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FRICTIONLESS COMPRESSOR

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Submitted By: ............................................................

K. M. SCHOOL OF MARINE ENGINEERING COCHIN UNIVERSITY OF SCIENCE AND TECHNOLOGY COCHIN-682022 DECEMBER, 2010

K. M. SCHOOL OF MARINE ENGINEERING COCHIN UNIVERSITY OF SCIENCE AND TECHNOLOGY

This is to certify that the seminar report entitled Frictionless Compressor, submitted by engineering cadet Mallick MD Fahad of Kunjali Marakkar school of Marine engineering toward the partial fulfilment of the requirement for the semester of Btech. degree course in

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marine engineering of cochin university of science and technology, is a bonafied record of the seminar talk presented by him on December,2010.

SEMINAR coordinator

(OFFICE SEAL)

ACKNOWLEDGEMENTS

Apart from the efforts of me, the success of any seminar depends largely on the encouragement and guidelines of many others. I take this opportunity to express my gratitude to the people who have been instrumental in the successful completion of this seminar. I would like to express my gratitude towards my parents & member of KUNJALI MARAKKAR SCHOOL OF MARINE ENGINEERING for their kind co-operation and encouragement which help me in completion of this project. I am highly indebted to Mc QUAY for providing necessary information regarding the seminar & also for their support in completing the seminar. The guidance and support received from all the members who contributed and who are contributing to this seminar, was vital for the success of the seminar. I am grateful for their constant support and help.

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TABLE OF CONTENTS

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LIST OF FIGURES

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ABSTRACT Magnetic bearing centrifugal compressor eliminates the efficiency-robbing friction inherent in traditional centrifugal chiller. Integrated VFD optimized part load efficiency, a key performance feature since most chillers operate at part load 99% of their life. Sustainable performance assured for the operating life of the chiller. The positive pressure, oil-free design eliminates performance degradation due to non-condensable and oil contamination of the refrigerant. Easy integration with our open choices feature using BACnet, LonWorks or Modbus communications without an expensive panel.R-134a refrigerant has no depletion potential and no phase=out schedule. Reduced maintenance costs due to elimination of oil. Oil system, purge system, and shaft seals found in order technology chillers. Small unit footprint helps the magnitude chiller fit in place where space is limited, making it ideal for retrofit projects. Unmatched unloading with the integrated VFDs since the on-board digital control reduce compressor speed to match the load. Low inrush current at start-up is ideal for operation with backup or emergency power systems. Touch screen operator panel is graphically intuitive and easy o use for enhanced operator productivity. Important status and control information is available at a glance or a touch.

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1.INTRODUCTION
Traditional centrifugal compressors use roller bearings and hydrodynamic bearings, both of which consume power and require oil and lubrication system. This can be overcome by the introduction of new compressor technology called frictionless compressor technology. The frictionless compressor technology is compressor with the application of magnetic bearings and permanent magnet synchronous motor. In frictionless compressor instead of roller bearings and hydrodynamic bearings, magnetic bearings are used. Magnetic bearings consume less power and there is no need for oil and lubrication systems. Permanent magnet brushless synchronous motor has permanent magnet instead of copper windings. After 10 years of development, magnetic bearing compressors offer economic, energy, and environmental benefits. Chief among them are increased energy efficiency, the elimination of oil and oil management and considerable less weight, noise, and vibration. This is initial mid-range package offers centrifugal compression efficiencies previously reserved for large tonnage systems only. This compressor has high reliability, efficiency, less maintenance cost and staff. With the help of digital control system the controlling and monitoring of work is very easy. The frictionless compressor technology makes new revolutions in the field of air conditioning, refrigeration etc. Frictionless Compressor Technology is one of the fast growing Technology in the engineering field. The Frictionless compressor is also the worlds first totally Oil-Free compressor specifically designed for the Heating, Ventilation, Air Conditioning and Refrigeration (HVACR) industry. The variable-speed centrifugal compression and digital electronic technologies enables the frictionless compressors (nominal 60-150 ton capacity range) to achieve the highest compressor efficiencies, cost effectively, for middle-market, watercooled, evaporative cooled and air-cooled HVACR applications. The well-proven energy performance advantages of variable-speed centrifugal Compressors are now brought to mainstream middle-market applications through the use of High-speed, two-stage centrifugal compression with integral variable-speed drive. Compressor speed is reduced as the condensing temperature and/or heat load reduces, Optimizing energy performance through the entire operating range from 100% to 20% or below of rated capacity. Operations to near zero loads are achievable via an optional, digitally controlled, load balancing valve.

