HVAC Systems for Rail Vehicles. Area to fit in a picture - facultative. March 8, Knorr-Bremse Group

Transcription

1 HVAC Systems for Rail Vehicles Area to fit in a picture - facultative March 8, 2011 Knorr-Bremse Group

2 Agenda Merak Overview Product Overview Overview of the design process Transit Industry specific requirements Mechanical Thermal Refrigerant Overview 5 min 10 min 15 min 30 min 15 min Knorr-Bremse Group 2

3 The Knorr-Bremse Group Knorr-Bremse Group

4 Knorr-Bremse at a glance Founded 1905 Experience Independence 100 years of Innovation Family owned Employees * Sales R&D expenses Investments Locations Two Main Divisions Product portfolio 2,761 Mrd. EUR* 5,5 % vom Umsatz* 101 Mio. EUR* More than 65 locations in 25 countries Systems for Rail Vehicles, Systems for Commercial Vehicles Global market- and technological leader with two main pillars: Brake systems for rail vehicles + On-Board Systems Brake systems for commercial vehicles + torsional vibration damper *Source: Annual Report 2009 Knorr-Bremse Group 4

5 More than 65 Knorr-Bremse sites in over 25 countries America Europe/Africa Asia/Pacific Brazil Canada Mexico USA Belgium Germany France UK Italy Netherlands Austria Poland Romania Sweden Switzerland Spain Czech Republic Turkey Hungary South Africa Australia China India Japan Russia South Korea Knorr-Bremse Group 5

6 Corporate Vision of Knorr-Bremse Systems for Rail Vehicles Brake Systems Air Conditioning Systems Automatic Door Systems Worldwide Worldwide system-partnership Strong Strong commitment commitment to to innovation innovation Broad, Broad, safety safety related related product product range range Superior Superior services services Best Best in in class class performance performance Other On-Board Systems (e.g.) Platform Screen Doors Information Systems Knorr-Bremse Group 6

7 Knorr-Bremse the competent system supplier (Example: Metro Madrid S 9000) HVAC Systems: Roof-mounted unit Power Supply & Distribution: Contactors: LTC250/1P LTHS800/1P LTHS800/2P Door Systems: RLS E2 Brake Systems: Air Supply Brake Control Bogie Equipment Knorr-Bremse Group 7

8 Knorr-Bremse the competent system supplier (Example: High-Speed EMU CRH3) HVAC Systems: Roof-mounted unit Windscreen Wiper Door Systems: DET Brake Systems: Air Supply Brake Control Bogie Equipment Knorr-Bremse Group 8

9 Knorr-Bremse the competent system supplier (Example: Alstom Citadis) HVAC Systems: Roof-mounted unit Power Supply & Distribution: Contactors: LTHS Resistors Door Systems: RLS Brake Systems: Hydraulic Brake Control Bogie Equipment Knorr-Bremse Group 9

10 Applications MT Metros Covering all types of vehicles Madrid Stockholm Hong-Kong Singapore Fortaleza Guangzhou Porto Commuters Tramways Cabins More than units running (NY M-7) CIVIA Train 2000 Oresund LD Citadis BCN Boston Porto Madrid High Speed More than 200 different designs Double Decker More than 200 different designs ICE-Velaro Lanzadera Korea T TGV Rio Tajo Knorr-Bremse Group 10

11 References in Metro Projects LIRR M7 (New York MTA) Metro-North Railroad M7 (New York MTA) WMATA 2K, 3K, 5K, and 6K Series (Washington, DC) CTA 2200 (Chicago) CTA 2600 (Chicago) CTA 5000 (Chicago) Vancouver Knorr-Bremse Group 11

12 References in LRV Projects JFK (New York / USA) MBTA No. 8 Cars (Boston / USA) PAAC (Pittsburgh / USA) Vancouver BCT (Canada) Hiawatha (Minneapolis / USA) Knorr-Bremse Group 12

13 Product Overview Merak is is one of of the world leading company specialized in in the design, manufacture and maintenance of of Air Conditioning Systems (HVAC) only for railway vehicles Focused on railways since more than 40 years Covering all types of railways vehicles HVAC units running in the 5 continents Experts in every type of climate Knorr-Bremse Group 13

14 Main Components of Transit air conditioning system Knorr-Bremse Group 14

15 Duct work as necessary Knorr-Bremse Group 15

16 Exhaust air Unit Exhaust air unit Knorr-Bremse Group 16

17 Overpressure protection damper system Knorr-Bremse Group 17

18 Overpressure protection damper system Technical Development Entering tunnel Closing dampers Crossing tunnel at 200km/h Outside pressure Leaving tunnel Inside pressure Opening dampers p (Pa) ,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 t (s) Knorr-Bremse Group 18

