Improving Cold Chain Competitiveness with Danfoss Energy Efficiency Solutions www.danfoss.com
Agenda Brief on Danfoss Danfoss Business Divisions / Areas Danfoss Drive Solutions for Energy Efficiency in HVAC & Refrigeration Systems Chiller Compressor Applications of Drives Fans and Pumps Applications of Drives Retrofit Applications of Drives in Various System Configurations Danfoss Drives Value Proposition Case Story on Screw Compressor Retrofit Danfoss Automatic Controls September 2013 2
Introduction to Danfoss Danfoss Automatic Controls www.danfoss.com September 2013 3
Danfoss Global in brief Global Company with Core Competencies in Solutions that sustain Climate and Energy 80 years of experience within energy-efficient technologies Solutions ready to combat climate challenge Global competence center for energy efficiency rooted in Southern Denmark Danfoss Global Organization is Family owned Business Danfoss Automatic Controls September 2013 4
Facts in figures Sales Number of employees globally Factories, globally Global Presence Own sales companies, globally Top 3 Markets 34,007m DKK (6 b US$) 23,092 56 in 18 countries >100 countries in 51 countries US, Germany & China Danfoss Automatic Controls September 2013 5
Danfoss India 100% Subsidiary of Danfoss A/S Established in 1998 Employs over 450+ Corporate Headquarters Chennai Turnover INR 4000 Million 10 Offices & 60 Partner companies Major Investments on R&D, Manufacturing & Talent acquisition Engineered Panel Solution Facility Danfoss Automatic Controls September 2013 6
Our Aspiration Danfoss is recognised as a global trendsetter. We passionately push boundaries on results and reputation. Global Management Meeting 2010 7
Our Promise We provide leadership in our businesses through reliability, excellence, and innovation driving true customer satisfaction and solutions within Climate & Energy Our Promise to our customers and ourselves Reliability Excellence Innovation We commit we deliver On -Time delivery Value for money Easy to do business with Value Creation Focus on true customer needs Total quality Everywhere Continuous improvement Trend-setting Road show 2010 8
Our Behaviour We will build our business on trust. We will be innovative in our ambition to exceed expectations. We will be global while respecting local cultures. We will treasure sustainable results. Global Management Meeting 2010 9
Climate and energy The solutions are ready! Danfoss is a global leader focusing on energy-efficiency solutions Well-proven technologies that save energy and costs, and reduce CO2 emissions We have built up our competencies since 1933 Making modern living possible through climate and energy solutions used in areas such as cooling food, air conditioning, heating buildings, and controlling electric motors Introduction to Danfoss 2013 10
Solutions ready going forward Utilize existing energy efficiency solutions to an optimum and boost economy Invest in new solutions based on core energy efficiency competencies, e.g.: Solar inverters Efficiency components for wind turbines Heat pumps Cooling systems based on natural refrigerants Introduction to Danfoss 2013 11
Business areas Danfoss Climate & Energy Danfoss Refrigeration & Air Conditioning Controls Danfoss Power Electronics Danfoss Heating Solutions Danfoss Commercial Compressors Danfoss District Energy Introduction to Danfoss 2013 12
Climate & Energy Danfoss Refrigeration & Air Conditioning Controls Danfoss Refrigeration & Air Conditioning Controls includes four product areas: Automatic Controls Electronic Controllers & Services Industrial Automation Heat Exchangers The division provides customers (e.g. OEMs, wholesalers and installers) with solutions on a global scale in the fields of commercial refrigeration, industrial refrigeration, air-conditioning, supermarket refrigeration and industrial automated systems. Introduction to Danfoss 2013 13
Climate & Energy Danfoss Power Electronics The Danfoss Power Electronics division includes three business units: Danfoss VLT Drives Danfoss Customised Power Electronics Danfoss Inverters for Solar and Wind The division has supply chain, research and development centers in China, Denmark, United States and Germany and a global network of sales offices offering customers high-quality energy-efficient power electronics solutions. Introduction to Danfoss 2013 14
Climate & Energy Danfoss Heating Solutions Danfoss Heating Solutions offers solutions within: Residential Heating Hydronic Balancing & Controls Burner Components Electrical Heating Heat Pumps Ventilation Through sales companies and agents, the division offers solutions for generating, distributing and adjusting heat for optimum indoor comfort and energy savings in residential heating all over the world. Introduction to Danfoss 2013 15
