TT300 Centrifugal Compressor www.turbocor.com A little history please! 1993: Turbocor started as an R&D company in Australia with an international team of designers and engineers working to bring high efficiency compressor technology to heating, ventilation, air conditioning and refrigeration's (HVACR) middle market. 11 years in development. $ 50,000,000.00 in research & development costs. 1999: Turbocor moves to Montreal to become a North American operating business with corporate headquarters, stage-one manufacturing plant, testing and engineering labs, and training facility. 2004: Danfoss Turbocor form a 50/50 joint venture called 1
In 1993,the Turbocor development team was given some simple goals: To develop a small centrifugal compressor that: hd had a capacity in the 60to 90ton range, was environmentally friendly, did not use a lubricant, was direct drive, was as small as a matchbox, was 100% efficient, was silent, had all its component technologies fully integrated, weighed less than 1lb.. X X X X Not totally, but on a few points: It is rated at 60 to 90 ton It operates on R134a It eliminated lubricants by using magnetic bearings We failed. It uses a high speed synchronous permanent magnet direct drive motor It is very small compared to its competition (25-30% of the size) but is not as small as a matchbox It is the most efficient mid-size compressor in the world, (IPLV.406) however we have not hit 100% efficiency yet It is very quiet (70 dba at 1.5 meters) however it is not silent It has a fully integrated control system including bearing and inverter control It is light weight, weighing 265 lbs, which is about 25% the weight of its competition however it does weigh more than 1 lb. 2
The first Turbocor Compressor The compressor has undergone extensive life cycle and beta testing 3
Turbocor Award Winning Technology: The ASHRAE/AHR Expo s Energy Innovation Award 4
The Canadian Energy Award The U.S. EPA s Climate Protection Award 5
U.S. Green Building Council www.turbocor.com R134a R134a was chosen as the refrigerant because of: its high efficiency, Its environmental friendliness, its proven acceptance in the market place, its availability, and dthe fact tthat titi is not a blend, 6
Important Aspects of Compressor Selection Highly Reliable Simple High Efficiency At Full Load And Part Load Reduced Maintenance Cost Capacity Modulation Infinite Stages of Modulation Wide Range of Stable Operation Quiet Four Types of Compressors Reciprocating Scrolls Screws Centrifugals 7
The Turbocor Compressor at a Glance Inverter Speed Control 2 Stage, Direct Drive, Hermetic Centrifugal Compressor Permanent Magnet Motor Inlet Guide Vanes Motor and Bearing Control Reliability 8
Why a centrifugal compressor? It offers highest aerodynamic compression efficiency With variable-speed drive, it provides best part load efficiency The compressor has a single moving part It has high speed capability, thus reducing its overall size It has a well-proven long life in central plant applications Why magnetic 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 More durable than hydrostatic, foil or air bearings 9
Magnetic bearing system 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 who s signal is fed back to a digital controller. Back up bearings are fitted should a catastrophic failure occur. Direct Drive Centrifugal with Magnetic Bearings Magnetic bearings and sensors keep the shaft properly centered and positioned at all times. 10
What is IPLV? Integrated Part Load Value IPLV is a rating standard developed by ARI (American Refrigeration Institute) to determine the efficiency of a compressor over a range capacities. The old standard only compared compressor at full load. However, compressors rarely run at full load. This new standard takes that reality into consideration. Integrated Part Load Value Weighted average values % load 100 75 50 25 1992 standard 17% 39% 33% 11% 1998 standard 1% 42% 45% 12% ARI Standard 550/590-98 11
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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 Magnetic bearing system The shafts position is consistently monitored by the 5 axis proximity sensors, these signals are sent to the digital controller which then sends a command to the 5 separate pulse width modulators (PWM), repositioning the shaft on a continual basis. Movements of less than.00002 are sensed and adjustments are made accordingly 13
Magnetic bearing system Accidents happen: Auto-balance compensation is a unique part of the Turbocor bearing system. In this case, the compressor continued to operate safely even though this hole saw slug was embedded in the 1 st stage impellor. 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. Power outage? In the case of a power outage, the TT-300 is fully protected. Within 05ofamicro-second 0.5 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 enough power to fully support the bearing system during the switch from motor to generator mode. After the compressor comes to a complete stop, the rotor de-levitates normally onto touchdown bearings. Touchdown bearings are used as a back up bearing system as well as to act as a cradle for the rotor during the off-mode 14
