Efficiency Percent Oil Percent Oil An ASHRAE study determined that the vast majority of installed chillers have an excess amount of oil in the cooling system. ASHRAE research study % of oil in the refrigerant charge reduces system efficiencies by 8 % 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. 23

19 Performance standards have started to reflect the new market paradigm ASHRAE : 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 New ASHRAE Minimizes efficiency differences between screw and OFCC New whole-building standard ASHRAE 189 in public draft Sep 2009 reflects design approach aligned with LEED. 24

20 LCC of Oil Free Chillers vs. Conventional 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. 28

21 Oil Free Centrifugal Chillers (OFCC) represents a significant portion of the market OFCC represent over 50% of market share in ton WCC range OFCC represent about 20-25% of all WC chillers Smardt has 1500 in NA and 3500 total OFCC chillers 29

22 Smardt have shared history and roots in Turbocor compressor and oil free chiller development Lab testing 2001 Compressor mapping a major task for each design iteration. 30

23 Global Smardt Footprint Montreal, Global HQ Stuttgart, European, HQ Dubai, Sales Operation Guangzhou, China Singapore, Sales Operation Melbourne Asia Pacific, HQ 31

24 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 32

25 Smardt has comprehensive and fully integrated manufacturing capability Leading OFCC. 35

26 Testing facility capable of performing load test up to 1200 tons. 36

27 Smardt chiller controller graphics package leads the industry, for data acquisition, intuition and flow 37

28 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 40

29 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 41

30 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 43

31 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 49

32 Economizer improvement in efficiency in two typical sizes. Smardt Model Eff Max Cap Additional Features WA 096.2H Previous non-econ performance WA 096.2H ECON New Econ Performance- Most efficient, stretches capacity above 300 tons WA 130.2L Previous non-econ performance WA 130.2L ECON Most efficient with econ, 4% more efficient than WMC

33 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 51

34 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 F Latest project to be delivered in Mar compressors 1100 TR Cooling 400 TR Heat Recovery 52

35 Smardt Air Cooled Chillers with Heat Recovery Available in sizes up to 300 tons 53

36 48 Smardt Models GPM Range Head Range AC028.1B.4A AC040.1E.8A AC054.2B.8A AC065.2E.10A AC080.2E.12A AC086.3B.12A AC120.3E.16A AC 150.3E.20A 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 1 54

37 Simplified Designs using Oil Free Chillers N+1 is achieved without adding another chiller. Multiple Compressors, no risk of cross contamination Multiple circuits, controls and electrical systems, vessels Multiple Serviceable Expansion Valves 55

38 Level control chamber directly measure refrigerant in vessel Smardt Competitors Not provided, use a calculated superheat value to determine liquid level 56

39 Very Efficient Low Maintenance Flexible Design Extremely Quiet 1800 Trans Canada Highway Dorval, Quebec H9P 1H7 Phone: (514) Fax: (514)