www.danfoss.com
Improving Cold Chain Competitiveness with
Danfoss Energy Efficiency Solutions
September 2013 | 2Danfoss Automatic Controls
Agenda
• Brief on Danfoss
• Danfoss Business Divisions / Areas
• Danfoss Drive Solutions for Energy Efficiency in HVAC & Refrigeration Systems
• Chiller Compressor Applications of Drives
• Fans and Pumps Applications of Drives
• Retrofit Applications of Drives in Various System Configurations
• Danfoss Drives Value Proposition
• Case Story on Screw Compressor Retrofit
September 2013 | 3Danfoss Automatic Controls
Introduction to Danfoss
�www.danfoss.com
September 2013 | 4Danfoss Automatic Controls
Danfoss Global in brief
� Global Company with Core Competencies in Solutions that sustain Climate and Energy
� 80 years of experience within energy-efficient technologies
� Solutions ready to combat climate challenge
� Global competence center for energy efficiency – rooted in Southern Denmark
� Danfoss Global Organization is Family owned Business
September 2013 | 5Danfoss Automatic Controls
Facts in figures
Sales 34,007m DKK (6 b US$)
Number of employees globally
23,092
Factories, globally 56 in 18 countries
Global Presence >100 countries
Own sales companies, globally
in 51 countries
Top 3 Markets US, Germany & China
September 2013 | 6Danfoss Automatic Controls
Danfoss India
�100% Subsidiary of Danfoss A/S
�Established in 1998
�Employs over 450+
�Corporate Headquarters – Chennai
�Turnover INR 4000 Million
�10 Offices & 60 Partner companies
�Major Investments on R&D, Manufacturing & Talent acquisition
�Engineered Panel Solution Facility
Global Management Meeting • 2010 | 7
Danfoss is recognised as a global trendsetter.
We passionately push boundaries on
results and reputation.
Our Aspiration
Road show • 2010 | 8
Our PromiseWe provide leadership
in our businessesthrough reliability,
excellence, and innovation
– driving truecustomer satisfactionand solutions withinClimate & Energy
Our Promise– to our customers and ourselves
Reliability Excellence Innovation
We commit – we deliver
On -Time delivery
Total quality Everywhere
Value for money
Easy to do business with
Continuous improvement
Value Creation
Focus on true customer needs
Trend-setting
Global Management Meeting • 2010 | 9
Our Behaviour
We will build our business on trust.
We will be innovative in
our ambition to exceed expectations.
We will be global
while respecting local cultures.
We will treasure sustainable results.
| 10Introduction to Danfoss 2013
Climate and energy
The solutions are ready!
� Danfoss is a global leader focusing on energy-efficiency solutions– Well-proven technologies that save energy and costs, and reduce CO2 emissions
� We have built up our competencies since 1933– Making modern living possible through climate and energy solutions used in areas such as cooling food, air conditioning, heating buildings, and controlling electric motors
| 11Introduction to Danfoss 2013
Solutions ready going forward
� Utilize existing energy efficiency solutions to an optimum and boost economy
� Invest in new solutions based on core energyefficiency competencies, e.g.:
– Solar inverters
– Efficiency components for wind turbines
– Heat pumps
– Cooling systems based on natural refrigerants
| 12Introduction to Danfoss 2013
Business areas – Danfoss Climate & Energy
� Danfoss Refrigeration & Air Conditioning Controls
� Danfoss Power Electronics
� Danfoss Heating Solutions
� Danfoss Commercial Compressors
� Danfoss District Energy
| 13Introduction to Danfoss 2013
Climate & Energy
Danfoss Refrigeration & Air Conditioning Controls
� Danfoss Refrigeration & Air Conditioning Controls includes four product areas:
� Automatic Controls
� Electronic Controllers & Services
� Industrial Automation
� Heat Exchangers
� The division provides customers (e.g. OEMs, wholesalers and installers) with solutions on a global scale in the fields of commercial refrigeration, industrial refrigeration, air-conditioning, supermarket refrigeration and industrial automated systems.
