S. Inc. Basic

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S. Inc. Basic

  1. 1. Smardt Chiller Training PRODUCT BASICS PRESENTATION Presented By: Christine Lazo Vertical Systems 7113 Telegraph Rd. Montebello, CA 90640 310 451 0630 christine@vertisys.net
  2. 2. Smardt History in Brief• Turbocor compressor was invented in Australia in 1993• Turbocor was relocated to Montreal in 1999• Smardt was founded in 2004 to manufacture chillers• Danfoss formed 50/50 partnership with Turbocor in 2004• Smardt and PowerPax form common ownership .• Smardt, PowerPax and Axima signed a global agreement.• Water Cooled product range grows up to 1200 tons in 2010• Air cooled Product range grows up to 300 tons in 2010
  3. 3. Smardt Nomenclature
  4. 4. Smardt Nomenclature
  5. 5. Smardt Chiller Variety Air Cooled  60 tons – 400 tons Largest Water Cooled Range and Flexibility in  60 tons – 1200 tons TurboCor Applications Heat Recovery Condenser Less / Evap Condensed
  6. 6. Air Cooled Chillers 90 to 400 tons Capable of operating at as low as 45F ambient
  7. 7. Water Cooled Chillers 60 to 1200 tons
  8. 8. Heat Recovery
  9. 9. Evaporative Condensed Discharge EVAPCO P Line D ATCE P A E S Liquid Chilled T V Line water Pumps F D S Evaporator
  10. 10. Smardt Nomenclature
  11. 11. Turbocor Compressor
  12. 12. Turbocor Compressor: Components 2 Stage Centrifugal Compressor Variable Speed Drive Soft Start Pressure & Temp Transducers DC MotorOn Board Digital Controls Inlet Guide Vanes
  13. 13. Turbocor Compressor: Components 2 Stage Centrifugal Compressor Inlet Guide Vanes
  14. 14. Turbocor Components Centrifugal Compressor  Two stage  Operates on R-134A  Has infinitely variable capacity control  Uses guide vanes and diffusers to optimize performance  Does not require oil for compression sealing
  15. 15. Turbocor Compressor: Components DC Motor &Magnetic Bearings
  16. 16. Turbocor Components Synchronous Permanent Magnet Brushless DC Motor  Gives the compressor:  Low 2A inrush current  High reliability – minimal stress on stator windings  High efficiency throughout operation range  Compact size and light weight  Lower cost
  17. 17. Turbocor Components Magnetic Bearings  Rotor shafts and impellers levitate during rotation and float on a magnetic cushion.  97% efficient  When not powered, the rotor is supported by carbon composite, touchdown bearings designed for years of use.
  18. 18. Turbocor Components Magnetic Bearings (cont’d)  Two radial and one axial magnetic bearing are employed.  Bearing sensors feed back real-time orbit information to digitally controlled bearings.  Centered rotation is instantaneously self-corrected and maintained
  19. 19. Turbocor Components Magnetic Bearings (cont’d)  Shaft position is monitored and centered 100,000 per second!  Centered rotation is instantaneously self-corrected and maintained
  20. 20. Turbocor Component BenefitsMagnetic Bearings Mean NO Oil!
  21. 21. Turbocor Component Benefits Magnetic Bearings Mean NO Oil! Percent Oil •Efficiency loss accounts for substantial operation costs• ASHRAE sampling showsaverage percentages of oilpresent in chillers
  22. 22. Turbocor Component BenefitsNO Oil =Maintained Heat Transfer Efficiencies
  23. 23. Turbocor Component BenefitsNO Oil Means Less Maintenance!
  24. 24. Turbocor Component Benefits Magnetic Bearings One Moving Part Eliminates high mechanical friction losses Eliminates oil-related heat transfer losses Eliminates cost of oil management systems (controls and hardware) Eliminates maintenance of oil management Increases equipment life – no wear surfaces
  25. 25. Turbocor ComponentsVariable Speed Drive Soft StartOn Board Digital Controls
  26. 26. Turbocor Components Built-in Variable Frequency Drives  Unmatched part load efficiency  Compressor speed adjusts to changes in load and/or condensing temperature.  As compressor speed reduces due to lower loads and /or condensing temperatures, energy consumption dramatically reduces.  Part load energy efficiency is outstanding, with energy savings greater than 30% compared to traditional screw compressors.
