ClimaCheck Introduktion

ClimaCheck
Enhance performance
save energy and environment
in air-conditioning
refrigeration and
heat pumps
systems
Field inspection unit
Fixed installation
ClimaCheck Sweden AB
Klas Berglöf
www.climacheck.com
ClimaCheck Sweden
• World leader in Performance Analysing for refrigeration and
air-conditioning systems
• Potential to reduce energy and peak load with 20-30%
for air conditioning and refrigeration systems
• Reduce failures - extend life of equipment – early warning
• Distributors in 20+ countries – UL/CSA/CB certification
• Work with leading universities/companies in many countries
• Refrigeration Product of the Year 2009 in UK
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15-20% of all electricity used for
refrigeration, air-conditioning and heat pumps
3
International trend to push energy efficiency
through legislation and green building certification
In EU - Energy Performance in Building Directive (EPBD)
Inspection of all AC-system
with more than 12 kW cooling capacity
The inspection is to include
“an assessment of the air conditioning efficiency
and the sizing compared to the cooling requirements of the building”.
Advice is also to be provided to the users on
“possible improvement or replacement of the air-conditioning system and
on alternative solutions”.
4
13% of 164 systems were OK!
Source: Master Thesis by John Arul Mike Prakash, , KTH Stockholm 2006
90
80
70
60
50
40
30
20
10
0
78
51
27
20
No
Co
nt
ro
ls
ys
te
m
Se
co
nd
ar
y
flo
w
Ch
ar
ge
e
va
lv
n
Ex
pa
ns
io
fa
ul
ts
4
3
Co
m
pr
es
so
r
Number of systems
Representation of faults for all the sectors
Inspections were planned and contractor informed
Huge difference between theory and practice!
5
Huge variation in COP
Source: Master Thesis by John Arul Mike Prakash, , KTH Stockholm 2006
% Variation in COP (vs.) Nominal capacity kW
% variation in COP
10
0
-10
-20
-30
-40
0
200
400
600
Nominal capacity kW
6
800
1000
ClimaCheck performance analyses
Unique innovative method – total visualisation of performance
Flexible PC and Web based systems to document:
 Commissioning





Performance inspection
Continuous monitoring
Preventive maintenance
Trouble shooting
Decision support
– minimize warranty cost
– optimisation
– early warning and optimisation
– reduce failure rate – optimise
– avoid damage to product
– expansion retrofit
Any expert - independent or from supplier can analyse system
Also used by 40+ manufacturer development and production test rigs
7
Do not retrofit without knowing what you retrofit!
Pre-retrofit analyses
Do not invest in poor
systems that are failing
Fixed system
Establish baseline
consumption
R-22 Retrofit
Post-retrofit analyses
ClimaCheck
optimisation
Optimise
Document performance
Detect future deviation
Easy to apply –
to standard service “points”
Electrical input
7 surface temperatures
2 pressures from
service ports
9
Application of sensors to standard system
(typically done in 20-30 minutes)
• 2 pressures
• 7 temperatures
• 1 power input
No information about system or compressor added
10
Simple Refrigeration Cycle
P
m
condensation
m
Expansion
m
m
compression
m
Vaporization
h
11
Analyzes on the “standard” process
Pressure
1. Low pressure and
suction temp.
Ideal Compression
3
2. High Pressure and
discharge Temp.
3. High pressure and
liquid temperature.
Heat Capacity
P HP
Enthalpy
Difference
P LP
Cooling Capacity
1
Power Energy
Consumption
Mass Flow = (Power consumption – heat losses) / Enthalpy Increase
COP = Cooling Capacity / Power Energy Consumption
Use the Theory for practical use on field
12
2
Enthalpy
Theory Performance analysing using
”Black Box” perspective on compressor
Enthalpy increase refrigerant
Heat losses
(relatively small and predictable)
Electric energy input
(e.g. Electric input = enthalpy increase + heat losses from shell)
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What about error in the heat loss estimate?
Conditions
+5/50°C R407C
T = 85°C
T = +15°C
33kW
Heat Loss
%
5
7
Enthalpy
Increase
48.5
48.5
Mass Flow
Rate kg/s
0.653
0.641
Capacity
kW
100
98.2
40% error in the Heat Loss results in <2% Capacity Error
Key Results
•
•
•
•
•
•
Cooling capacity (± 7% accuracy)
Heating capacity (± 7% accuracy)
COP
(± 5% accuracy)
Compressor efficiency
Super heat and sub cooling
Functionality of Control
• Evaporation, Condenser pressure and temperature
• UA and mean temperature differences in evaporator and
condenser
• Flow of secondary systems based on Capacity and temp.
difference
Listed are only key information – standard template consist of
> 40 outputs allowing detailed analyses of each component
15
Inspections and monitoring
Documentation of performance in refrigeration process
is a prerequisite for efficiency and optimisation
Stop assuming all is OK – look inside the “black box”
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Global references in all sectors
• Carrier Europe for Chiller optimisation performance inspections
–
Use portable Performance Analysers in all EU countries for Inspections and trouble shooting.