| 14Introduction to Danfoss 2013
Climate & Energy
Danfoss Power Electronics
� The Danfoss Power Electronics division includes three business units:
� Danfoss VLT Drives
� Danfoss Customised Power Electronics
� Danfoss Inverters for Solar and Wind
� The division has supply chain, research and development centers in China, Denmark, United States and Germany and a global network of sales offices offering customers high-quality energy-efficient power electronics solutions.
| 15Introduction to Danfoss 2013
Climate & Energy
Danfoss Heating Solutions
� Danfoss Heating Solutions offers solutions within:
� Residential Heating
� Hydronic Balancing & Controls
� Burner Components
� Electrical Heating
� Heat Pumps
� Ventilation
� Through sales companies and agents, the division offers solutions for generating, distributing and adjusting heat for optimum indoor comfort and energy savings in residential heating all over the world.
| 16Introduction to Danfoss 2013
Climate & Energy
Danfoss Commercial Compressors
� Danfoss Commercial Compressors offers efficient and energy-optimized compressor solutions such as scroll compressors, reciprocating compressors for air conditioning, commercial refrigeration and heat pumps as well as condensing units and variable speed solutions.
� The division has global manufacturing facilities spread across three continents, and customers can benefit from 40 years of experience within the development of hermetic compressors.
� The products are used in a variety of key customer applications such as cold rooms, supermarkets, milk tank cooling, residential air conditioners, rooftops applications, chillers, heat pumps and industrial cooling processes.
| 17Introduction to Danfoss 2013
Climate & Energy
Danfoss District Energy� The Danfoss District Energy Division includes four business units
� Heat Exchangers
� Controls
� Heavy duty stations
� Small Duty Stations
� Danfoss District Energy offers solutions within the control and transfer of heat in district heating and cooling applications. District energy is energy-efficient, it capitalizes on economies of scale, and can be used with both renewable and fossil energy sources by providing an efficient green infrastructure which contributes to achieving individual comfort, while reducing energy consumption.
� Danfoss District Energy is a total supplier of substations and automatic controls for the district heating and cooling market and has sales companies and agents around the world.
Danfoss Energy Efficiency Solution for
HVAC and Refrigeration Systems
VLT® Refrigeration Drive
Danfoss
VLT® Refrigeration Drives
(VLT® FC 103)
For
� Compressors
� Condenser Pumps / Fans
� Evaporator Fans
� Liquid Feed Pumps
� Cooling Towers
�| 20
VLT® DRIVE APPLICATIONS IN REFRIGERATION SYSTEM
�| 21
What Savings VLT® Brings to the Refrigeration System
� Save Energy by System Capacity Modulation
(Reducing System Speed at Part Loads)
� Save Overall System Cost (DG Size/ Compressor
Size/ Cables etc.)
� Brings System Automation
� Safety and Protection
| Confidential/Property of Danfoss Drives A/S | Thursday, 21 August, 2008 | JSP-INSC | 22
Starting currents = FLC
� VFDs allow starting current equal to that of full load current of motor
� Lower Switchgear sizes
� Peak Demand under control
� Smooth start
� Reduction in DG Set capacity requirement
VLT® Refrigeration Drive
Chiller Compressor Application
| Confidential/Property of Danfoss Drives A/S | Thursday, 21 August, 2008 | JSP-INSC | 24
Flow ∝ Speed
Energy ∝ Speed
20% Reduction in Speed of
Compressor saves 20% Energy
Physics Law governing Positive Displacement Devices
Law applicable for Reciprocating / Screw Compressors
�| 25
Drives Application on Compressors
�| 28
Reduced capacityMaximum capacity
Slide-Capacity
Slide stopSlide stop
Slide-
CapacitySlide stopSlide stopSlide stop
Active compression part
Screw Compressors with Slider Valve Capacity control
| Confidential/Property of Danfoss Drives A/S | Saturday, 14 September, 2013 | 29
Traditional Capacity Control Screw Compressor – Slide Valve Capacity Control
� Traditional Screw Compressor Capacity Control:• Slide Valve controls compressor capacity• Slide Valve position is determined by
suction pressure PID control• Slow system control due to 300s of dead
band • System delay causes energy losses –
lower temperature operation• Compressor COP decreases with its
capacity `
� 60% of Capacity demands 80% of Energy – 20% energy losses
0
20
40
60
80
100
10 20 30 40 50 60 70 80 90 100
Capacity %
Pow
er
%
Slide
Ideal
Slide valve
curve
Ideal curve
| Confidential/Property of Danfoss Drives A/S | Saturday, 14 September, 2013 | 30
Screw Compressor- VFD Capacity Control
� VFD Screw Compressor Capacity Control• Slide Valve & VFD actuate together for
Compressor Capacity control• VSD speed is determined by suction
pressure PID control• There is no dead band (Ramp up/down
time is max 30s)• Faster system response allows higher
temperature operation• Compressor COP is linear up to 60% of
the capacity• Minimum speed must be maintained
(Motor cooling, Oil pressure)0
20
40
60
80
100
10 20 30 40 50 60 70 80 90 100
Capacity %
Pow
er
%
Slide
VFD
Ideal
VFD Curve
� 60% of Capacity demands 60% of Energy – Linear Energy Consumption
VFD Capacity Control
�| 31
� No in-rush currents at start-up (Max. upto 200% of FLC).