Climate & Energy Danfoss Commercial Compressors Danfoss Commercial Compressors offers efficient and energy-optimized compressor solutions such as scroll compressors, reciprocating compressors for air conditioning, commercial refrigeration and heat pumps as well as condensing units and variable speed solutions. The division has global manufacturing facilities spread across three continents, and customers can benefit from 40 years of experience within the development of hermetic compressors. The products are used in a variety of key customer applications such as cold rooms, supermarkets, milk tank cooling, residential air conditioners, rooftops applications, chillers, heat pumps and industrial cooling processes. Introduction to Danfoss 2013 16
Climate & Energy Danfoss District Energy The Danfoss District Energy Division includes four business units Heat Exchangers Controls Heavy duty stations Small Duty Stations Danfoss District Energy offers solutions within the control and transfer of heat in district heating and cooling applications. District energy is energy-efficient, it capitalizes on economies of scale, and can be used with both renewable and fossil energy sources by providing an efficient green infrastructure which contributes to achieving individual comfort, while reducing energy consumption. Danfoss District Energy is a total supplier of substations and automatic controls for the district heating and cooling market and has sales companies and agents around the world. Introduction to Danfoss 2013 17
VLT Refrigeration Drive Danfoss Energy Efficiency Solution for HVAC and Refrigeration Systems
Danfoss VLT Refrigeration Drives (VLT FC 103) For Compressors Condenser Pumps / Fans Evaporator Fans Liquid Feed Pumps Cooling Towers
VLT DRIVE APPLICATIONS IN REFRIGERATION SYSTEM 20
What Savings VLT Brings to the Refrigeration System Save Energy by System Capacity Modulation (Reducing System Speed at Part Loads) Save Overall System Cost (DG Size/ Compressor Size/ Cables etc.) Brings System Automation Safety and Protection 21
Starting currents = FLC VFDs allow starting current equal to that of full load current of motor Lower Switchgear sizes Peak Demand under control Smooth start Reduction in DG Set capacity requirement Confidential/Property of Danfoss Drives A/S Thursday, 21 August, 2008 JSP-INSC 22
VLT Refrigeration Drive Chiller Compressor Application
Physics Law governing Positive Displacement Devices Law applicable for Reciprocating / Screw Compressors Flow Speed Energy Speed 20% Reduction in Speed of Compressor saves 20% Energy Confidential/Property of Danfoss Drives A/S Thursday, 21 August, 2008 JSP-INSC 24
Drives Application on Compressors 25
Screw Compressors with Slider Valve Capacity control Slide stop Slide- Capacity Slide stop Slide- Capacity Maximum capacity Reduced capacity Active compression part 28
Traditional Capacity Control Screw Compressor Slide Valve Capacity Control Power % 100 80 60 40 20 Slide valve curve Ideal curve Traditional Screw Compressor Capacity Control: Slide Valve controls compressor capacity Slide Valve position is determined by suction pressure PID control Slow system control due to 300s of dead band System delay causes energy losses lower temperature operation Compressor COP decreases with its capacity ` 0 10 20 30 40 50 60 70 80 90 100 Capacity % Slide Ideal 60% of Capacity demands 80% of Energy 20% energy losses Confidential/Property of Danfoss Drives A/S Saturday, 14 September, 2013 29
VFD Capacity Control Screw Compressor - VFD Capacity Control Power % 100 80 60 40 20 0 VFD Curve 10 20 30 40 50 60 70 80 90 100 Capacity % VFD Screw Compressor Capacity Control Slide Valve & VFD actuate together for Compressor Capacity control VSD speed is determined by suction pressure PID control There is no dead band (Ramp up/down time is max 30s) Faster system response allows higher temperature operation Compressor COP is linear up to 60% of the capacity Minimum speed must be maintained (Motor cooling, Oil pressure) Slide VFD Ideal 60% of Capacity demands 60% of Energy Linear Energy Consumption Confidential/Property of Danfoss Drives A/S Saturday, 14 September, 2013 30
Advantages of Drives on Chiller Compressors No in-rush currents at start-up (Max. upto 200% of FLC). Drastic Reduction in Backup DG Sets Less Power Bills with lower Peak Demand (Improved power factor and Low Inrush Current) At least 20% Extra capacity available with the compressor (60 Hz operation) Smooth start and low wear and tear of Compressor 10% -30 % Energy Savings with Capacity Modulation as per requirement Motor Protection and Safety Reduced risk of liquid refrigerant in compressor at start-up through use of crankcase heater function 31
Other Benefits Better System Performance: Precise Temperature Conditions maintained by capacity modulation Flexibility and system simplification: Easy to Retrofit Smaller Compressors can be used with increased Capacity 32
VLT Refrigeration Drive Fan & Pump Applications
Physics Laws governing Centrifugal Devices including Centrifugal Compressors Basic Centrifugal laws applicable for Centrifugal Devices Flow Speed Pressure (Speed) 2 Energy (Speed) 3 20% Reduction in Speed of Pumps / Fans saves 50% Energy Confidential/Property of Danfoss Drives A/S Thursday, 21 August, 2008 JSP-INSC 34
