Transcript Arctic Cool Oil-Free Chillers The Arctic Chiller Group Remarkable Turbocor Compressor • 100% Oil Free eliminates oil system maintenance costs. • R134a Refrigerant.

Arctic Cool Oil-Free Chillers
The Arctic Chiller Group
Remarkable Turbocor Compressor
• 100% Oil Free eliminates oil
system maintenance costs.
• R134a Refrigerant meets
Montreal protocol and is not
subject to phase-out.
• Magnetic Bearings eliminate
frictional losses.
• One moving part assures long
service life.
• Unmatched Efficiency as low as
.30 kw/ton IPLV.
• Low 2-amp In-Rush Current
reduces installed cost and peak
load.
• Lowest Noise - Only 70 dBa.
The Turbocor Compressor
Soft-Start
(<2amps Inrush)
Inverter speed
control
2 stage centrifugal
compressor
Pressure and
temperature
sensors
Synchronous
brushless DC
motor
Motor and
bearing control
Inlet Guide
Vanes
VFD and Inlet Guide Vane Operation
•
•
•
The Compressors speed adjusts
automatically to match the load and
current operating conditions so that
optimum efficiency is gained.
Primary capacity control is done using
the onboard VFD and only use the
Inlet Guide Vanes to supplement VFD
controls. IGVs prevent surge
conditions at low turndown. IGVs
normally operate at the 110% position.
The slower the compressors, the
greater the efficiency. As speeds is
reduced, energy consumption is
reduced by the cube of the energy
The Magnetic Direct-Drive System
Magnetic bearings and sensors keep the shaft properly centered and positioned at all times.
The rotor shaft is held in position with ten separately controlled electro magnetic cushions
which continually changes in strength to keep the shaft centrally positioned.
The shafts position is monitored with 10 sensor coils whose signal is fed back to a digital
controller. Movements of less than .00002”are sensed and adjustments are made accordingly.
Shaft is monitored and positioned 100,000 / sec.
The Magnetic Bearing System
• Permanently magnetized shaft does
not require electrical power.
• 97% energy efficient
• Uses 0.5% of the energy required for
conventional bearings.
• Eliminate high mechanical friction losses
• Eliminate oil-related heat transfer losses
• Eliminate cost of oil management
systems (controls and hardware)
• Increase equipment life through
elimination of wear surfaces
Leveraging Affinity Laws
Energy Used is Proportional to the Cube of the Speed of the Motor
Two pumps at 50% speed use 25% of the power of one pump at 100% speed
Optimizing the System involves leveraging Affinity Laws and Real-Time
Tracking and Tuning of Components to shift Load to where total PLANT
ENERGY across all related components is reduced.
This is not simple PID loop feedback, but Dynamic Optimized kW Input
8
Variable Speed Factors
• Power is proportional to the speed cubed
• To achieve power reduction, the speed of fans, pumps and
compressors should be reduced at lower loads.
• Emerging VFD plant controllers optimize the technology.
• Flooded designs with water in tubes can limit flow range due to
velocity and laminar flow issues. DX can be better solution in
some applications, but with efficiency loss.
• Cooling tower selections optimized for lower temp and flow. Can
increase installed cost yet reduce operation costs.
Load Profile Reveals Dollars
Why Is Turbocor So Compelling?
Compressor Sizes and Uses
Model
Capacity
IPLV
Turndown
TT300
90 tons
.375
17 tons
TT350
125 tons
.359
28 tons
TT400
150 tons
.336
35 tons
.342
55 tons
TT500
190 tons
Chilled Water Range – 28F to 60F – 134a limited
Condenser Water Range – 50F to 90F
Ambient Range – 10F to 108-110F
Rule of thumb – 12 degrees minimum between LWT and ECT
Compact Size - Easy to Service
125 HP motor is in the foreground.
150 HP Turbocor permanent magnet
motor behind.
Variable-speed, magnetic bearing
and cooling controls.