  27. 27. Turbocor Components Built-in Digital Controls  Worlds first "smart" compressors.  Digitally controlled bearings  Digitally controlled power electronics  Digitally controlled compressor control  Digitally controlled chiller control  Digitally controlled expansion valve controls
  28. 28. Turbocor Components Built-in Digital Controls  Microprocessors proactively manage compressor operation.  Self-diagnosis and correction are built in.  Eliminates traditional HVACR product control and power electronics functions saving costs for OEMs.  Plug nPlay control modules are easy to replace on site.  Interactive control capability with easy access for BAS and web-enabled monitoring.
  29. 29. Turbocor Components The Electronics  Designed to maximize compressor performance  Maximum energy efficiency  Low vibration  Higher reliability  Efficient component cooling
  30. 30. Energy Efficiency The achievement of Turbocor’s high efficiency comes from:  The compression technology  The magnetic bearing technology  The motor technology  The power electronics technology  The controls  The combination of all these features into one product FULLY INTEGRATED SYSTEM
  31. 31. Energy Efficiency
  32. 32. Why is Part Load So Important?
  33. 33. Energy Efficiency
  34. 34. Turbocor Benefits Quiet Operation  Quietest compressors in the industry!  They operate at 70dBA (conversation level) sound with virtually no vibration.  Given normal equipment room background sound levels, one literally can not hear the compressor operate.
  35. 35. Turbocor Benefits Lightweight  Under 300 lbs  Fraction of weight of conventional compressors
  36. 36. Turbocor Benefits Small Footprint  ~ 50% smaller footprint than conventional compressors
  37. 37. Turbocor Overview  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 .33 kw/ton IPLV.  2A Low In-Rush Current reduces installed cost and peak load.  Lowest Noise - Only 72 dBa  Intelligent Control – high full load and part load performance
  38. 38. Turbocor Compressor Models TT300 : 60 to 90 tons  250 – 320 kW nominal capacity  Air cooled and Water cooled TT400 : 100 to 145 tons  400 – 500 kW nominal capacity  Water cooled ONLY TT500 : 150 to 185 tons  600 – 700 kW nominal capacity  Water cooled ONLY
  39. 39. Turbocor Compressor Models
  40. 40. Chillers Using Turbocor
  41. 41. Why Smardt? If Turbocor is the key component and there are other manufacturers who use it on their chillers, then….. Why use ?
  42. 42. Smardt Nomenclature
  43. 43. Smardt and Turbocor How Smardt uses Turbocor to Size Chillers  Each compressor is infinitely selectable for rated capacity in its range  Each compressor is applied in parallel up to qty (6)  WC: Chiller barrels are matched to compressor’s size range  AC: Chiller barrel and fans are matched to compressor range
  44. 44. Turbocor Compressors Turbocor TT300 – infinitely selectable Head limit as function Power of max power Limit Full Vane Part Vane Area Area Capacity Limit
  45. 45. Multiple Turbocor Compressors 45 Scaleable 1 to 6 compressors per chiller 60-140 ton Selections/Compressor Brings Peak Size to 1200 tons Largest range and flexibility of Turbocors in market kW/ TonR Vs System Capacity 0.75 0.70 1 comp 0.65 2 comp kW / TonR 3 comp 4 comp 5 comps 0.60 6 comps 0.55 0.50 0.0 100.0 200.0 300.0 400.0 500.0 600.0 Evaporator CAPACITY - TonR
  46. 46. Smardt Nomenclature
  47. 47. Barrel Types Narrow  Standard Configuration  Stacked Orientation  Slim Design  Up to 4 compressors
  48. 48. Barrel Types Compact  Designed for tight fits  Can be modular  Dimensioned to fit through elevators and doors  Limited to 1 compressor  60 tons – 150 tons
  49. 49. Compact Parallel Modular Approach
  50. 50. Barrel Types Side by Side  Barrels are oriented beside each other  Panels are mounted above condenser barrel  For short and wide layouts  Up to 3 compressors
  51. 51. Barrel Types Low Profile  Condenser is located on top  For height sensitive projects  For largest tonnages  550 tons – 900 tons  Only 4 and 5 compressors
  52. 52. Barrel Types Fat Max  Fatter/ Bigger Barrels  Staggered compressor orientation  More expensive to make  Up to 6 compressors
  53. 53. Air Cooled – Fan Types V=Variable Speed F=Fast Speed S=Slow Speed H=High Static Variable
