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Frictionless Compressor Technology
Frictionless Compressor Technology
Frictionless Compressor Technology
Contents
1. Introduction ............................................................................................................................................... 1
2. Types of Compressors............................................................................................................................... 2
2.1 Centrifugal Compressors .................................................................................................................... 2
2.2 Diagonal or Mixed-Flow Compressors ............................................................................................... 2
2.3 Axial-Flow Compressors .................................................................................................................... 3
2.4 Reciprocating Compressors ................................................................................................................ 3
2.5 Rotary Screw Compressors ................................................................................................................. 3
2.6 Rotary Vane Compressors .................................................................................................................. 4
2.7 Scroll compressors .............................................................................................................................. 4
3. The Emerging Technology In Centrifugal Compressor ............................................................................ 5
4. Main Components ..................................................................................................................................... 6
4.1 Mechanical Components ..................................................................................................................... 6
4.2 Electrical Components ......................................................................... Error! Bookmark not defined.
5. The Bearings ........................................................................................................................................... 10
6. Shutdown And Power Failures ............................................................................................................... 11
8. The Motor ............................................................................................................................................... 11
9. Capacity And Efficiency ......................................................................................................................... 12
10. Sound And Vibration ............................................................................................................................ 13
11. Frictionless Compressor Technology.................................................................................................... 14
12. Advantages And Disadvantages OF Frictionless Compressor Technology.......................................... 16
13. Conclusion ............................................................................................................................................ 17
14. References ............................................................................................................................................. 18
1. INTRODUCTION
A new compressor technology introduced during the 2008 International Air Conditioning
Heating Refrigerating Exposition (AHR Expo), held at January in Chicago, may have a
significant effect on the future of mid-range chillers and rooftop applications in water cooled,
evaporative cooled, and air-cooled chilled water and direct-expansion (DX) systems. Designed
and optimized to take full advantage of magnetic-bearing technology, the compressor was
awarded the first AHR Expo Innovation Award in the energy category, as well as Canada’s
Energy Efficiency Award for its potential to reduce utility-generated greenhouse-gas emissions.
The compressor is key to a new water cooled centrifugal-chiller design, with Air Conditioning
and Refrigeration Institute (ARI) tests indicating integrated part-load values (IPLVs) not
normally seen with conventional chillers in this tonnage range.
Frictionless Compressor Technology is one of the fast growing Technology in the mechanical
engineering field. In the case of Traditional centrifugal compressors, we use roller bearings &
hydrodynamic bearings, both of them consume power & require oil & lubrication system. This
can be overcome by introduction of the new compressor technology which is called as
frictionless compressor technology.
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its
volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can
transport the fluid through a pipe. As gases are compressible, the compressor also reduces the
volume of a gas. Liquids are relatively incompressible, so the main action of a pump is to
transport liquids.
2. TYPES OF COMPRESSOR
The main types of gas compressors are illustrated and discussed below:
Compressor Types
Positive
Dynamic
Displacement
Reciprocatin Rotar Centrifug
Axial
g y al
Single
Diaphgram
Acting
Double Liquid
Lobe Screw Scroll Vane
Acting Ring
to the axial direction. The diagonal compressor has a lower diameter diffuser than the equivalent
centrifugal compressor.
also used for many automobile engine superchargers because it is easily matched to the induction
capacity of a piston Engine
With suitable port connections, the devices may be either a compressor or a vacuum pump. They
can be either stationary or portable, can be single or multi-staged, and can be driven by electric
motors or internal combustion engines. Dry vane machines are used at relatively low pressures
(e.g., 2 bars) for bulk material movement whilst oil-injected machines have the necessary
volumetric efficiency to achieve pressures up to about 13 bars in a single stage. A rotary vane
compressor is well suited to electric motor drive and is significantly quieter in operation than the
equivalent piston compressor.
The Frictionless compressor is the world’s first totally Oil-Free compressor specifically
designed for the Heating, Ventilation, Air Conditioning and Refrigeration (HVACR) industry.
The convergence of aerospace and industrially proven magnetic bearings, variable-speed
centrifugal compression and digital electronic technologies enables the frictionless compressors
(nominal 60-150 ton capacity range) to achieve the highest compressor efficiencies, cost
effectively, for middle-market, water-cooled, evaporative-cooled and air-cooled HVACR
applications.
Optimizing energy performance through the entire operating range from 100% to 20% or below
of rated capacity. Operations to near zero loads are achievable via an optional, digitally
controlled, load balancing valve.
Centrifugal compressors tend to be more efficient than screw or scroll compressors, and take
advantage of speed control more effectively, but they are usually only available in larger sizes.
By using the smaller shaft, they are able to take advantage of the centrifugal compressor
technology in a smaller size than is normally available.
High-speed variable frequency operation affords high efficiency, compactness and soft
start capability
3. Touchdown bearings
Carbon-lined radially and axially located bearings support the rotor when the compressor
is not energized
Prevents contact between the rotor and other metallic surfaces.
5. Compressor cooling
Liquid refrigerant flow is controlled electronically, cooling electronic, mechanical and
Electromechanical compressor components to assure maximum efficiency and safe
operation
IGBT (Insulated Gate Bipolar Transistor) is an inverter that converts a DC voltage into an
adjustable three-phase AC voltage
Signals from the motor/bearing controller determine the inverter output frequency,
voltage and phase, thereby regulating the motor speed converts mechanical energy back
into electrical energy.
In case of power failure, this patented control scheme allows for a normal deLevitation
and shutdown.