19 Passenger area HVAC system Knorr-Bremse Group 19

20 Merak Overview Design Process Knorr-Bremse Group 20

21 Transit Industry Requirements Shock and Vibration Mobile Environment Mechanical Size and Weight Environmental Sealing Maintainability Knorr-Bremse Group 21

22 Mechanical Requirements Shock and Vibration Requirements -Direction of travel -Vertical Direction +/- 8 g s +/- 3 g s Roof mounted units must be able to support 250 lbs - Covers must support workers Roof mounted units on/in the roof - Mounting for all accelerations - Maintain sealing to the car - Provide access for maintenance - Quick removal and replacement of unit Knorr-Bremse Group 22

23 Example of Frame design Knorr-Bremse Group 23

24 FEM (Finite Element Modeling) Stress Analysis Static Calculation Knorr-Bremse Group 24

25 Requirements- Vibration Testing Knorr-Bremse Group 25

26 Acoustic Noise Testing 6m Knorr-Bremse Group 26

27 Transit Industry Requirements External Conditions 105/120 F Thermal Interior Conditions Temp, humidity System Design Passenger Loading Airflow and Control Knorr-Bremse Group 27

28 Transit Industry Requirements Performance External Conditions based on Transit Authority Specification Specification usually considers modified ASHRAE Data for equipment location Additional requirements for the following: Tunnel Conditions Passenger load conditions Station stops and door configuration (fresh air infiltration) Internal Heat loads (lights, motors, electrical) Fresh air infiltration Tunnel conditions station stops and passenger loading Specification typically dictates the HVAC unit rating conditions Knorr-Bremse Group 28

29 Transit Industry Requirements Examples The control system shall be designed to automatically maintain the car interior temperature, including both cabs, at the specified conditions, under any ambient temperature from 22 F (-6 C) to 115 F (46 C), with a condenser air entering temperature of up to 125 F (52 C), with or without variable internal heat loads such as passengers, motors, lights and solar gain, when the auxiliary power supply (APS) is at its nominal voltage. Knorr-Bremse Group 29

30 Transit Industry Requirements Examples Washington Metro Requirements (WMATA) The Heating, Ventilation, and Cooling system (HVAC) shall provide automatic control of interior temperatures as required herein at any ambient temperature from -18 F to +105 F at the specified wet bulb conditions, with or without solar gain or variable internal heat loads such as passengers, miscellaneous electrical apparatus, and lights. Unless otherwise specified herein, the HVAC shall be powered by the Auxiliary Power System (APS) and shall start and operate within the voltage and frequency ranges specified in Section 1.3 and Section 17. Knorr-Bremse Group 30

31 Introductions to Load Calculations Load calculations, used for equipment sizing Standard developed over years of experience Vehicle parameters (Transmission gain) Passenger heat gains Solar gain, window parameters Vehicle, ISO, and ASHRAE data used Company developed Software for Calculation Tailored for Rail Vehicles Verified with historical data Provides quick and effective method for calculations Results are used for equipment sizing (Coils, compressors, blowers) Knorr-Bremse Group 31

32 Load Calculation Output - Overview Parameter Inputs Heat Gain Calculations Solar Transmission Occupants Internal equipment Results Knorr-Bremse Group 32

33 Load Calculation - Overview Outside: Baseline: 41 o C (11%RH) Tucson Spec Option 1: 41 o C (25 %RH) Option 2: 41 o C (50% RH) Passengers: Baseline: 115 (AW2) Option 1: 154 (AW3) Knorr-Bremse Group 33

34 Load Calculation - Overview Based on Vehicle Parameters (LxWxH) Transmission gains from Data Base Internal gains 115 Passengers 14 kw (50,000 BTU/hr) Knorr-Bremse Group 34

35 Load Calculation Key Parameter Output Total Cooling Required per Car (11 tons) Total Airflow per Car Knorr-Bremse Group 35

36 Load Calculation Key Parameter Output Knorr-Bremse Group 36

37 Systems Design System Overview - HVAC Design Parameters example System Parameters Unit Capacity: 9 tons (108,000 BTUH) Condenser Inlet Temperature: 110 F (115 F max ambient air full capacity cooling) Fresh Air Inlet Temperature: 100 FDB / 75 FWB Return Air Temperature: 75 FDB, 62 FWB (50% RH) Evaporator Air Volume : 2400 ACFM (fresh air 600, return air 1800) Operating Voltages Power : 208/3ph/60 Hz Control: 37.5 VDC nominal / 120 VAC (26 VDC 42 VDC) Knorr-Bremse Group 37

