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Blue Star Cooling Solutions
Nitin JoshiSenior General ManagerBlue Star Ltd.
Latest Trends &
Technologiesin HVAC
31st Oct 2012
Green Building Congress 2012
BSL Turbocor Chiller
Turbocor Compressor- Features
• Environment-friendly R134a Refrigerant
• Magnetic Bearings eliminate frictional losses.
• Only one moving part assures long service life.
• Unmatched Efficiency; IPLV 0.35 kW/TR
• Low In-Rush Current reduces generator cost.
• Lowest Noise Level of Compressor i.e only 72 dBA
• Smallest Foot Print for equivalent size.
Turbocor Compressor
Integrated VFD - Capacity Modulation
• The Compressor speed adjusts automatically to match the load.
• Operating speed: 18,000 to 48,000 RPM
• Inbuilt inverter in the compressor along with rest of the control system
• Capacity control by the onboard VFD
• Inlet Guide Vanes supplement VFD controls. IGVs prevent surge conditions
• High efficiency at lower compressor speed. (Energy Speed3 )
• Another advantage of this system is its Low Starting Current . The
compressor draws 2 amps to start as compared to 500 amps of equivalent
capacity Screw/ Recip Compressor
The Magnetic Direct-Drive System
Magnetic bearing and sensors keep the shaft properly centered and positioned at all times. 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.
Shaft is monitored and positioned 100,000 / sec.
Magnetic Motor & Bearing System
• Permanently magnetized shaft does not
require electrical power.
•Permanent Magnet motor is 97% energy
efficient
• Eliminates -� high mechanical friction losses� oil-related heat transfer losses� cost of oil management system
• Increased equipment life throughelimination of wear surfaces present in conventional rolling contact bearings.
Compressor System Integration
• Inbuilt Pressure and Temperature transducers
• Inbuilt Motor and Electronic Cooling Circuit
• Port to communicate with Chiller Controller/ PC
• Guide vane control
• Inbuilt Capacitor Bank to protect shaft in case of
Sudden Power Failure
What Happens during sudden Power Outage?
•Within 0.5 micro-second, the motor becomes a generator which 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 change-over from motor to generator mode.
• After the compressor comes to a complete stop, the rotor de-levitates normally onto touchdown bearing.
• Touchdown bearing are used as a back up bearing system as well as to act as a cradle for the rotor during the off-mode .
Lowest Noise and Vibration Levels• “Best in Class” low sound levels: 72 dBA at 1 meter with no
sound attenuation. • Screw compressors generate 80 dBA or higher even with
Acoustic Enclosure Option.
• 450 TR Turbocor chiller produces 75 dBA of sound at 1m distance.
• Vibration is essentially non-existent.
-300
Advantages of Oil-free Technology
-Chiller-System
-Efficiency -Loss
cent Oil
An ASHRAEresearch project (no. 601) determined that the majority of installed chillers have an excess amount of oil in the cooling system
Turbocor is OIL FREE Compressor hence there is no dr opin Efficiency even after prolong operation in the f ield.
Red
uctio
n in
Effi
cien
cy
Blue Star TurbocorChiller Range
Model Name Nominal Cooling capacity (TR) IPLV
LCWT1-0305F 90 0.390
LCWT1-0515F 150 0.359
LCWT2-0615F 180 0.372
LCWT2-1015FA 300 0.354
LCWT3-1565FA 450 0.350
% load
100
75
50
25
2011 standard
1%
42%
45%
12%
Integrated Part Load Value: AHRI 550/590 - 2003
Weighted average values
IPLV (COP) = 0.01*A + 0.42*B + 0.45*C + 0.12*DA: EER or COP at 100% capacityB: EER or COP at 75% capacityC: EER or COP at 50% capacityD: EER or COP at 25% capacity
99% of the time Chiller operates at 75% & below %ge Load where Turbocor is the Most Energy Efficient Compressor .
Blue Star Turbocor Chiller-Key Features
• Flooded evaporator for close approach.
• High Efficiency Doubly-enhanced Tubes.
• Precise control of liquid level.
• Up to 3 compressors in single refrigerant circuit.
• Highest Part Load Efficiency.
Blue Star Turbocor Chiller –Key Features
•CKD (Knock Down & Assembly at Site) Option available for ease of Installation
•180, 300 & 450 TR models available in CKD option.
• Hot gas bypass to enlarge the min. Loading& ensure steady set point in Process applications.
• Isolation valve for ease of service with Min Pressure Drop.