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Centrifugal compressors tend to be more efficient than screw or scroll Compressors, and take advantage of speed control more effectively, but they are usually only available in larger sizes. By using the smaller shaft, they are able to take advantage of the centrifugal compressor technology in a smaller size than is normally available. 1.1 Mechanical components of frictionless compressor

Figure 1.1: Mechanical components of frictionless compressor

1.1.1 Magnetic bearings and bearing sensors Composed of both permanent and electromagnets
Enables precisely controlled frictionless compressor shaft rotation on a levitated

magnetic cushion
Bearing sensors, located at each magnetic bearing, feedback rotor orbit and

thrust/axial information in real time to bearing control

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1.1.2 Permanent-magnet synchronous motor Powered by PWM (pulse width modulated) voltage supply High-speed variable frequency operation affords high efficiency, compactness and soft start capability

1.1.3 Touchdown bearings

Carbon-lined radially and axially located bearings support the rotor when the

compressor is not energized

Prevents contact between the rotor and other metallic surfaces

1.1.4 Shaft and impellers

P a g e | 10 Only one major moving compressor component

Acts as rotor for permanent-magnet synchronous motor Impellers are keyed directly to the motor rotor

1.1.5 Compressor cooling Liquid refrigerant flow is controlled electronically, cooling electronic, mechanical and electromechanical compressor components to assure maximum efficiency and safe operation 1.1.6 Inlet guide vane assembly Trims compressor capacity and is digitally integrated with the variable-speed control, to optimize energy efficiency and compressor performance

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1.2 Electrical components of frictionless compressor

Figure 1.2: Electrical components of frictionless compressor

1.2.1 Soft start module Significantly reduces high in-rush current at startup The startup inrush current is only 2 amps vs typically up to 500-600 amps experienced by traditional screw compressors in this tonnage range truly redefining soft starts 1.2.2 Variable frequency drive IGBT (Insulated Gate Bipolar Transistor) is an inverter that converts a DC voltage into an adjustable three-phase AC voltage. Signals from the motor/bearing controller determine the inverter output frequency, voltage and phase, thereby regulating the motor speed. Converts mechanical energy back into electrical energy. In case of power failure, this patented control scheme allows for a normal de-levitation and shutdown.

1.2.3 Three-phase terminal block

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Connection point for primary power supply.

1.2.4 Rectifier Converts AC line power into a high-voltage DC power source for motor, bearings and control operations. 1.2.5 Capacitors Energy storage and filter for smooth DC voltage. Provide power to the magnetic bearings, along with motor rotation, to ensure rotor shaft levitation through compressor coastdown in the event of an external power loss.

1.2.6 DC-DC converters Supplies and electrically isolates the high and low DC voltages required for the control circuits. 1.2.7 Controls connection Network connection for external control and monitoring. 1.2.8 Bearing sensor feedthroughs Hermetically sealed connections enabling the transfer of power to the electromagnetic bearings and shaft position and rotation signals to the control modules.

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1.2.9 Driver Board/EXV Control 1.2.10 Compressor and bearing controller Central processor of the compressor system. Continuously updated with critical data from the motor/bearing and external sensors that indicate the compressor and chiller/rooftop package operating status. Software enabled, it responds to changing conditions and requirements to ensure optimum system performance. Computes the required shaft position signals that control the magnetic bearings.
Processes motor current information to control motor speed.

1.2.11 PWM amplifier Supplies power to the electromagnetic bearings.

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Magnetic-bearing technology Magnetic-bearing technology is significantly different. A digitally controlled magneticbearing system, consisting of both permanent magnets and electromagnets, replaces conventional lubricated bearings. The frictionless compressor shaft is the compressors only moving component. It rotates on a levitated magnetic cushion. Magnetic bearingstwo radial and one axialhold the shaft in position (Figure 2). When the magnetic bearings are energized, the motor and impellers, which are keyed directly to the magnetic shaft, levitate. Permanent magnetic bearings do the primary work, while digitally controlled electromagnets provide the fine positioning. Four positioning signals per bearing hold the levitated assembly to a tolerance of 0.00002 in. As the levitated assembly moves from the center point, the electromagnets intensity is adjusted to correct the position. These adjustments occur 6 million times a minute. The software has been designed to automatically compensate for any out-of-balance condition in the levitated assembly. The rotor shafts position is held by front and rear electro-magnetic cushions. The shafts position is monitored with 10 sensors that send a signal to a digital controller which then sends a command to the 5 separate pulse width modulators (PWM), for a proper shaft repositioning.

FIGURE 2. A digitally controlled magnetic-bearing system consisting of two radial and one axial bearing levitate the compressors rotor shaft and impellers during rotation.