• Carrefour, Metro supermarkets in Italy, TESCO, Sainsbury in UK
–
Saved 20-30% in pilot on 6 hypermarkets 2010 - now installed in 50+.
• Johnson Control industrial contractor in Spain/Sweden/UK
–
Correct problems and improve efficiency in large industrial ammonia plants
• Copeland Europe and Bitzer compressor manufacturers
– Use ClimaCheck in trouble shooting and development work with their customers
• DuPont and Solway refrigerant manufacturers
– Use ClimaCheck to document retrofit projects
• Several projects on-going in US, Australia, Middle East and India
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Report from Carrier site inspection
Carrier Performance Analyser
Rapport från mätning
Site:
Anläggning:
Datum:
Tidpunkt start:
Tidpunkt stopp:
Title
COOL_EWT
COOL_LWR
COND_EWT
COND_LWT
POWER KW
COOLING CAPACITY
EER
HEATING CAPACITY
COP
TrioPlast, Landskrona KM11
20100426
11:57
13:17
Measured
Value
9.5
5.7
35.6
45.1
350.2
1177.4
3.36
1503.2
4.29
°C
°C
°C
°C
kW
kW
kW
Nominal
Data
9.5
5.7
35.6
45.1
342.0
1160.0
3.39
1484.0
4.41
Deviation
0.00
0.00
0.00
0.00
8.20
17.40
0.03
19.20
0.12
Comment
K
K
K
K
kW
kW
kW
ap 2,3 % negativ deviation
ap 1.5 % positiv deviation
ap 1.3 % positiv deviation
ap 2,8 % negativ deviation
Nominal data is the values we get from running E Cat with actual values from the measurement.
Measurement made by:
Stefan Orwén, Carrier AB, Malmö
Un-biased validation of
Performance – no Carrier inputs
ClimaCheck on-line
Fixed installation with web access
Energy monitoring - statistics
Early Warning
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Hourly energy/cost statistics for owners
• Energy statistics - cost
• Monitor kWh and USD per hour
• Documents “energy profile” versus ambient
temperatures
• Compare consumption with “energy profile”
• Document energy optimisation projects
• Benchmark different plant
20
Energy Statistics
as optimisation
tool
Red line average daily temp
Visualisation of optimisation June 14th
Green line is 12 month average kWh at daily ambient
22
CONFRONTO SETTIMANALE CONSUMO IMPIANTO
Italian Supermarket in Milano
saving corresponds to 16 000 Euro per year
Adj.
controls
Drift som
tidigare
24
27% higher
COP
24
Compressor Pack in Supermarket
Comp 2 Low Efficiency
25
Compressor Pack in Supermarket Comp 2 Low Efficiency
Full load
Full load
Full load
Comp. Eff. 1, 3 and 4
Average Comp. Efficiency
Comp 2 Low Efficiency
26
Stab.
Stab.
Stab.
Savings achived in 6 Italian Supermarkets
27
PC-Software
Documentation of performance
and component by component evaluation
Complete documentation
20 minutes to connect
28
Presentation of data is key for analyses
29
Comp. eff
Start-up
Part load
Full load
Part load
Start-up
Full load
100%
Temp. diff.
9.3 K
Secondary out –
evaporation
Good ≈ 3-5 K
67%
Temp. diff.
9.3 K
secondary out
– condensing
Good ≈ 1-4 K
COP +10%
at full load
Compressor eff.
48% to 64%
When part to
full load
Super heat. 0.8 K
at part load -critical
32
8 compressors no need for part load > saving more than 5000 Euro
33
CO2 cascade system with R134a
34
Method has few limitation
(complex systems can be made understandable)
Industrial ammonia plant screws + oil cooling
35
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Validated and well proven
• Experience since 1986 when it was patented
• Validated 1989 by SP - Swedish National Testing and Research
Institute
• 400 field measurement systems in use
• Method used in education
– Royal Institute of Technology in Stockholm (University level)
– Swedish, German, Slovak, UK “trade training institute”
• Used by 40 manufacturers of heat pumps, dehumidifiers,
refrigeration and air conditioning equipment
– Development laboratories
– Product control in production
– Commissioning, trouble shouting, warranty inspections and
aftermarket
• Integration in
– OEM control systems
– Building Management system (BMS)
36
ClimaCheck is achieving
international acceptance
•
More than 40 manufacturers in 10 countries
– World leading Compressor factories
– Swedish, German, UK, Italian, Slovak, Czech, Thai, Korean, Finnish and
Australian manufacturers use ClimaCheck in product development, prototype
testing and trouble shooting
•
Leading installer – maintenance contractors (400+)
•
Leading supermarket chains in Sweden require documented
commissioning with “ClimaCheck method” at commissioning of
supermarkets and cold stores
•
TESCO, Sainsbury, Metro, Carrefour and El Gigante is now investing and
setting requirements for contractors to document operation
–
You can test http://www.online.climacheck.com/
• user > climacheck , password > demo 001
37
Global
Industry need
tools
and training
to
optimise
Dynamics in real systems not
well taken care off or understood
38