38 System Overview - General Design Features example Design Features Unitized Roof mounted package Stainless steel support frame with aluminum walkable covers and access doors Refrigerant control compartment easily accessible from the inside of the vehicle Control Panel, pressure controls, gauge ports, sight glass within return air plenum Microprocessor control Cooling modes from 50 F to 125 F Refrigerant R-134a Hermetic Scroll Compressors PTE access through car locker Knorr-Bremse Group 38

39 Mechanical System Schematic Piping The design and selection of components begins! Knorr-Bremse Group 39

40 Transit Industry Requirements Performance Design performance will be verified in laboratory (chamber testing) Performance based on design point conditions Example based on Dallas Specification The control system shall be designed to automatically maintain the car interior temperature, including both cabs, at the specified conditions, under any ambient temperature from 22 F (-6 C) to 115 F (46 C), with a condenser air entering temperature of up to 125 F (52 C), with or without variable internal heat loads such as passengers, motors, lights and solar gain, when the auxiliary power supply (APS) is at its nominal voltage. Note: Performance data will be established at 115 F! Knorr-Bremse Group 40

41 Transit Industry Requirements Power and Power supplies Electrical/software Train communication Onboard Power Rail Power Diagnostics Inverter Power from 600 vdc Knorr-Bremse Group 41

42 Typical System Interface Electrical PTE Air Conditioning Control Unit ACCU RS232 HVAC System 208V AC / 37.5V DC / 24V AC Control Panel Logic CN4 CN1 CN2 RS232 CN3 Car Cabinet Power Supply 280V AC 3Phase 120V AC 1Phase Layover Heat Thermostat HVAC Fault Floor Heater Control Panel Floor Heater Fresh Air Circuit Duct Air Sensor Return Air Sensor Knorr-Bremse Group 42

43 Typical System Interface Electrical F- End F- End 700 Vdc (OH Heater) Low Voltage (control, sensors, feedback) 230 Vac 3 (compressors, blowers, fans) HVAC Control Box 700 Vdc in Local Car (electronics, contactors, breakers, ect) 230 Vac 3 Other Car Train Lines, Ethernet Low Voltage In Knorr-Bremse Group 43

44 Transit Industry Requirements Full Manuals Manuals, training Parts Catalogs Diagnostic tool (computer) Bench Test Equipment Knorr-Bremse Group 44

45 Manuals Knorr-Bremse Group 45

46 Special Tools and Test Equipment Bench Test Equipment Off-car testing of ACCU boards Automatic test routine ACCU board testing and troubleshooting Verifies I/O and processing functions Displays fault information Knorr-Bremse Group 46

47 HVAC Technology and Innovation CFD Computational Fluid Dynamics Aerodynamic study of condenser air-flow Knorr-Bremse Group 47

48 HVAC Technology and Innovation CFD Computational Fluid Dynamics y = 1,8 m y = 1,65 m 1 2 Air discharge y = 1 m Comfort parameters Knorr-Bremse Group 48

49 Merak test facilities Test Facilities: Acoustic tools Intensimetry Acoustic photography Knorr-Bremse Group 49

50 Merak test facilities Test Facilities Airflow test (equipment & Mock-up) Thermodynamic Laboratory Extreme conditions testing Refrigeration Cooling Capacity Test Control Equipo de Ensayo Software de Control Diseñado por Merak en base a la herramienta LabView Control Humidificadores Cálculo de Capacidad: - Método Entálpico - Método de Potencia Registro de Medidas Temperatura aire seca y húmeda-presión aire-consumos eléctricos Presión refrigerante-temperatura refrigerante Control Sala Interior Consumos Eléctricos Control Sala Exterior Knorr-Bremse Group 50

51 Typical PTU Interface Knorr-Bremse Group 51

52 Transit Industry Requirements Refrigerants R- 22 R-134 a R-407c Future?? Knorr-Bremse Group 52

53 Transit Industry Requirements Refrigerants Refrigerant Past Present Future R-22 R-407c R-134a R R-410a 2 HFO-1234yf 3 1. Under investigation, working pressures extremely high 2. Working pressures are high 3. Poor flammability characteristics Knorr-Bremse Group 53

54 Knorr-Bremse Group 54