VLT Drives Application On Fans 35
Laws of Affinity -Applicable on CentriCompressors / Fans / Pumps If Fan Speed is reduced thru VFD to 80% = 0.8 Then Air Flow Rate (0.8) = 80% Pressure Developed by Fan (0.8 x 0.8) = 64% Power Consumed by Fan (0.8 x 0.8 x 0.8) = 51% Therefore with 20% Speed Reduction, the Power Consumption is reduced to 50% 36
Evaporator Pump Applications Speed Control thru Temp Sensor or RH Sensor Speed Reduction upto 50% Automatic Temp. Control thru PID Controller One Drive can run multiple fans (One drive for One Chamber) Precise Temp. conditions maintained with substantial Energy savings Evaporator sync with Compressor to have capacity Modulation for whole system VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 37
Condenser Fans Applications Speed Control thru Refrigerant Outlet Temp. Speed Reduction upto 80% Automatic Speed Control thru PID Controller One Drive can run multiple fans (One drive for all Condenser Fans Units) Uniform Condenser performance with substantial Energy savings Condenser in sync with Compressor / Evaporator achieves maximum Energy Savings VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 38
Condenser Pump Applications Speed Control thru Condenser Water Outlet Temp. Speed Reduction upto 80% Automatic Speed Control thru PID Controller Uniform Condenser performance with substantial Energy savings Condenser in sync with Compressor / Evaporator achieves maximum Energy Savings VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 39
Brine / Glycol Pumps Applications Speed Control thru Temp Sensor on Return Temp. to Heat Exchanger Speed Reduction upto 50% Automatic Speed Control thru PID Controller Precise Temp. maintained at inlet of Evaporator Coils / Receiver with substantial Energy savings VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 40
Cooling Tower Fan Applications Speed Control thru Temp of Water Sump Speed Reduction upto 50% Automatic Speed Control thru PID Controller Precise Temp. maintained at Water Outlet from Cooling Tower leading to stable inlet Condenser Temp. resulting in substantial Energy savings VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 41
Typical Load Profile of a Refrigeration System & Savings Potential Energy Consumption Profile of System components Compressor Consumption Is Highest : 60% ~90% Typical Savings With VLTs 10-20% Evaporator Fans Consumption is 5~15% Typical Savings With VLTs 20-50% Condenser is 3~5% Typical Savings With VLTs 15-20% Brine Pump is 2 ~3% Typical Savings With VLTs 20-40% Condensor Pumps Evap Fans Secondary Pumps Compressor Compressor Condensor Pumps Evap Fans Secondary Pumps 42
VFD Retrofit Solutions on Compressors connected in Common Header Both the compressor contribute to the Refrigeration load Suction Header is also common for both Compressors Single Suction Pressure sensor is sufficient Cascade Control / Master Slave systems can be proposed VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 43
VFD Retrofit Solutions on Controlled Atmosphere Cold Stores VFD Retrofit possible on Compressor Application Evaporator Fans in a chamber can be fitted with Single Drive for Speed Control Inside Temp of the Chamber to be the feedback for Speed Control VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 44
VFD Retrofit Solutions on Cold Stores Chambers Single VFD Drive for Multiple Fan Cooler Units (FCUs) in one Chamber Inside Temp of the Chamber to be the feedback for Speed Control VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 45
VFD Retrofit Solutions on Multi- Purpose Cold Stores VFD Retrofit possible on Compressor Application Evaporator Fans in a chamber can be fitted with Single Drive for Speed Control Inside Temp of the Chamber to be the feedback for Speed Control VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 46
Danfoss Value Proposition www.danfoss.com
Easy to Install / Retrofit IP 55 / IP 54 / IP 66 enclosures Reliable operation in harsh environments No need for cabinets Fast and easy wall mounting VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 48
Pack controller for Multiple Compressor Operation Minimum energy consumption over a wide load range Compressor variable speed No external controller required Compressor fixed speed Compressor fixed speed VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 49
Cascade Control and Master Slave Control Cascade Control and Master Slave Control for Multiple Compressors Compressor variable speed System Optimization in a cost effective manner Compressor fixed speed Compressor fixed speed VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 50
Built-in Cascade Controller Replace external controllers Multiple Compressor optimized to save maximum energy VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 51