Variable speed drive The Compressors speed adjusts automatically to match the load and current operating conditions so that optimum efficiency is gained. The slower the compressors, the greater the efficiency. As speeds is reduced, energy consumption is reduced by the cube. Speed Energy 3 Variable speed drive The compressors speed varies dependent on the conditions. Its operating speed ranges from 18,000 to 48,000 RPM. The inverter is built into the compressor as is the rest of the control system Another advantage of this system is its low starting current, the compressor draws 2 amps to start compared to 500 amps on a conventional compressor 15
The motor The permanent magnet motor has many unique features: It is a 140hp motor that is the size of a conventional 1hp induction motor. It operates at high speed (18,000 to 48,000 RPM) It has a very low starting current (2 amps). It is refrigerant cooled. It is fully protected with thermistors The working end It is a centrifugal compressor that: is two stage, uses open shrouded impellors has an economizer feature operates on R134a has infinitely variable capacity control, uses guide vanes and variable diffusers to optimize its performance, is not worried about oil return, and does not mind the occasional slug of liquid, 16
TT-300 vs. leading screw compressor Energy Efficiency Performance TT-300 vs. leading screw compressor Energy Efficiency Performance 17
More about the systems integration Power electronics: The line reactor this is an optional feature that is not housed within the compressor. The LR is used for improving the power factor to better than.95 The rectifier converts incoming AC supply (50/60hz) to a DC current The capacitors smoothes out the current ripple so that the IGBT is fed with a stable current The integrated gate bi-polar transistor (IGBT) converts the DC current into a variable frequency of between 0 and 800 hz. The synchronous permanent magnet brushless DC motor is a two pole design and is refrigerant cooled More about the systems integration Compressor controller: The Soft start module this module charges the capacitors with a trickle charge preventing a large inrush current when power is first switched onto the compressor, in normal operation, the compressor remains live and is switched on and off by the IGBT. The compressor controller not only controls the compressors performance, but also has features like two stage expansion control, chiller control and remote monitoring. 18
More about the systems integration Bearing and motor controller: The bearing and motor control (BMC) is used to digitally control the speed of the motor as well and to control the position of the shaft. The pulse width modulator (PWM) is an onboard amplifier that is used to provide a fast response signal to the bearing actuators so that the shaft is kept in the correct position. The BMC has built in 5 axis proximity sensors which through the processor control the shaft position. More about the systems integration Other features: Inbuilt pressure and temperature transducers Motor and electronics cooling circuit DC/DC power supplies Communication port Guide vane control Mounting vibration isolators (protects the compressor from external vibration) Lifting lugs 19
Training and monitoring Monitoring and trouble shooting of the compressor can be performed via the Internet. Training modules will also be available shortly on the Internet Why retrofit? Usually when a chiller is replaced, it involves major capital works: Structural modifications, expensive crainage, major plumbing and electrical works, permits, power upgrades etc. etc. etc. You not only save on the cost of the chiller, the cost of the capital works, putting up with the inconvenience of the system being down for extensive periods of time, when you retrofit with Turbocor, you end up with the same net effect at a fraction of the cost. 20
Retrofit Rack Why rebuild when you can replace? From a clients point of view:- By changing out the compressor with a Turbocor, rather than rebuilding it for the umpteenth time, you add system reliability, improve energy savings, upgrade the system with the latest in technology, reduce noise and vibration and save money. 21
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OEM s that are using Turbocor Multistack 23
McQuay Power Pax - Australia 24
Axima - Germany What sizes do they come in? The Current Offering: Model - TT300 Refrigerant - R134a Capacities - 60, 70, 80 & 90 tonr Voltage - 400V 480V 50/60 Hz Application Water and evaporative cooled 25
The Current Offering: Refrigerant R22 What sizes do they come in? Capacities 90, 100, 110 tonr Voltage 400V 480V 50/60 Hz What sizes do they come in? Next Generation : Models TT300 & TT500 Refrigerant R134a Capacities 60, 70, 80, 90, 110, 130, 150 tonr Models - TR200, TR300 & TR400 26
TT300 Centrifugal Compressor www.turbocor.com Projet Bell Cadillac Présentation Mohamad Jamous ing. Services Immobiliers Assurance qualité technique 27