� Drastic Reduction in Backup DG Sets
� Less Power Bills with lower Peak Demand (Improved power factor and Low Inrush Current)
� At least 20% Extra capacity available with the compressor (60 Hz operation)
� Smooth start and low wear and tear of Compressor
� 10% -30 % Energy Savings with Capacity Modulation as per requirement
� Motor Protection and Safety
� Reduced risk of liquid refrigerant in compressor at start-up through use of ”crankcase heater” function
Advantages of Drives on Chiller Compressors
�| 32
Other Benefits
Better System Performance:
� Precise Temperature Conditions maintained by capacity modulation
Flexibility and system simplification:
� Easy to Retrofit
� Smaller Compressors can be used with increased Capacity
VLT® Refrigeration Drive
Fan & Pump Applications
| Confidential/Property of Danfoss Drives A/S | Thursday, 21 August, 2008 | JSP-INSC | 34
Flow ∝ Speed
Pressure ∝ (Speed)2
Energy ∝ (Speed)3
20% Reduction in Speed of Pumps /
Fans saves 50% Energy
Physics Laws governing Centrifugal Devices including Centrifugal Compressors
Basic Centrifugal laws applicable for Centrifugal Devices
�| 35
VLT Drives Application On Fans
| 36
Laws of Affinity - Applicable on Centri Compressors /
Fans / Pumps
If Fan Speed is reduced thru VFD to 80% = 0.8
Then
Air Flow Rate ∝∝∝∝ (0.8) = 80%
Pressure Developed by Fan ∝∝∝∝ (0.8 x 0.8) = 64%
Power Consumed by Fan ∝∝∝∝ (0.8 x 0.8 x 0.8) = 51%
Therefore with 20% Speed Reduction, the Power Consumption
is reduced to 50%
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 37
�Speed Control thru Temp Sensor or RH
Sensor
�Speed Reduction upto 50%
�Automatic Temp. Control thru PID
Controller
�One Drive can run multiple fans (One
drive for One Chamber)
� Precise Temp. conditions maintained
with substantial Energy savings
� Evaporator sync with Compressor to
have capacity Modulation for whole
system
Evaporator Pump Applications
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 38
�Speed Control thru Refrigerant Outlet
Temp.
�Speed Reduction upto 80%
�Automatic Speed Control thru PID
Controller
�One Drive can run multiple fans (One
drive for all Condenser Fans Units)
�Uniform Condenser performance with
substantial Energy savings
�Condenser in sync with Compressor /
Evaporator achieves maximum Energy
Savings
Condenser Fans Applications
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 39
�Speed Control thru Condenser Water
Outlet Temp.
