.

NN

“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 …