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Cross-section of axial bearing

Cross-section of radial bearing

SHUTDOWNS AND POWER FAILURES When the compressor is not running, the shaft assembly rests on graphite-lined, radially located touchdown bearings. The magnetic bearings normally position the rotor in the proper location, preventing contact between the rotor and other metallic surfaces. If the magnetic bearings fail, the touchdown bearings (also known as backup bearings) are used to prevent a compressor failure. The compressor uses capacitors to smooth ripples in the DC link in the motor drive. Instantaneously after a power failure, the motor becomes a generator, using its angular momentum to create electricity (sometimes known as back EMF) and keeping the capacitors charged during the brief coast down period. The capacitors, in turn, provide enough power to maintain levitation during coast down; allowing the motor rotor to stop and DE levitate. This feature allows the compressor to see a power outage as a normal shutdown. In case of power failure, within 0.5 micro-seconds, the motor acts as a generator for the magnetic bearings and the compressor comes gradually to a complete stop; the rotor delevitates normally unto backup bearings.

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ROTOR AND SHAFT ELECTROMAGNETIC CUSION

THE MOTOR Most hermetic compressors use induction motors cooled by either liquid or suction-gas refrigerant. Induction motors have copper windings that, when alternating current is run through them, create the magnetic fields that cause the motor to turn. These copper windings are bulky, adding size and weight to the compressor. Two-pole, 60-Hz induction motors operate at approximately 3,600 rpm. A higher number of revolutions per minute can be obtained by increasing the frequency. Compressors that require higher shaft speeds tend to use gears. While gears are a proven technology, they create noise and vibration, consume power, and require lubrication. The magnet-bearing compressor features a synchronous

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permanent-magnet brushless DC motor with a completely integrated variable-frequency drive (VFD). The stator windings found conventional induction motors are replaced with a permanent-magnet rotor. Alternating current from the inverter energizes the armature windings. The stator (excitation) and rotor (armature) change places. The motor and key electronic components are internally refrigerant cooled, so no special cooling is required for the VFD or the motor. The use of permanent magnets instead of rotor windings makes the motor smaller and lighter than induction motors. Using magnetic-bearing technology, a 75-ton compressor weighs 265 lb about one-fifth the weight of a conventional compressor. A variable-speed drive (VSD) is required for the motor to operate. The VSD varies the frequency between 300 and 800 Hz, which provides a compressor-speed range from 18,000 to 48,000 rpm. This avoids a gear set. The VSD is integrated into the compressor housing, avoiding long leads and allowing key electronic components to be refrigerant-cooled. The VSD also acts as a soft starter; as a result, the compressor has an extremely low startup in-rush current: less than 2 amps, compared with 500 to 600 amps for a traditional 75-ton, 460-v screw compressor with a cross-the-line starter. With the integration of the motor, VSD, and magnetic-bearing system, the capacitors required for the motor and drive can be used as a backup power source for the bearings in the event of a power outage or emergency shutdown.

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Soft start An added benefit of having the integrated VFD is that the motor has a built-in soft start. It uses a unique method of soft start that ramps the motor up gradually, making inrush current effectively the full load current. The inrush current is 2 amps, or 5 amps in some places, meaning, presumably, that the ramping up process starts with this very low current. It is not clear how this information is useful, since the information about inrush current is generally used for sizing circuit breakers. The breaker would simply have to be sized for the full load amperage.

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CONTROLS The new technology range features user interface and adjustment software with a graphic display for reading and writing control parameters. The controller also comprises a mimic panel for real-time visualization of compressor operating status. Chillers can communicate with Modbus, LonWorks or BACnet as well as other systems. The Turbocor compressor includes an integral microprocessor to control cooling capacity and magnetic bearing function. It also provides monitoring and documentation to assist commissioning, provide energy data, and display performance. The compressor itself uniquely provides outputs to support end user. The electronics and controls have been fully integrated into the system. They were designed to be easy to access and maintain and offer plug-and-play ease. The high-voltage and low-voltage systems are separated for ease of maintenance and troubleshooting. The controls can be integrated with a building management system for automation and data logging. The user interface is available in several different communication protocols for use with almost any system.

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OIL FREE DESIGN Oil management, particularly as it pertains to the lubrication of compressor bearings, is a critical issue in refrigeration system design. But with magnetic bearings, this issue is avoided. Only a very small amount of oil is required to lubricate other system components, such as seals and valves; often, however, experience shows that even this small amount of oil is not needed. Avoiding oil-management systems means avoiding the capital cost of oil pumps, sumps, heaters, Coolers, and oil separators, as well as the labor and time required to perform oil related Services. Reports indicate that for many installations, compressormaintenance costs have been cut by more than 50 percent. Most air-cooled products

