Improving Rotary Screw Compressor Performance using Variable Speed Drives

John Cosner, JCI/Frick

A Global Energy Situation.

Efficiency In The Engine Room

Optimum
Constant Speed @ 100% Cap. Constant Speed @ 100% Cap. VFD @ 30% Cap. S.V. Loaded

Better
Constant Speed @ 100% Cap. Constant Speed @ 100% Cap. Constant Speed @ 30% Cap.

Inefficient
Constant Speed @ 100% Cap. Constant Speed @ 70% Cap. Constant Speed @ 60% Cap.

Compressor Facts

Often the most concentrated and largest consumers Most new installations use rotary screw compressors. At least one compressor will go to a part load condition.

Constant Torque / Variable Horsepower Screw Compressors

Torque and Power

100% 80% 460V / 60Hz = 7.67V : 1Hz 60% 40% 20% 0% 0% 20% 40% 60%
Horsepower Torque

80%

100%

Constant Torque Horsepower = % Speed

Speed

Full Load Power = 500HP / 375KW FLA = 580 Running @ 35% Capacity (by speed) Voltage = 161Vpwm HP = 175 Amps = 580

VSD
35% Out 21 Hertz 1260 RPM

Voltage = 460vac HP = 175 Amps = 203

580 Amps 132 KW

Motor

Variable Torque / Variable Horsepower Pumps & Fans

100% Torque and Power 80% 60% 40% 20% 0% 0%

Torque = % Speed Horsepower = % Speed
Horsepower Torque

20%

40%

60%

80%

100%

Speed

Part Load Efficiencies @ Approximately 6:1 CR

Throttling, Step Loading (Poppet), Slide Valve w/Var. Vi, VFD w/Var. Vi and Ideal

110.00 100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0% 20% 40% 60% 80% 100% % Capacity

% Full Load Power

Throttling Poppet Slide Valve VFD Ideal Eff.

Improved Part Load Efficiency Solution

Capacity 20% -100% (720 RPM 3600 RPM ) 100% Slide Valve

Base Loaded, Capacity 100% 3600 RPM 100% Slide Valve

The improvement in part load efficiency will vary based on Compression Ratio Minimum Speed Volume Control

Compression Ratio (CR)

194.8psiaD / 48.7psiaS 4:1 CR

194.8psiaD / 19.48psiaS 10:1 CR

Example: Improvement at 40% capacity by speed over 40% capacity by slide valve
4:1 CR = 19% Improvement 10:1 CR = 33% Improvement

Minimum Speed

Minimum speed established by the limitations of the: compressor motor oil type refrigerant.
NH

Compressor Minimum Speed

Sleeve bearings 1800 rpm. Rolling element bearings 720 rpm Viscosity required at 1800rpm is 11cSt. Viscosity required at 720rpm is 18cSt. Speeds below design limits may cause a mixed film or boundary lubrication condition.

Oil & Refrigerant

R-717@ 20F (-6.5C)SST 720 RPM Minimum

R-22 @ 10F (-12C)SST 1250 RPM Minimum

R-22 @ 20F (-6.5C)SST 1500 RPM Minimum

Motor Minimum Speed

Fractional HP Squirrel Cage Fan/s Ensure Adequate Air Flow At All Speeds

An issue of bearings and heat rejection. Air-flows at speeds below 50% speed may not be adequate. Check with manufacturer for minimum speed. Motor stator temperature protection is now required (NEC 2005).

Variable Volume Control

5.0 4.0 With VSD at part load Vi stays ideal Vi at part load by slide valve

5.0

Vi 3.0
2.0 1.0

2.2

15 20

40

60

80

100

% Capacity

% Capacity to % Slide Valve Position

Energy Savings @ Part Load

Slide Valve w/Variable Vi VFD w/Variable Vi

HP to $$$ - 10HP may cost over $5,200 annually (.08 KWH).