�Speed Reduction upto 80%
�Automatic Speed Control thru PID
Controller
�Uniform Condenser performance with
substantial Energy savings
�Condenser in sync with Compressor /
Evaporator achieves maximum Energy
Savings
Condenser Pump Applications
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 40
�Speed Control thru Temp Sensor on
Return Temp. to Heat Exchanger
�Speed Reduction upto 50%
�Automatic Speed Control thru PID
Controller
� Precise Temp. maintained at inlet of
Evaporator Coils / Receiver with
substantial Energy savings
Brine / Glycol Pumps Applications
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 41
�Speed Control thru Temp of Water
Sump
�Speed Reduction upto 50%
�Automatic Speed Control thru PID
Controller
� Precise Temp. maintained at Water
Outlet from Cooling Tower leading to
stable inlet Condenser Temp. resulting
in substantial Energy savings
Cooling Tower Fan Applications
�| 42
Typical Load Profile of a Refrigeration System & Savings Potential
� Energy Consumption Profile of System components
�Compressor Consumption Is Highest : 60% ~90%
�Typical Savings With VLTs – 10-20%
�Evaporator Fans Consumption is 5~15%
�Typical Savings With VLTs – 20-50%
�Condenser is 3~5%
�Typical Savings With VLTs – 15-20%
�Brine Pump is 2 ~3%
�Typical Savings With VLTs – 20-40%
Compressor
Evap Fans
Condensor PumpsSecondary Pumps
Compressor Evap Fans
Condensor Pumps Secondary Pumps
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 43
VFD Retrofit Solutions on Compressors connected in Common Header
� Both the compressor contribute to the
Refrigeration load
� Suction Header is also common for both
Compressors
� Single Suction Pressure sensor is
sufficient
� Cascade Control / Master Slave systems
can be proposed
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 44
VFD Retrofit Solutions on Controlled Atmosphere Cold Stores
� VFD Retrofit possible on Compressor
Application
� Evaporator Fans in a chamber can be
fitted with Single Drive for Speed Control
� Inside Temp of the Chamber to be the
feedback for Speed Control
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 45
VFD Retrofit Solutions on Cold Stores Chambers
� Single VFD Drive for Multiple Fan Cooler
Units (FCUs) in one Chamber
� Inside Temp of the Chamber to be the
feedback for Speed Control
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 46
VFD Retrofit Solutions on Multi-Purpose Cold Stores
� VFD Retrofit possible on Compressor
Application
� Evaporator Fans in a chamber can be
fitted with Single Drive for Speed Control
� Inside Temp of the Chamber to be the
feedback for Speed Control
www.danfoss.com
Danfoss Value Proposition
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 48
Easy to Install / Retrofit IP 55 / IP 54 / IP 66 enclosures
�Reliable operation in harsh
environments
�No need for cabinets
� Fast and easy wall mounting
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 49
Pack controller for Multiple Compressor Operation
�Minimum energy consumption over a wide
load range
�No external controller requiredCompressor variable speed
Compressor fixed speed
Compressor fixed speed
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 50
Cascade Control and Master Slave Control
�Cascade Control and Master Slave Control
for Multiple Compressors
�System Optimization in a cost effective
manner
Compressor variable speed
Compressor fixed speed
Compressor fixed speed
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 51
Built-in Cascade Controller
�Replace external controllers
�Multiple Compressor optimized to
save maximum energy
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 52
4 PID controller
� Independent closed loop applications
without external controller
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 53
ADAP KOOL® Electronic Controls
�Complete and integrated system from fully
Automated Refrigeration Plant
�Customised Control Solutions to suit the
specific application and requirement
� Pre-Loaded Applications provide flexible
control schemes
�Can be extended to provide Web based
Remote Monitoring and Control
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 54
Communication via bus systems
� Integration with System Manager / BMS
systems on commonly used Communication
Protocols
�RS485 Port for Communication Protocol
