CTTC Technology Consultant Report ASHRAE Annual Meeting Denver 2013

High Speed Centrifugal Compressors

June 21, 2013 John Dieckmann TIAX LLC Lexington, MA dieckmann.j@tiaxllc.com
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Small high speed centrifugal compressors

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high speed (10s of thousands of RPM, 3 to 4 inch impeller diameter) centrifugal compressors have become commercially available over the past several years.
Water cooled and air cooled chiller applications Potential for unitary air conditioning Oil free Capacities down to 50 tons

Centrifugal Compressors/Chillers -Background

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Centrifugal compressors a standard refrigerant compressor type since Willis Carrier in the early 20th century. For the rest of the 20th century centrifugal compressors came in two basic configurations

Multistage induction motor direct drive at 3600 RPM Single stage, induction motor driven via a speed increase gear drive (~10,000 RPM)

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Speed/size scaling laws result in best performance multi hundreds of tons and larger. Oil lubricated bearings and gears. Predominantly used in water cooled chillers.
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Centrifugal Compressors/Chillers -Background

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At constant speed and impeller diameter, matched for one evaporator to condenser temperature lift. Part load, partial lift handled by:

Inlet guide vanes (i.e., prerotation vanes) Hot gas bypass when needed to prevent surging

In the 1990s, continuing into the 2000s, variable frequency drive technology improved significantly.

Lower cost High reliability

Variable frequency drive technology applied to conventional chillers allows matching speed to lift, less use of both inlet guide vanes and hot gas bypass
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Small high speed centrifugal compressors

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frequency drives also allow motor rotation speeds >> 3,600 RPM. z Opened up possibility of direct drive, high speed centrifugal compressors. z High speed and small impeller diameter + scaling laws extends efficient range of centrifugal compressors to smaller capacity.
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Small high speed centrifugal compressors

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Several mechanical approaches have been followed, all aimed at oil free systems, all with two stages to provide sufficient lift for air cooled applications

Refrigerant lubricated ball bearings Foil type gas bearings Magnetic bearings

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Oil less system improves evaporator heat transfer Two stage, variable speed provides good part load performance, little need for hot gas bypass to prevent surging
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Small high speed centrifugal compressors one example of a mechanical design - 2 stages on opposite ends of motor, refrigerant lubricated ball bearings

Small high speed centrifugal compressors another example of a mechanical design 2 stages on same end of motor, magnetic bearings

Conclusions

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Small high speed centrifugal compressors are now a viable option for small to medium sized chiller applications, both water and air cooled. Products are available from several manufacturers from approximately 50 tons to over 1,000 tons. Full and part load performance is generally good.

Competitive kW/ton Competitive IPLV

High speed centrifugals are another solid option for cooling in the 50 to several hundred ton capacity range. Specifics of each application should be considered before deciding on chilling equipment selection.
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Other resources

ASHRAE TC 8.2 Centrifugal Machines.

Sponsors seminars at many ASHRAE meetings Maintains the centrifugal compressor part of a handbook chapter (Chapter 38, 2012 HVAC Systems and Equipment volume) Maintains the centrifugal chiller part of a handbook chapter (Chapter 43, 2012 HVAC Systems and Equipment volume)

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ASHRAE 2012 HVAC Systems and Equipment Handbook chapt 38 Compressors p. 38.2738.37 ASHRAE 2012 HVAC Systems and Equipment Handbook chapter 43 Liquid-Chilling Systems pp. 43.7 43.13 Many major manufacturers of HVAC equipment offer chillers with high speed centrifugal compressors, with extensive product literature.
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