  54. 54. Why Smardt? PRODUCT FLEXIBILITY Widest product variety with Turbocor technology  Air cooled, Water cooled, Split Systems  60 to 1200 tons range – Up to 6 compressors  Competitors limited to 2 compressors  Variety of chiller barrel configurations  Enables higher flexibility in design
  55. 55. Why Smardt? TRUE REDUNDANCY• Up to 6 compressors on single barrel• Mechanical Isolation on each compressor• Electrical disconnects for each compressor• ZERO down time on compressor changeouts• Single chiller operation becomes viable when applied to 2 or more compressors
  56. 56. Why Smardt? PROTECTION• Temperature sensors• Fuses• Disconnects• Flow switch – Paddle Type• Flow Switch – Thermal Type• Flow Switch – Differential Pressure Transducer/Switch• Control Limits – discharge High Pressure Low pressure switch
  57. 57. Why Smardt? SUPERIOR LIQUID LEVEL CONTROL Immersion sensors provide real time input verification of condenser levels Allows precise expansion valve control Results in SUPER LOW LIFT essential for optimal all variable plant performance. Competitors use superheat control  Requires conservative chiller temperature and flow limits  “Guessing”
  58. 58. Why Smardt?SUPERIOR CONTROLS KNOWLEDGE
  59. 59. Smardt Advanced Controls Sophisticated Control Easy to use Color Touch Screen
  60. 60. Why Smardt? SUPERIOR CONTROLS KNOWLEDGE TurboCor compressor maps built into controls  Avoids chokes and surges
  61. 61. Why Smardt? SUPERIOR CONTROLS KNOWLEDGE Adaptive, non static microprocessor controls  Real time compressor mapping monitoring 150+ points  Far advanced than competition’s offering
  62. 62. Why Smardt? SUPERIOR CONTROLS KNOWLEDGE Compressor Status Feedback  Real-time Chiller Controller Output of Compressor Data  Compression Ratio  Compressor Actual Speed  Surge Speed  Choke Speed  Essential for optimal chiller staging in all variable central plants
  63. 63. Why Smardt? Compressor Status Feedback
  64. 64. Why Smardt? SUPERIOR CONTROLS KNOWLEDGE Patented compressor staging algorithms work at the optimized power curves  Smardt is more efficient across ENTIRE load profile. Real-Time Feedback and Compressor Selection Logic  Maximizes the compressors online to minimize RPM  Requires lowest chiller power input
  65. 65. Control System kW Optimization 65
  66. 66. Why Smardt? SYSTEMS KNOWLEDGE = ENERGY SAVINGS Control of High Performance All Variable Plants
  67. 67. Why Smardt? SYSTEMS KNOWLEDGE = ENERGY SAVINGS Optimized control of system yields 20:1 turndown
  68. 68. Why Smardt? SYSTEMS KNOWLEDGE = CPECS Central Plant Energy Control System A proven & repeatable packaged system that optimizes plant performance Factory mounted package on Smardt Chiller Package includes:  Controls  Sensors  NIST Certified BTU Meter  Touch Screen Swing Arm Panel  Central Plant Start up (single source)  No finger pointing on startup!
  69. 69. Why Smardt?SYSTEMS KNOWLEDGE = ENERGY SAVINGS CPECS combined with SMARDT oil free variable speed chillers aims to provide the following:  Optimized tower water temperature control.  Load matched variable speed condenser water pump control that respects chillers minimum safe flow limits.  Optimized chiller sequencing.  Load based chilled water temperature reset  Variable primary chilled water pump control.
  70. 70. Why Smardt? CPECS combined with SMARDT provides the highest performance targets 0.4 – 0.5 kW/ton for the ENTIRE Plant
  71. 71. Why Smardt? EXPERIENCE Most experienced with Turbocor than any other manufacturer  Smardt CEO is original co-founder of Turbocor and former CEO of Turbocor  Turbocor development engineers designed Smardt controls
  72. 72. Why Smardt? EXPERIENCE Most experienced with Turbocor than any other manufacturer  Best understanding of Turbocor nuances  Only chiller built from ground up to optimize Turbocor compressors
  73. 73. Why Smardt? PROVEN INSTALLATIONS Largest installed base with Turbocor than any other manufacturer  Over 1,300 installations. More than twice the competition.  ~100 local installations in Southern California  Patented control system assures accurate trouble-free operation  Global sales and service support
  74. 74. Why Smardt?PROVEN INSTALLATIONS
  75. 75. Smardt Overview

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