High Capacity – Smaller Size
Oil-Free Eliminates Piping Complexity
No need for elaborate
piping designs compared
with oil management
systems.
• No traps and risers
• Lower installed costs
• Eliminates leak sources
• Enables centrifugal
chiller with remote
condenser to be placed at
greater distance.
Lowest Cost of Service
• Annually check
electronics for tight
connections
• No oil service or oil
disposal - EVER.
•Replace capacitors
every ten years
Lowest Noise and Vibration Levels
• “Best in Class” low sound levels. No
moving mechanical part touches any part
of the housing or frame to transmit
acoustic energy.
• Tested at 70 dBa at 1 meter with no
sound attenuation. Other compressors, by
comparison, are approximately 80 dBa and
higher.
• Vibration is essentially non-existent.
• The chiller with 5 compressors operating
at full speed only produces 75 DB of sound
at 10 feet., about the sound level of your
television.
What Happens with a Power Outage?
• In the case of a power outage, the compressor is fully protected.
• Within 0.5 of a micro-second, the motor becomes a generator which then
feeds power to the various controls and bearing actuators during a
controlled coast-down. The onboard capacitors have adequate power to
fully support the bearing system during the switch. Capacitors are replaced
every ten years.
•After the compressor comes to a complete stop, the rotor de-levitates
normally onto touchdown bearings. Carbon or roller touchdown bearings
are also used as a back up bearing system to act as a cradle for the rotor
during the off-mode.
• The system then determines if normal power is restored, if YES, the shaft
levitates. If there is a call for cooling, the rotor will then begin to rotate.
The entire cycle from loss of power to normal operation takes about 3-5
minutes.
Automatic Bearing Compensation
This compressor continued to
operate even though this hole
saw slug was embedded in the
1st stage impeller.
The compressor is not designed
to pump hole saw slugs, however
when faced with this problem, the
auto-balance feature was robust
enough to handle the challenge.
The compressor continued to
operate at 35,000 rpm with
this imbalance.
Turbocor Monitoring Software
Turbocor Monitoring Software
The Dramatic Effects of Oil
ASHRAE 601-TRP - Oil contamination can be caused by several factors, including gasket
failure, but the most common cause of oil migration in comfort chillers is the continued
use of a chiller at low loads during the beginning or end of the cooling season. How much
does excess oil in the evaporator degrade performance? Table 1 gives typical ranges.
Oil in Evaporator
Performance Loss
1-2%
3-4%
5-6%
7-8%
2-4% loss
5-8% loss
9-11% loss
13-15% loss
Percent Oil
ASHRAE study reached the same conclusion: “Flow boiling results have been obtained for
newer enhanced boiling tubes with R-134a. This enhanced tube shows a decrease in heat
transfer with the addition of even a small amount of oil throughout various heat loadings. Even
at 1 percent (by weight) oil, the heat transfer coefficient is reduced by 25 percent from its no oil
baseline. At higher oil content, a 30 percent reduction has been typically measured.”
Oil causes 50% of downtime and cost
The Dramatic Effects of Oil
Percent Oil
ASHRAE study shows
average percentages of
oil present in chillers
Efficiency loss in heat
exchangers account for
substantial operation costs
Percent Oil
The Dramatic Effects of Oil
Efficiency loss - %
In the ten chillers
tested in the ASHRAE
study, the average
overcharge of oil in
the system was
12.88%, this equated to
an average energy loss
of about 21%
Percent of oil
High Cost of Chiller Maintenance
Procedure
Record operating conditions (log)
Daily
Weekly
Quarterly
Yearly
X
Check oil levels
X
Check refrigerant levels
X
Check oil return system
X
Check operation of motor starter
X
Check sump heater and thermostat operation
X
Inspect and adjust safety controls
X
Leak check and repair leaks
X
Lubricate motor
X
Check and tighten all electrical connections
X
Megohm motor windings
X
Perform oil analysis on compressor lube oil
X
Replace oil filter and oil return filter/dryers
X
Replace or clean starter air filters
X
High Cost of Oil - Bearings
Stop Operation & provide backup chiller (rental)
Open the compressor and hermetic motor for inspection
In addition to normal annual maintenance, inspection occurs
every 40,000 hrs of operation or every 5 years, whichever occurs
first. 5 times during a 30 year service life.
