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 Constant Speed VFD @ 30% Cap.

@ 100% Cap. @ 100% Cap. S.V. Loaded

Better

Constant Speed Constant Speed Constant Speed

@ 100% Cap. @ 100% Cap. @ 30% Cap.

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

100%
Torque and Power

80% 460V / 60Hz = 7.67V : 1Hz

60%

40%

20%
Horsepower
Torque
0%
0% 20% 40% 60% 80% 100%
Constant Torque Speed
Horsepower = % 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
580 Amps
Voltage = 460vac
HP = 175 132 KW
Amps = 203

Motor
 Variable Torque / Variable Horsepower
Pumps & Fans

100%
Torque and Power

80%

60%

40%

20%
Horsepower
Torque
0%
0% 20% 40% 60% 80% 100%
Speed
Torque = % Speed²
Horsepower = % Speed³
 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
% Full Load Power

90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
Throttling 0% 20% 40% 60% 80% 100%
Poppet
Slide Valve
VFD
% Capacity
Ideal Eff.
 Improved Part Load Efficiency
Solution

Capacity 20% -100% Base Loaded, Capacity 100%

(720 RPM 3600 RPM ) 3600 RPM
100% Slide Valve 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 194.8psiaD / 19.48psiaS

4:1 CR 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.

NH³
 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@ 20˚F (-6.5˚C)SST

720 RPM Minimum

R-22 @ 10˚F (-12˚C)SST R-22 @ 20˚F (-6.5˚C)SST

1250 RPM Minimum 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 5.0
With VSD at part load
4.0 Vi stays ideal

Vi 3.0 Vi at part load

by slide valve
2.0 2.2

1.0

0 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 @ 20˚F (-6.7˚C) SST / 95˚F (35˚C) SDT 4.06:1 CR on Ammonia
Slide Valve, VFD and Ideal Part Load Efficiencies

700.00
S.V. Control 650HP
650.00
600.00 VFD Control
550.00
Horse Power

500.00
450.00 19
400.00 HP
350.00
300.00 52
250.00
200.00 HP
150.00
100.00 107
50.00 HP
0.00
0% 20% 40% 60% 80% 100%
% Capacity
RWFII-270 @ 20˚F (-6.7˚C) SST / 75˚F (24˚C) SDT / 2.9:1 CR on Ammonia
Slide Valve, VFD and Ideal Part Load Efficiencies

500.00
S.V. Control 475HP
450.00
VFD Control
400.00
Horse Power

350.00
9
300.00
HP
250.00
200.00
31
150.00 HP
100.00
62
50.00 HP
0.00
0% 20% 40% 60% 80% 100%
% Capacity
RWFII-270 @ -40˚F (-40˚C) SST / 95˚F (35˚C) SDT / 18.75:1 CR on Ammonia
Slide Valve, VFD and Ideal Part Load Efficiencies

450.00
S.V. Control 420HP
400.00 VFD Control
350.00
Horse Power

300.00 26
250.00 HP
200.00
82
150.00 HP
100.00 137
50.00 HP

0.00
0% 20% 40% 60% 80% 100%
% Capacity
RWFII-270 @ -40˚F (-40˚C) SST / 75˚F (24˚C) SDT / 13.45:1 CR on Ammonia
Slide Valve, VFD and Ideal Part Load Efficiencies

350.00 S.V. Control 335HP

300.00 VFD Control
Horse Power

250.00
18
200.00 HP

150.00 60
100.00 HP

102
50.00 HP
0.00
0% 20% 40% 60% 80% 100%
% Capacity
 Typical VSD Operation
Slide Valve Unloaded – NH3

Capacity Control Strategy

Capacity Control Strategy

100%
100% Speed
90%
90%
80%
Valve
Percent Slide Valve

70%
60% SV
50%
40%
Percent

30%
Speed
20%
10% Off Run
0%
0%
0%
0% 20%
20% 40%
40% 60%
60% 80%
80% 100%
100%
Percent
Percent Speed
Speed
 Typical VSD Operation
Slide Valve Loaded – NH3

Capacity Control Strategy

100% SpeedRun
SV
Off Speed
90%
80%
Percent Slide Valve

70%
60%
50%
40%
30%
20%
10%
0%
0% 20% 40% 60% 80% 100%
Percent Speed
 Typical VSD Operation
with Standby Mode (Vyper™)

Capacity Control Strategy

Stand-by
100% Speed Run Speed Speed
at 100%SV
90%
80%
Percent Slide Valve

70%
Up To
2Up
HrsTo
60%
2 Hrs.
50%
40%
30%
20%
10%
0%
0% 20% 40% 60% 80% 100%
Percent Speed
 Economizing

Econo. Improvement of HP/TR -40F/95F

14

12

10

Non E SV
8
HP/TR

Econ VSD
Non E VSD
6
Econ SV
4

0
0 50 100 150
Tons
 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. Hours of Operation? What is My

Part Load
2. Compression Ratio? Profile?
3. Cost per KWH?
4. 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!