Improving Rotary Screw Compressor Performance using Variable Speed Drives. John Cosner, JCI/Frick

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1 Improving Rotary Screw Compressor Performance using Variable Speed Drives John Cosner, JCI/Frick

2 A Global Energy Situation.

3 Efficiency In The Engine Room Optimum Constant 100% Cap. Constant 100% Cap. 30% Cap. S.V. Loaded Better Constant 100% Cap. Constant 100% Cap. Constant 30% Cap. Inefficient Constant 100% Cap. Constant 70% Cap. Constant 60% Cap.

4 Compressor Facts Often the most concentrated and largest consumers Most new installations use rotary screw compressors. At least one compressor will go to a part load condition.

5 Constant Torque / Variable Horsepower Screw Compressors Torque and Power 100% 80% 60% 40% 20% Constant Torque 0% 0% 20% 40% 60% 80% 100% Horsepower = % Speed 460V / 60Hz = 7.67V : 1Hz Speed Horsepower Torque

6 Full Load Power = 500HP / 375KW FLA = % Capacity (by speed) Voltage = 460vac HP = 175 Amps = 203 VSD 35% Out 21 Hertz 1260 RPM 580 Amps 132 KW Voltage = 161Vpwm HP = 175 Amps = 580 Motor

7 Variable Torque / Variable Horsepower Pumps & Fans 100% Torque and Power 80% 60% 40% 20% 0% Horsepower Torque 0% 20% 40% 60% 80% 100% Torque = % Speed² Speed Horsepower = % Speed³

8 Part Load Approximately 6:1 CR Throttling, Step Loading (Poppet), Slide Valve w/var. Vi, VFD w/var. Vi and Ideal % Full Load Power Throttling Poppet Slide Valve VFD Ideal Eff. 0% 20% 40% 60% 80% 100% % Capacity

9 Improved Part Load Efficiency Solution Capacity 20% -100% (720 RPM 3600 RPM ) 100% Slide Valve Base Loaded, Capacity 100% 3600 RPM 100% Slide Valve The improvement in part load efficiency will vary based on Compression Ratio Minimum Speed Volume Control

10 Compression Ratio (CR) 194.8psiaD / 48.7psiaS 4:1 CR 194.8psiaD / 19.48psiaS 10:1 CR Example: Improvement at 40% capacity by speed over 40% capacity by slide valve 4:1 CR = 19% Improvement 10:1 CR = 33% Improvement

11 Minimum Speed Minimum speed established by the limitations of the: compressor motor oil type refrigerant. NH³

12 Compressor Minimum Speed Sleeve bearings 1800 rpm. Rolling element bearings 720 rpm Viscosity required at 1800rpm is 11cSt. Viscosity required at 720rpm is 18cSt. Speeds below design limits may cause a mixed film or boundary lubrication condition.

13 Oil & Refrigerant 20 F (-6.5 C)SST 720 RPM Minimum 10 F (-12 C)SST 1250 RPM Minimum 20 F (-6.5 C)SST 1500 RPM Minimum

14 Motor Minimum Speed An issue of bearings and heat rejection. Air-flows at speeds below 50% speed may not be adequate. Check with manufacturer for minimum speed. Motor stator temperature protection is now required (NEC 2005). Fractional HP Squirrel Cage Fan/s Ensure Adequate Air Flow At All Speeds

15 Variable Volume Control With VSD at part load Vi stays ideal Vi Vi at part load by slide valve % Capacity

16 % Capacity to % Slide Valve Position

17 Energy Part Load Slide Valve w/variable Vi VFD w/variable Vi HP to $$$ - 10HP may cost over $5,200 annually (.08 KWH).

18 20 F (-6.7 C) SST / 95 F (35 C) SDT 4.06:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies Horse Power S.V. Control VFD Control 107 HP 52 HP 19 HP 0% 20% 40% 60% 80% 100% 650HP % Capacity

19 20 F (-6.7 C) SST / 75 F (24 C) SDT / 2.9:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies Horse Power S.V. Control VFD Control 62 HP 31 HP 9 HP 0% 20% 40% 60% 80% 100% 475HP % Capacity

20 -40 F (-40 C) SST / 95 F (35 C) SDT / 18.75:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies Horse Power S.V. Control VFD Control 137 HP 82 HP 26 HP 0% 20% 40% 60% 80% 100% 420HP % Capacity

21 -40 F (-40 C) SST / 75 F (24 C) SDT / 13.45:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies Horse Power S.V. Control VFD Control 102 HP 60 HP 0% 20% 40% 60% 80% 100% % Capacity 18 HP 335HP

22 Typical VSD Operation Slide Valve Unloaded NH3 Capacity Control Strategy Percent Slide Valve 100% 90% 80% 70% 60% Speed SV 50% 40% 30% Speed 20% 10% Off Run 0% 0% 20% 40% 60% 80% 100% Percent Speed

23 Typical VSD Operation Slide Valve Loaded NH3 Capacity Control Strategy Percent Slide Valve 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Off SVSpeed Run Speed 0% 20% 40% 60% 80% 100% Percent Speed

24 Typical VSD Operation with Standby Mode (Vyper ) Capacity Control Strategy Percent Slide Valve 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Stand-by Speed at 100%SV Run Speed Speed Up To 2 Up HrsTo 2 Hrs. 0% 20% 40% 60% 80% 100% Percent Speed

25 Economizing Econo. Improvement of HP/TR -40F/95F HP/TR Non E SV Econ VSD Non E VSD Econ SV Tons

26 Controlling The VSD Manufacturers Controller To Be The Supervisory Control Low Oil Flow High Motor Amps High discharge Pressure Low Mass Flow The PLC Controls The Speed But Is Routed Through The Package Mounted Controller

27 VSD Control with Quantum LX Capacity Control Setup

28 Motor & Drive Setup

29 Skip Frequencies Speed trend line

30 Can I Retrofit My Existing Equipment??? VSD?

31 Retrofitting Existing Equipment For Energy Savings Ensure the VSD is constant torque. Motor is inverter duty rated. Minimum speed is identified. Ensure environment is adequate. Total cable distance between drive and motor is within spec. Controller is able to protect the compressor as well as control the drive.

32 To VSD or Not To VSD? Qualifying Expense Through Savings (ROI) Total Load Profile 1. Hours of Operation? 2. Compression Ratio? 3. Cost per KWH? 4. Part Load Profile? What is My Part Load Profile? How Do I Accurately Get This Information? Items 1-3 Are Easy

33 Quantum LX Load Profile Screen

34 The VSD Energy Savings Calculator The Load Profile Data is Entered Payback in 1.8 yrs.

35 What About Step Loading Machines?

36 Vyper Retrofit At JCI-Frick in Waynesboro, PA

37 In Conclusion.. When Properly Applied, VSDs On Rotary Screw Compressors Can: Lower Energy Usage & Cost Enhance Economizer Boost Remove Setpoint Over-Shoot Provide Quicker Response To Load Fluctuation Keep Capacity Slides Fully Loaded Reduce Maintenance Costs Reduce Noise Levels Properly Applied Is The Key! Thank You!

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