Shutdown, disassemble motor,
replace bearings, replace seals.
Cost approximately $25,000 each
time 5 times over 30 year service
life $125,000 over life of equipment.
Burnout & oil induced acid eliminated.
ArcticCool Chillers vs Screws
ARI 550/590-1998
Conditions
Leading Screw
WATER COOLED
ArcticCool Chiller with TT300
WATER COOLED
Load
ECW
F/C
LCHW
F/C
SST
F/C
SCT
F/C
COP
kW/Ton
SST
F/C
SCT
F/C
COP
kW/Ton
100%
85/29.5
44/6.7
42/5.6
98/36.7
5.33
0.64
42/5.6
98/36.7
5.56
0.63
75%
75/23.9
44/6.7
42.3/5.8
89.6/32
5. 73
0.6
42.3/5.8
85/29.5
7.31
0.48
50%
65/18.3
44/6.7
42.5/5.9
89.6/32
5.49
0.64
42.5/5.9
72.2/2.2
11.38
0.30
25%
65/18.3
44/6.7
42.8/6.
89.6/32
4.11
0.845
42.8/6
70/21.1
10.86
0.32
IPLV
COP
kW/Ton
5.4
.65
9.55
Conclusion – The Arctic Cool Chiller using the Turbocor TT300
compressor is 45% more efficient than the leading screw compressor
0.36
ArcticCool Chillers vs Screws
ARI 550/590-1998
Conditions
ArcticCool with TT300
AIR COOLED
Leading Screw
AIR COOLED
Load
Air
F/C
LCHW
F/C
SST
F/C
SCT
F/C
COP
kW/Ton
SST
F/C
SCT
F/C
COP
kW/Ton
100%
95/35
44/6.7
35.5/2
122/50
3.19
1.10
35.5/2
122/50
3.08
1.13
75%
80/26.7
44/6.7
36.5/2.5
104/40
4.20
0. 83
36.5/2.5
104/40
4.44
0.79
50%
65/18.3
44/6.7
37.5/3
86/30
5.26
0.69
37.5/3
82.5/28
7.23
0. 48
25%
55/12.8
44/6.7
38/3.5
86/30
3.98
0.88
38/3.5
66.2/19
9.77
0.35
IPLV
COP
kW/Ton
4.6
0.76
6.32
Conclusion – The Air Cooled Chiller using the Turbocor TT300
compressor is 29% more efficient than the leading screw compressor
0. 55
Standard Stacked Design
• Oil-Free design eliminates
frictional losses and high cost.
• Lowest IPLV in the industry.
• Variable-speed Drive.
• Flooded evaporator for thermal
buffer and approach.
• Cleanable condensers.
• NEMA 1 Panels Standard.
• Danfoss Controls Standard
• Marine Water Box Option.
Compact 90 Ton Low Profile
• Sub-cooled Inter-stage and
condensed liquid can increase both
Capacity and Efficiency
• Compact Low Profile Design
Allows for difficult rigging under
existing piping.
Standard Low Profile Design
Standard designs
include stacked, offset
and low profile.
Air Cooled systems to
400 tons.
Split systems are
available.
Multiple Circuits
available.
Condenser-less and
Condensing Units
available.
Water Cooled Chillers
• Up to four compressors
per circuit
• Provides the ability to
use the entire heat
transfer surface even
when using few
compressors, thereby
ensuring close approach
temperatures.
•Water cooled products
from 60 to 1,500 tons.
Low Profile Water Cooled Chillers
• Low Profile Design
• 60 to 1,500 tons
• Removable
Controls Option
• Evap-Condensed
Options
Air Cooled Chillers
• Single Turbocor
compressor per
circuit to 420 tons.