RWFII-270 @ 20F (-6.7C) SST / 95F (35C) SDT 4.06:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies

700.00 650.00 600.00 550.00 500.00 450.00 400.00 350.00 300.00 250.00 200.00 150.00 100.00 50.00 0.00 0%

S.V. Control VFD Control

650HP

Horse Power

19 HP 52 HP 107 HP

20%

40%

60%

80%

100%

% Capacity

RWFII-270 @ 20F (-6.7C) SST / 75F (24C) SDT / 2.9:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies

500.00 450.00 400.00 350.00 300.00 250.00 200.00 150.00 100.00 50.00 0.00 0%

S.V. Control VFD Control

475HP

Horse Power

9 HP 31 HP 62 HP

20%

40%

60%

80%

100%

% Capacity

RWFII-270 @ -40F (-40C) SST / 95F (35C) SDT / 18.75:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies

450.00 400.00 350.00 300.00 250.00 200.00 150.00 100.00 50.00 0.00 0%

S.V. Control VFD Control

420HP

Horse Power

26 HP 82 HP 137 HP

20%

40%

60%

80%

100%

% Capacity

RWFII-270 @ -40F (-40C) SST / 75F (24C) SDT / 13.45:1 CR on Ammonia Slide Valve, VFD and Ideal Part Load Efficiencies

350.00 300.00 Horse Power 250.00 200.00 150.00 100.00 50.00 0.00 0%

S.V. Control VFD Control

335HP

18 HP 60 HP 102 HP

20%

40%

60%

80%

100%

% Capacity

Typical VSD Operation Slide Valve Unloaded NH3

Capacity Control Strategy Strategy Capacity Control
100% 100% 90% 90% 80%
70% 60% 50% 40% 30% 20% 10% 0% 0%

Speed

Percent Slide Valve Percent Valve

SV

Speed

Off
0% 0%

Run
20% 20% 40% 60% 40% 60% Percent Percent Speed Speed 80% 80% 100% 100%

Typical VSD Operation Slide Valve Loaded NH3

Capacity Control Strategy
100% Percent Slide Valve 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0% 20% 40% 60% 80% 100% Percent Speed

SpeedRun SV Off

Speed

Typical VSD Operation with Standby Mode (Vyper)

Capacity Control Strategy
100% Percent Slide Valve 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0% 20% 40% 60% 80% 100% Percent Speed
Stand-by Speed Run at 100%SV

Speed

Speed

Up To 2Up Hrs To 2 Hrs.

Economizing
Econo. Improvement of HP/TR -40F/95F
14 12 10 HP/TR 8 6 4 2 0 0 50 Tons 100 150 Non E SV Econ VSD Non E VSD Econ SV

Controlling The VSD

Manufacturers Controller To Be The Supervisory Control
Low Oil Flow High Motor Amps High discharge Pressure Low Mass Flow The PLC Controls The Speed But Is Routed Through The Package Mounted Controller

VSD Control with Quantum LX Capacity Control Setup

Motor & Drive Setup

Skip Frequencies
Speed trend line

Can I Retrofit My Existing Equipment???

VSD?

Retrofitting Existing Equipment For Energy Savings

Ensure the VSD is constant torque. Motor is inverter duty rated. Minimum speed is identified. Ensure environment is adequate. Total cable distance between drive and motor is within spec. Controller is able to protect the compressor as well as control the drive.

To VSD or Not To VSD?

Qualifying Expense Through Savings (ROI)

Total Load Profile 1. 2. 3. 4. Hours of Operation? Compression Ratio? Cost per KWH? Part Load Profile?
What is My Part Load Profile?

How Do I Accurately Get This Information? Items 1-3 Are Easy

Quantum LX Load Profile Screen

The VSD Energy Savings Calculator

The Load Profile Data is Entered

Payback in 1.8 yrs.

What About Step Loading Machines?

Vyper Retrofit At JCI-Frick in Waynesboro, PA

In Conclusion..
When Properly Applied, VSDs On Rotary Screw Compressors Can: Lower Energy Usage & Cost Enhance Economizer Boost Remove Setpoint Over-Shoot Provide Quicker Response To Load Fluctuation Keep Capacity Slides Fully Loaded Reduce Maintenance Costs Reduce Noise Levels Properly Applied Is The Key!

Thank You!