4 PID controller Independent closed loop applications without external controller VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 52
ADAP KOOL Electronic Controls Complete and integrated system from fully Automated Refrigeration Plant Customised Control Solutions to suit the specific application and requirement Pre-Loaded Applications provide flexible control schemes Can be extended to provide Web based Remote Monitoring and Control VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 53
Communication via bus systems Integration with System Manager / BMS systems on commonly used Communication Protocols RS485 Port for Communication Protocol ADAP KOOL VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 54
Inbuilt Dry run and end of curve pump protection Additional safety without external components VLT Refrigeration Drive FC 103 Saturday, 14 September 2013 55
Innovative Design Back Channel Cooling Lowest Heat Loss with Efficient Cooling System 80% heat can be taken out of Panel Room
No need for Special or Inverter Grade Motors No need for Special Inverter Grade Motors Runs the standard Squirrel Cage Induction Motors Safe for all Retrofit applications
Danfoss drives offer Patented VVC+ technology-motor friendly Conventional PWM Output PWM VFD OUTPUT RESULT: Motor does not get 100% fundamental voltage Stress on motor insulation and winding High heat generation Need for higher frame or inverter grade motor VVC+ TECHNOLOGY OUTPUT RESULT: VVC VVC PLUS Output Increased motor life-motor gets 100% fundamental voltage Less heat generation Motor works as if it is working on Mains No need of inverter grade motor
Danfoss VLT HVACR Drives Family VLT FC 102 VLT HVAC Drive VLT FC 101 VLT HVAC Basic Drive VLT FC 103 VLT Refrigeration Drive VLT FC 051 VLT Micro Drive Confidential/Property of Danfoss Drives A/S Thursday, 21 August, 2008 JSP-INSC 59
Local Service Global Expertise Dedicated HVAC sales organisation in India with skilled specialists Spare parts Hotline suppport Preventative service Service around-the-clock Global service network Confidential / Property of Danfoss Drives A/S 14 September, 2013 JSP/INSC/MKTG 60
Case Story - VFD Retrofit on Screw Compressor Successful Integration of VLT FC 102 Drive with Screw Compressor Presenting Power Electronics Confidential/Property of Danfoss Power Electronics Saturday, 14 September 2013 61
Installation Brewery Plant in North India Application Screw Compressor on Process Chilled Water Refrigeration System Brewery Plant in India Screw Compressor Application in Chiller Water / Ammonia Refrigeration System Motor KW 315 KW & Danfoss Drive - 315 KW Combined - Primary Ammonia + Chilled Water Application Presenting Power Electronics Confidential/Property of Danfoss Power Electronics Saturday, 14 September 2013 62
Test Results and Energy Savings Calculations Compressor with Slide Valve without VFD KW consumed to produce 1 Ton of Refrigeration = 0.94 KW Compressor with Slide Valve With VFD KW consumed to produce 1 Ton of Refrigeration = 0.69 KW Presenting Power Electronics Confidential/Property of Danfoss Power Electronics Saturday, 14 September 2013 63
Energy Savings Calculations - Conclusion Comparison of Energy Savings for Corresponding Refrigeration Load 300.00 KW Consumption. 250.00 200.00 150.00 173.14 127.25 203.93 149.87 210.02 154.35 225.40 165.65 254.75 187.22 160.75 118.14 176.00 129.35 193.69 142.35 221.26 162.61 239.87 176.28 100.00 50.00 45.90 54.06 55.67 59.75 67.53 42.61 46.65 51.34 58.65 63.58 0.00 184.73 217.57 224.07 240.47 271.79 171.50 187.78 206.65 236.07 255.91 Refrigeration Load TR KW Consumption without VFD KW Consumption with VFD Savings in KW KW/TR WITHOUT VFD 0.94 KW/TR WITH VFD 0.69 %age DIFFERNECE IN KW/TR WITH VFD 26.51% AVERAGE SAVINGS IN POWER CONSUMPTION / TR. OF REFRIGERATION LOAD 26.51% Presenting Power Electronics Confidential/Property of Danfoss Power Electronics Saturday, 14 September 2013 64
Calculated Energy Savings Projections - ROI Parameters Calculations Formulae Values A E Calculated Average Savings per Hour Rs. 436.60 A E Assuming power saving to be Rs 300 considering the load and season variation. Rs 300.00 R D Running Hours / day (Assumed) 16 Y Running Days / Year (Assumed) 300 H Total Running Hours per year R D x Y = H 4800 D Total Average Savings H x A E = D 1440000 C Cost of VFD System 1000000 ROI Return on Investment in Years ROI = D / C 0.69 Years Presenting Power Electronics Confidential/Property of Danfoss Power Electronics Saturday, 14 September 2013 65
Energy Savings Projections (Return on Investment) Important Points Even if the calculated ROI Projection is doubled, it is close to one year for the VFD system to pay back for the investment All in all, a very good case of enhanced Energy Savings using the Drive on Compressor Motor and very high return on Investment. Presenting Power Electronics Confidential/Property of Danfoss Power Electronics Saturday, 14 September 2013 66
Questions Confidential/Property of Danfoss Power Electronics Saturday, 14 September 2013 67