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(including chiller, rooftop units, and condensing units) use DX evaporators. Most DX systems allow oil to travel through the refrigeration circuit and back to the compressor oil sump. Great care must be taken during design to provide oil return, particularly at part load, when refrigerant flow rates are reduced. Water-cooled chillers often use flooded evaporators. In a flooded evaporator, even small amounts of oil can coat evaporator tubes and significantly diminish chiller performance. This can lead to an elaborate oil-recovery system. Magnetic bearings eliminate the need for these systems and oil management in general. In fact, the only required regular maintenance of the compressor is the quarterly tightening of the terminal screws, the annual blowing off of dust and cleaning of the boards, and the changing of the capacitors every five years. Complete service agreements and extended maintenance contracts can be provided by the manufacturer. Compare to normal centrifugal compressor NO Oil heater NO Oil cooler NO Oil pump and starter NO Reservoir NO Oil relief valves NO Oil piping NO Oil Sensors and controls Greater reliability Fewer things to break Reduced maintenance costs

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SOUND AND VIBRATION Consequently, floor mounted spring isolators are not usually required. Rubber mounting pads are shipped with each unit. It is wise to continue to use piping flexible connectors to reduce sound transmitted into the pipe and to allow for expansion and contraction. Because the rotating assembly levitates, there essentially is no structure-borne vibration. The magnetic bearings create an air buffer that prevents the only major moving partthe motor rotorfrom transmitting vibration to the structure. Similarly, sound levels are extremely low, primarily because of refrigerant-gas movement through the compressor and the rest of the refrigeration system. There are no tonal issues, such as those found with some screw compressors, and the noise occurs in the higher octave bands, where it is easier to attenuate. When two magnetic-bearing compressors were integrated into a chiller, the sound pressure was 77 dBA at 3.3 ft. under ARI Standard 575-94, Method of Measuring Machinery Sound within an equipment space.

Small and Lighter Using permanent magnets in the motor, rather than electrical windings as in an induction motor reduces the size and weight significantly. In addition, by running the shaft at high speeds, they are able to use a smaller, lighter, shaft. According to the manufacturer, the compressors, at 265 lbs., are one-fifth of the weight and half the size of an equivalent conventional compressor. Low Maintenance Oil management, particularly as it pertains to the lubrication of compressor bearings, is a critical issue in refrigeration system design. But with magnetic bearings, this issue is avoided. Avoiding oil management systems means avoiding the capital cost of oil pumps, sumps, heaters, coolers, and oil separators, as well as the labour and time required to perform oil-related services. Reports indicate that for many installations, compressor maintenance costs have been cut by more than 50 percent. In fact, the only required regular maintenance of the compressor is the quarterly tightening of the terminal screws, the annual blowing off of dust and cleaning of the printed circuit boards, and the changing of the capacitors every five years. CAPACITY AND EFFICIENCY

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Among the key parameters affecting performance are capacity (tons) and efficiency (kilowatts per ton). The compressors capacity ranges from 60 to 90 tons, depending on the operating conditions. Plans call for that range to be extended to 150 tons water-cooled and 115 tons air-cooled by the end of 2004 with the use of R-134a refrigerant. An R-22 version is planned for retrofit applications. Efficiency improvements stem from a combination of the centrifugal compressor, permanent magnet motor, and magnetic bearings. Within the compressor, efficiency is affected by the Compressor isentropic efficiency (the efficiency of the wheels), the motor, and the bearings. Traditional induction motors of this size typically are in the 92-percent efficiency range. This compressors permanentmagnet motor has an efficiency of 96 to 97 percent. Efficiency is further enhanced with the use of magnetic bearings, which avoid the friction of rubbing parts associated with traditional oiled bearings. Conventional bearings can use as much as 10,000 w, while magnetic bearings re- quire only 180 w. That amounts to 500 times less friction loss. Current development projects are expanding the range and duty of the compressor wheels and promise to offer even greater efficiency for watercooled and air-cooled duties and different capacities. The Compressors speed adjusts automaticallyto match the load and operating conditions for maximum efficiency. The slower is the compressors speed, the greater the energy savings. Energy is proportionally to Speed(n).

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% Load

Figure: According to ARI testing, a 150-ton frictionless chiller has a full-load performance of 0.629 KW per ton (5.6 COP) and an IPLV of 0.375 KW per ton (9.4 COP). LIGHT WEIGHT Most hermetic compressors use induction motors that are cooled by refrigerant.Induction motors have copper windings which, when alternating current is run through them, create the magnetic fields that cause the motor to turn. These copper windings are bulky, adding size and weight to the compressor. Frictionless chillers employ a permanent magnet motor with a completely integrated variable frequency drive. Permanent magnet motors do not require motor windings, so they are much smaller and lighter than induction motorsabout onefifth the weight of a conventional compressor.

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REFERENCES www.mcquay.com and mcquay broacher www.turbocor.com