ADAP KOOL®
| VLT® Refrigeration Drive FC 103| Saturday, 14 September 2013 | 55
Inbuilt Dry run and end of curve pump protection
�Additional safety without external
components
80% heat can
be taken
out of Panel
Room
Innovative Design Back Channel Cooling
� Lowest Heat Loss with Efficient Cooling System
� No need for Special Inverter Grade Motors
� Runs the standard Squirrel Cage Induction Motors
� Safe for all Retrofit applications
No need for Special or Inverter Grade Motors
VVCVVC
Conventional PWM Output
VVCPLUS OutputVVC+ TECHNOLOGY OUTPUT RESULT:
•Increased motor life- motor gets 100%
fundamental voltage
•Less heat generation
•Motor works as if it is working on Mains
•No need of inverter grade motor
PWM VFD OUTPUT RESULT:
•Motor does not get 100% fundamental voltage
•Stress on motor insulation and winding
•High heat generation
•Need for higher frame or inverter grade motor
Danfoss drives offer Patented VVC+ technology-Motor friendly
| Confidential/Property of Danfoss Drives A/S | Thursday, 21 August, 2008 | JSP-INSC | 59
� Danfoss VLT® HVACR Drives Family
� VLT FC 102 – VLT® HVAC Drive
� VLT FC 101 – VLT® HVAC Basic Drive
� VLT FC 103 – VLT® Refrigeration Drive
� VLT FC 051 – VLT® Micro Drive
60
Confidential / Property of
Danfoss Drives A/S
14 September, 2013
JSP/INSC/MKTG
Local Service – Global Expertise
Dedicated HVAC sales organisation in India with skilled specialists
• Spare parts
• Hotline suppport
• Preventative service
• Service around-the-clock
• Global service network
| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 61Presenting Power Electronics
Case Story - VFD Retrofit on Screw Compressor
Successful Integration of VLT FC 102 Drive with Screw Compressor
| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 62Presenting Power Electronics
Installation – Brewery Plant in North India
� Brewery Plant in India
� Screw Compressor Application in Chiller Water / Ammonia Refrigeration System
� Motor KW – 315 KW & Danfoss Drive - 315 KW
� Combined - Primary Ammonia + Chilled Water Application
• Application – Screw Compressor on Process Chilled Water Refrigeration System
| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 63Presenting Power Electronics
Test Results and Energy Savings Calculations
Compressor with Slide Valve without VFD
KW consumed to produce 1 Ton of Refrigeration = 0.94 KW
Compressor with Slide Valve With VFD
KW consumed to produce 1 Ton of Refrigeration = 0.69 KW
| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 64Presenting Power Electronics
Energy Savings Calculations - Conclusion
KW/TR WITHOUT VFD 0.94
KW/TR WITH VFD 0.69
%age DIFFERNECE IN KW/TR WITH VFD 26.51%
AVERAGE SAVINGS IN POWER CONSUMPTION / TR. OF REFRIGERATION LOAD 26.51%
Comparison of Energy Savings for Corresponding Refrigeration Load
173.14
203.93
210.02
225.40
254.75
160.75
176.00
193.69
221.26
239.87
127.25
149.87
154.35 16
5.65
187.22
118.14 12
9.35 14
2.35
162.61
176.28
45.90 54.06
55.67
59.75 67.53
42.61
46.65
51.34 58.65
63.58
0.00
50.00
100.00
150.00
200.00
250.00
300.00
184.73 217.57 224.07 240.47 271.79 171.50 187.78 206.65 236.07 255.91
Refrigeration Load TR
KW Consumption.
KW Consumption without VFD KW Consumption with VFD Savings in KW
| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 65Presenting Power Electronics
Calculated Energy Savings Projections - ROI
Parameters Calculations Formulae Values
AE Calculated Average Savings per Hour Rs. 436.60
AE Assuming power saving to be Rs 300 considering the load and season variation. Rs 300.00
RD Running Hours / day (Assumed) 16
Y Running Days / Year (Assumed) 300
H Total Running Hours per year RD x Y = H 4800
D Total Average Savings H x AE = D 1440000
C Cost of VFD System 1000000
ROI Return on Investment in Years ROI = D / C 0.69 Years
| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 66Presenting Power Electronics
Energy Savings Projections (Return on Investment)
Important Points
� Even if the calculated ROI Projection is doubled, it is close to one year for the VFD system to pay back for the investment
� All in all, a very good case of enhanced Energy Savings using the Drive on Compressor Motor and very high return on Investment.
| Confidential/Property of Danfoss Power Electronics| Saturday, 14 September 2013 | 67
�Questions