•Interchangeability of Front & Rear Water Head based on convenience in Plant Room Layout
Part A Part B
Chiller Controller
Gaphical Touch Screen
Display
Data Logging
BMS Compatibility
Remote Monitoring
•On-line measurement of Cooling Capacity & Power Consumption
•Ensure optimum performance throughout operation
•Proactive Maintenance
Life Cycle CostRs in L
Typical
Screw
Chiller
Magnasmart
Turbocor
Chiller
Initial Cost 62 105
Electrical Power consumption in KWH for 24 Hours
a day, 6days a week, for 52 weeks a year
18 12
Electrical Power cost at Rs. 8/- per unit for one year 140 94
Electrical Power cost for 20 years 2804 1887
Cost of maintenance@Rs. 1000/- per Tr for 20 years 90 90
Total Lifecycle cost 3113 2188
Saving in 20 years 925
Falling Film Technology EvaporatorsIn Chillers
A falling film evaporator is an industrial device to concentrate solutions, especially with heat sensitive components.
In falling film evaporators the liquid product usually enters the evaporator at the head of the evaporator. The product is evenly distributed into the heating tubes. A thin film enters the heating tube and it flows downwards at boiling temperature and is partially evaporated.
Falling film evaporators are used extensively in chemical process industry, food and paper industry. Due to the absence of static head effect caused by liquid column as in other types of evaporators
Falling Film Evaporator Technology
DX & Flooded Evaporators
Category DX Evaporator Flooded Evaporator
Construction • Refrigerant Flows thru Tubes
• Water Flow through Shell• Inner Grooved Tubes• 5 - 10oC superheat
• Water Flows through Tubes• Refrigerant in Shell • Tubes with fins from both Inside & Outside
• Negligible superheatEfficiency
Air-cooledWater-cooled
• Low due to lower evaporating temp
• 1.15 ~ 1.2 IKW/TR• 0.72 ~ 0.8 IKW/TR
• High due to higher evaporating temp
• 1.05~ 1.08 IKW/TR• 0.57 ~ 0.65 IKW/TR
WATER OUT44°F
WATER IN54°F
GAS
REFRIGERANT LIQUID IN
35°F
REFRIGERANT
COOLER APPLICATION
NozzlesTube bundle in ref vapour
Tube bundle in refrigerant
Condenser
Water inside tubes, Refrigerant outside the tubes
Two distinct bundles of water tubes�Lower bundle flooded in refrigerant�Upper bundle covered in refrigerant film surrounded by vapour
Falling Film Evaporators
FALLING FILM EVAPORATOR
REFRIGERANT DISTRIBUTOR ELEMINATOR SUCTION LINE
SUPPORT
PLATE
OIL RETURN LINE SECONDARY DISTRIBUTOR
•System Refrigerant Quantity. Reduction by 30%• Elimination of Refrigerant Level Sensor & Chamber, as no need to monitor refrigerant Level.•High Efficiency of Heat Exchanger
Falling film evaporation Process
Thermal Developing Region
Fully Developed Region
Liquid
Evaporating & Boiling Region
Thin Film on Horizontal Tube
Liquid Film
Tube Wall
Vapour Bubble
Horizontal tube with nucleate boiling
Liquid Falling Film in�Droplet mode�Stable column mode�Sheet mode
Modes of Falling Film
Ref Qty
Efficiency
Low
Low
High
High
DX
Flooded Falling Film
Falling Film Evaporator
Droplet Mode, Droplet – Column modeColumn mode, Column Sheet mode, Sheet mode
Chiller can affect the environment significantly.
Ozone-depletion potential (ODP) & direct and indirect global-warming potential (GWP), are three factors affecting the environment because of the chiller.
We can improve environment by specifying HFC-134a, which has zero ODP. Efficiency improvement dramatically reduces the indirect GWP (which is 98% of the total impact) caused by greenhouse-gas emissions produced by utility to power the chiller. To reduce the 2% direct GWP impact, reduction in refrigerant-piping connections leading to leaking refrigerant is drastically reduced. Falling-film technology reduces refrigerant usage by 30%, which qualify for maximum Leadership in Energy and Environmental Design® (LEED) points for Enhanced Refrigerant Management.
Chiller’s high efficiency would earn additional points for the Optimized Energy Performance credit. Elimination of lubrication system avoids environmental issues of handling and disposing of refrigerant-saturated oil. Add it all to yield a positive environmental result.
Conclusion
Mumbai Nitin JoshiMb : 9769101130email : [email protected]
Hyderabad Tirumala RaoMb : 9989059614email : [email protected]
S SrikanthMb : 9391812123 [email protected]
Contact
Dec 3, 2004Dec 3, 2004
Thank You
Falling Film Process
• Total System Refrigerant Qty. Reduction by 30%, as no flood/storage of refrigerant like flooded Evaporator• Elimination of Refrigerant Level Sensor & Chamber, as no need to monitor refrigerant Level.
Falling Film Evaporators