• Assures that
refrigerant is
properly managed
during staging and
load variations.
•Eliminates the
known issues of
refrigerant migration
with single circuited
centrifugal
compressors.
Modular Chillers
• Modules with Scroll, Screw or
Turbocor Compressors. Any size.
• Air cooled, water cooled, freecooling and VFD pumping systems
are available.
Air Cooled Evap Condensed Chillers
New Advances in
Evap Condensing
• Microchannel Coils
• No Carry-Over
• Far Less Make-Up
• Far Less Charge
• Microprocessor
• VFD Fan Option
• Short Payback
Advantages of High-Side Float
• High-Side Float provides
enhanced performance, reliable
operation and system protection.
• Assures sub-cooling section in
the condenser with slightly better
efficiency.
• Any leak over time could result
in suction pressure fault, but
expensive compressors always
receive critical motor cooling.
Training and Certification
• Conducted by most knowledgeable in Turbocor technologies
and application nuances.
• Classes in Toronto, Florida and California
• Includes Compressor, Controls and Chillers
Application Notes
• Heat Recovery – 120 °F maximum. Special high-lift compressor required.
Only works with TT300, no TT400s.
•120 ton TT350 high-lift compressor is now available.
• Controller has settable minimum flows to avoid laminar conditions.
•Operating Envelope. 28°F min at 25% max PG. Glycol applications above 25%
may require DX, not flooded design.
• Staging relief valves required for process applications to increase
temperature stability. Also needed for most glycol and low unloading.
•Differential temp for TT300 is @ 7-8 °F. 10-12°F for TT400. This is the
difference between the entering condenser and leaving chilled water
Practical Application Constraints
• Capital Cost – Premium cost, less competitive with multiple compressors,
new high capacity models to reduce cost-per-ton. Better pay-back with higher
utility rates. DOE 23% prediction.
• Energy Only Emphasis – Lifecycle cost should contain annual maintenance,
U-value, rebuilds, green and LEED compelling story.
• Quality of Utility – Fluctuations of 10% of voltage and 3% of phase can reset
compressors. No harm done. Will not apply where power is poor. 460/3/60 only
– NO 208 Volt compressors.
• Local Remote Service – DTC mandate. No service, no sale. USA fine.
• Temperatures – Less than 25°F and 25% PG. Less than 110° ambient.
Process temp stability need staging valves.
• Rebates – many success stories include utility rebates to reduce pay-back
gap. Retrofit versus new chiller analysis.
Series Counter-flow Advantages
90°F
Condenser
85°F
Evaporator
50°F
44°F
90°F
95°F
Condenser
Evaporator
56°F
50°F
In series-series arrangements, both
evaporator and condenser circuits
are in series and counter current
flow, so the downstream chiller
producing the coldest chilled water
temperature rejects heat to the
coldest condenser water
temperature.
Where Parallel flow requires each
chiller to produce the entire system
Lift, Series-Counter-Flow reduces
the total work for each chiller
resulting in reduced total system
energy.
Lowest Total Cost of Ownership
• Lowest Energy Consumption – low as .30 IPLV
• Lowest Noise Levels – 70 dB compressor
• NO Oil Maintenance Costs
• NO Degradation of Tubing U-Value, Min 8%
• NO Compressor Rebuild Cycles - High MTBF
• Advanced Danfoss Controls, EnergyMonitor.NET
• Qualifies for Deepest Rebates, LEED Points.
• Fuel Cell Project – DC to DC lowest cost
•Reverse flow generator powers compressors.
Questions or Comments…
Questions…
Contacting Arctic Cool
The Arctic Chiller Group
2100 Steeles Avenue
Brampton, ON L6T 1A7
Phone: (905) 789-9988
www.arcticchillergroup.com
Patrick Legare, Vice President, Arctic Cool - 514-702-0600
Mark Rogan, Group VP Sales and Marketing - 540-855-8110
Barry Werts, VP ArctiChill - 800-849-7778