3. Three-phase terminal block
Converts AC line power into a high-voltage DC power source for motor, bearings and
control operations.
5. Capacitors
Supplies and electrically isolates the high and low DC voltages required for the control
circuits.
7. Controls connection
5. THE BEARINGS
Traditional centrifugal compressors use roller bearings and hydrodynamic bearings, both
of which consume power and require oil and a lubrication system. Recently, ceramic roller
bearings, which avoid issues related to oil and reduce power consumption, were introduced to the
HVAC industry. The lubrication of these bearings is provided by the refrigerant itself.
When the magnetic bearings are energized, the motor and impellers, which are keyed
directly to the magnetic shaft, levitate. Permanent-magnetic bearings do the primary work, while
digitally controlled electromagnets provide the fine positioning. Four positioning signals per
bearing hold the levitated assembly to a tolerance of 0.00002 in. As the levitated assembly
moves from the center point, the electromagnets’ intensity is adjusted to correct the position.
These adjustments occur 6 million times a minute. The software has been designed to
automatically compensate for any out-of-balance condition in the levitated assembly.
7. OIL-FREE DESIGN
Magnetic bearings eliminate the need for these systems and oil management in general. In fact,
the only required regular maintenance of the compressor is the quarterly tightening of the
terminal screws, the annual blowing off of dust and cleaning of the boards, and the changing of
the capacitors every five years. Complete service agreements and extended maintenance
contracts can be provided by the manufacturer.
8. THE MOTOR
Most hermetic compressors use induction motors cooled by either liquid or suction-gas
refrigerant. Induction motors have copper windings that, when alternating current is run through
them, create the magnetic fields that cause the motor to turn. These copper windings are bulky,
adding size and weight to the compressor. Two-pole, 60-Hz induction motors operate at
approximately 3,600 rpm. A higher number of revolutions per minute can be obtained by
increasing the frequency. Compressors that require higher shaft speeds tend to use gears. While
gears are a proven technology, they create noise and vibration, consume power, and require
lubrication. The magnet-bearing compressor features a synchronous permanent-magnet brushless
DC motor with a completely integrated variable-frequency drive (VFD). The stator windings
found conventional induction motors are replaced with a permanent-magnet rotor. Alternating
current from the inverter energizes the armature windings. The stator (excitation) and rotor
(armature) change places. The motor and key electronic components are internally refrigerant
cooled, so no special cooling is required for the VFD or the motor.
The use of permanent magnets instead of rotor windings makes the motor smaller and lighter
than induction motors. Using magnetic-bearing technology, a 75-ton compressor weighs 265
lb.—about one-fifth the weight of a conventional compressor. A variable-speed drive (VSD) is
required for the motor to operate.
The VSD varies the frequency between 300 and 800 Hz, which provides a compressor-speed
range from 18,000 to 48,000 rpm. This avoids a gear set. The VSD is integrated into the
compressor housing, avoiding long leads and allowing key electronic components to be
refrigerant-cooled. The VSD also acts as a soft starter; as a result, the compressor has an
extremely low startup in-rush current: less than 2 amps, compared with 500 to 600 amps for a
traditional 75-ton, 460-v screw compressor with a cross-the-line starter. With the integration of
the motor, VSD, and magnetic-bearing system, the capacitors required for the motor and drive
can be used as a backup power source for the bearings in the event of a power outage or
emergency shutdown.
Current development projects are expanding the range and duty of the compressor wheels and
promise to offer even greater efficiency for water-cooled and air-cooled duties and different
capacities.
ARI Standard 575-94, Method of Measuring Machinery Sound within an Equipment Space.
11. WORKING
Frictionless Compressor Technology
Frictionless Compressor Technology is one of the fast growing Technology in the
mechanical engineering field. In the case of Traditional centrifugal compressors, we use roller
bearings & hydrodynamic bearings, both of them consume power & require oil & lubrication
system. This can be overcome by introduction of the new compressor technology which is called
as FRICTIONLESS COMPRESSOR TECHNOLOGY. The frictionless compressor technology
is the compressor with which the application of the magnetic bearings & permanent magnet
synchronous motor. In the frictionless compressor instead of the roller bearings & hydrodynamic
bearings, magnetic bearings will be use. Magnetic bearings consume less power & there is no
need for the oil and lubrication systems. Permanent magnet brushless synchronous motor has the
permanent magnet instead of the copper windings. This compressor has the high efficiency,
reliability, less maintenance cost & the staff. With help of the digital control system, controlling
& monitoring of the work is very easy. The frictionless compressor technology makes new
revolutions in the field of air conditioning, refrigeration etc.
1. Magnetic bearings.
2. Oil-free design.
3. VFD control.
5. Less noise
3. Power Management.
Easy to control
Onboard digital electronics make the compressor “the compressor” with a brain. Inside,
the compressor is totally self-correcting and incorporates a system of sophisticated self-
diagnostics, monitoring and control. Outside, you can tap into this intelligence by using
control outputs in various for including web-enabled monitoring and control.
Disadvantages:
• Higher first-cost.
13. CONCLUSION
14. REFERENCES
2. Perry, R.H. and Green, D.W. (Editors) (2007). Perry's Chemical Engineers' Handbook, 8th
Edition, McGraw Hill. ISBN 0-07-142294-3.
4. Bloch, H.P. and Hoefner, J.J. (1996). Reciprocating Compressors, Operation and
Maintenance. Gulf Professional Publishing. ISBN 0-88415-525-0.