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1…8 compressors
Control cabinet
Condenser
Evaporator
Smardt Water Cooled Chillers (V-Class)
350-2500tonR(1230-8,800kWr)
1…7 compressors
1…4 compressors
Control cabinet
Evaporator
Smardt Evaporatively Cooled Chillers (E-Class)
60-360TR (200-1260kWr)
Condenser fitted with
EC-fans as standard
Control cabinet
1…3 compressors
2010
Establishment of
2000 USA Factory
Establishment of
2015
1985 2003 S.E. Asia Regional 2012 Licensed
Smardt. First
Foundation of 1st Turbocor chiller Office established 5th Factory Manufacturing
Compressors
OPK AG in the market in Singapore opened in China established in Brazil
Installed
% of Run Hours
50%
100% 1% 1%
40%
75% 42% 29% 30%
20% Majority of Run Time
50% 45% 65% 10%
0%
25% 12% 5%
25% 50% 75% 100%
% of Capacity
AHRI Standard 550/590-98 MS 1525:2014 Standard
Smardt-Chiller - Efficiency
1.2
1.1
1
Efficiency (kw/TR)
0.9
0.8
25% better
0.7 50% better efficiency
efficiency
0.6
0.5
0.4
60 120 180 210 240 300 360 420 480 540 600
Capacity (TonsR)
Conventional Chiller Issues –
Outdated Compressor Technology
• Conventional Compressors
reliance on oil results in;
– Increased energy consumption
– Inability to accurately match
operating conditions
– Increased operating costs
over a chillers lifetime 1922 – First Centrifugal Chiller
• Modern chillers still have the same historically fundamental issues:
– VSDs reduced power consumption, but increases oil-related issues,
particularly at part load.
– Noise and Vibration are still an issue
– High Start Up currents remain a problem
– Size and Weight of Components poses service and installation difficulties.
Complex Oil Management = Chiller Issues
• Conventional Chillers Require Oil Management
• Oil Management Adds Complexity
– Gears - Friction
– Oil Sump
– Emergency oil reservoir
– Oil cooler
– Oil filter
– Oil heater
– Oil Differential pressure switch
• Additional Complexity Leads to Failures
• Ongoing Operating Costs related to Oil
– Oil Sampling, Replacement, Top Ups, Disposal
Oil Management of a Conventional – Filters/Dryers/Sensors needing replacement
Centrifugal Compressor
The Affect of Oil on Performance
Heat exchanger efficiency drops because of oil slick / coating
Water Water
7⁰C 7⁰C
A brand new heat exchanger The effect of prolonged oil in the system
- A healthy approach of 1⁰C - Accumulation of oil increase the approach to 3⁰C
- Higher approach reduces Chiller Capacity and Performance
The Effects of Oil
Percentage of Oil in the System
• The top ASHRAE study determined the
average quantity of oil as a percentage in
older chillers.
Chiller The average is approx. 13%.
600000 kW/h
500000 kW/h
400000 kW/h
300000 kW/h
Smardt - Chiller
Centrifugal - Chiller
100000 kW/h
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Diagram: as this comparative study showed, over 20% of lubricated chiller's operating
efficiency is routinely lost in the early years as a result of oil clogging of heat transfer surfaces.
Reduction in Failures through Simplified Piping
Solenoid valves
for cooling
Press.Temp
Sensors
Permanent
Magnet,
DC Motor
• Magnetic Bearings
– Eliminate high mechanical
friction losses
– Increase equipment
life through elimination
of wear surfaces
– Eliminate oil-related
heat transfer losses
– Eliminate complex oil
management systems
(controls and hardware)
Magnetic Bearing System
• True Soft Start – with chillers starting < 2amps. — Smardt Soft Start
To achieve the best efficiency when operating the chiller, the maximum
number of compressors run in parallel.
This is controlled by propietary logic developed by Smardt and managed by
Smardt‘s own chiller controller
Active Redundancy
Peak load at 1800RT
Conventional oil based chiller with single compressor Night load @ 300RT
X
Chiller 1
Chiller 2
x
Each compressor is about 7%
Chiller 1 Chiller 2 Standby
Chillers 2000RT * 93% = 1860RT
Chiller Compressors
pre-start check run
0 70 Time (Secs)
Power Compressor
restored restarted
Chiller Compressors
pre-start check run
0 20 Time (Secs)
Power Compressor
restored restarted
Smardt Restart Advantages
• No oil related pressure and temperature checks, safeties
or timers.
• No mechanical stress on compressors during restart
• No thermal stress on motor during multiple restarts, and
no power surges, < 2 Amps starting current
• No hours based limitation on number of restarts (open
drive compressors should only be restarted twice an
hour)
• No loss of communications with Chiller controller.
• Fast chilled water recovery with Smardt’s proprietary
programme - eliminate the need for additional thermal
storage
Building Integration & Service Convenience
• Full Integration with BMS via HLI
• Descriptive Alarms and Faults
• Real Time Trending
0.75
0.7
0.65
Efficiency ikw/RT
0.6
0.55
0.5
0.45
0.4
VTT kW/tonR
0.35
McQuay
0.3
100 200 300 400 500 600 700 750 800 850 900 950 1000
Cooling Capacity (RT)
Smardt is the Global Leader in Oil-Free Chillers
Operating
Costs
Lowest Lifecycle Costs
first costs
first costs
$8,000,000
$7,000,000
$6,000,000
$5,000,000
1500%
$4,000,000
≈75% Savings
$3,000,000 675%
$2,000,000
375%
$1,000,000
$-
Conventional Smardt Smardt + CPECS
1 No. Of chillers 4
4 Redundancy 825 RT
1 No. Of chillers 2
4 Redundancy 625 RT
$20,000
$10,000
$-
January February March April May June July August September October November December
63
ALEXANDRA POINT CUMULATIVE ENERGY SAVINGS, SGD$
Cumulative Savings Monthly Savings
$1,000,000
$982,459
$938,310
$900,000 $883,190
$827,262
$800,000 $773,159
$723,550
$700,000 $671,107
$619,762
$600,000 $566,411
$508,487
$500,000
$452,498
$417,472
$400,000 $376,023
$346,999
$304,516
$300,000 $262,398
$226,660
$192,880
$200,000
$152,791
$125,962
$97,701
$100,000 $65,371
$21,973$37,116
$-
Alexandra Point – 2 Year Analysis
Results To Date – Jan ‘14 – Dec ’15 (2 years)
1. Energy Savings To Date : 2,906,889 kWh
2. Projected Annual Energy Saving : 1,729,386 kWh
3. Energy Cost Savings To Date : $ 982,459 SGD
4. Projected Annual Energy Cost Savings : $ 600,000 SGD
5. Simple Payback : 4.15 Years
6. Incremental Payback Achieved : 14 Months
Additional Benefits Realised Management Objectives
• 40% Reduction In Investment – 2 less chillers • Green Mark Platinum Achieved
• Exceptional ROI
• 40% Improvement In Plant Effiency
• Cost Efficient
• 45% Reduction In Energy Used • Resource Efficient
• 17% Reduction In Potable Water Used • Improved Redundancy
• 70% Reduction In Annual Maintenance Costs • Improved Reliability
Tiger Brewery
Case Study
Singapore, Tiger Breweries (300RT Retrofit)
40% improvement
in chiller efficiency
165RT AC
MY Oasis
Carnegie Hall,
New York City
Chicago Mercantile
Exchange
Sam Ringwaldt
Vice President – Asia/Pacific