Transcription
RevolutionaRy energy savingsfor THE BUILT ENVIRONMENTFrom the global leader in oil-free centrifugal chillers
Smardt chillers optimizethe benefits of the revolutionaryTurbocor oil-free centrifugaltechnology. The TT300compressor delivers 60 to 90 TRwhile the TT400 delivers 120to 150 TR and the TT500approximately 190TR – morewith fitted economizers.Advanced electronics meanthat mechanical forces can bemanaged with extraordinarilyfine tolerances, achieving veryhigh reliability. Not a surprise,when the shaft position isautomatically measured andadjusted 120 times per revolution.At a maximum operating speedof 48,000 rpm, this meanssix million times a minute.The Smardt Chiller Group now has some 4000operating chiller installations across the world –all delivering high reliability, outstandingpart-load efficiencies and the overall lowestcost of ownership to building owners.Achieving these goals as consistently and simplyas possible remains Smardt’s core purpose,and clearly differentiates it from competitorswith conventional machines.THE SMARDT Chiller Groupworld leader in oil-free chiller efficiencyThe Smardt Chiller Group was established to maximize thecustomer benefits of the Turbocor oil-free centrifugal compressortechnology in chiller performance. Driving whole life costs ofownership way down, your Smardt chiller saves you money, yearafter long year, while reducing your carbon footprint and makinga major contribution to the future of the planet.Decades of developmentThe Smardt engineering, development and manufacturing teamshares more than 20 years’ experience working with magneticbearings and oil-free centrifugal chillers – a greater body ofoil-free centrifugal experience than any other chiller company inthe world. The Group’s long experience actually developing theTurbocor compressor technology and its applications brings thedefinitive high-performance range of water-cooled and air-cooledoil-free centrifugal chillers to the world market. The team makessure each Smardt chiller saves its owners money throughout its longoperating life– money in operating costs, money in maintenancecosts, money because of high reliability and redundancy whichpractically removes mechanical risk altogetherAlgorithms used in all Smardt chiller controllers further enhance theintelligence built-in to the compressor – achieving further efficienciesacross each compressor’s operating map, and further, optimizingeach compressor’s intrinsic part-load efficiencies in deliveringintegrated chiller efficiencies that are currently unmatched.Global reach, single focusSmardt-PowerPax was founded in Melbourne, Australia in 2000and Smardt Inc was established in Montreal, Canada in 2005.They were followed in 2010 by a new Smardt factory inPlattsburgh, New York and a regional sales and service operationin Singapore. In 2011, Smardt-OPK Chillers AG of Stuttgart,Germany joined the Group, followed in 2013 by Smardt’s Chinamanufacturing operations in Guangzhou, Guangdong.2The heart of every Smardt chiller is its Turbocor oil-free centrifugalcompressors, which integrate rugged magnetic bearings systemswith variable-speed drive, high-efficiency centrifugal compressionand on-board digital electronics to achieve a revolutionary leap,a quantum leap, in part-load energy efficiency.Smardt’s worldwide leadership in chiller energy efficiency meansthere are more Smardt oil-free centrifugal chillers operating acrossthe globe (some 4000 already) than any other chiller brand –testament to their continued reliable delivery of energy savings inan array of different applications.A quantum leapin energy efficiencySmardt offers the widest range in the world of oil-free centrifugalchillers, and all Smardt chillers, whether water cooled or aircooled, evaporatively-cooled, modular, split or condenser-less,are designed to optimize the performance of oil-free centrifugalcompressors from Danfoss Turbocor Compressors Inc. These useoil-free magnetic bearings and variable-speed drives to deliverbetter IPLV efficiencies than conventional oil-lubricated centrifugal,reciprocating, scroll and screw compressors. They are also highspeed – up to 48,000 rpm, very compact, very quiet, ruggedand reliable. Power factor is a high .92.Proprietary magnetic bearings replace conventional oil-lubricatedbearings, eliminating high friction losses, mechanical wear andhigh-maintenance oil management systems to deliver energysavings of 35 percent and more over conventional chillerswhile ensuring long-term reliability. Over 90,000 magneticbearing machines are operating in the field, mainly in high-endvacuum pumps and CNC spindles – any innovation risk with thiscomponent technology has been long overcome.Turbocor’s one main moving part (rotor shaft and impellers)is levitated during rotation by a digitally controlled magneticbearing system. Position sensors at each magnetic bearingprovide real-time feedback to the bearing control system, 120times each revolution, ensuring constantly centered rotation.
2‑year cost comparison, San Diego, CA.As this comparative ASHRAE study showed, over 20% of a lubricated chiller’soperating efficiency is routinely lost in the early years as a result of oil cloggingof heat transfer surfaces.This decision between two different chillers has long term positive consequences forthe hotel which made it. The left-hand option is a low-cost lubricated screw chiller.The right hand option is a 300 TR Smardt water cooled chillerOil-free design optimizes heat transferVery quietThe well-known ASHRAE study (Research Project 361)concluded that typical lubricated chiller circuits showreductions in design heat transfer efficiency of 15-25%, aslubricant accumulates on heat transfer surfaces, denatures andblocks normal thermodynamic transfer processes. Logically,no oil in your chiller means no oil contamination over time,so design efficiency is maintained effortlessly.Very low sound and vibration levels, because there is nophysical contact between moving metal parts, eliminate theneed for expensive attenuation. Smardt chillers are typicallyso quiet, in fact, that a novice cannot tell whether they areactually operating. Testing of Smardt water cooled chillerswith reference to ARI standard 575 yields readings as low as77 dBA at 1 meter.Oil-free means major lifetime maintenance savingsEnergy cost savings can be spectacularOil-free means no need to check or change oil, no need forcrankcase heaters, no purge system. Maintenance needs andcosts are cut in half compared with a lubricated chiller.Compared with a new screw chiller, Smardt IPLV energyefficiency is routinely more than 32% better. Compared witholder lubricated reciprocating, screw, scroll or centrifugalchillers, year round savings with a Smardt can be spectacular,with well over 50% savings.Extraordinary soft-start efficiencyThe compressor’s power electronics, further enhanced bySmardt’s proprietary chiller controllers, require only 2 ampsfor start-up, compared with 500-600 amps in conventionalmachines. Further savings for owners, who can reducemaximum power loads and reduce backup generator size,cost and capacity.Built-in protection against power failureEach compressor has a bank of capacitors for energystorage and to filter DC voltage fluctuations. In case of apower failure, the capacitors provide continuity power to thebearings to keep the shaft levitated, allowing the motor to turninto a generator and to power itself down to a stop. Extendedlife testing confirms the system’s remarkable durability.Under AHRI conditions, Smardt IPLV performance is spectacular.Why part loads are criticalThe graph below (data source: AHRI, 2005) shows verysimply that a wide range of large US cities all demand thevast bulk of their chiller operations at part load – enablingmuch lower operating costs from a Smardt chiller than from alubricated alternative.HFC-134a refrigerantR134a has no Ozone Depletion Potential and no phase-outschedule under the Montreal Protocol. It has an A1 ratingunder ASHRAE standard 34 (no flame propagation, lowertoxicity). Positive pressure chiller designs (compared withnegative pressure designs using R123, for example) enhancesustainable performance, as neither air nor moisture can leakinto the chiller. No purge unit is required – a further saving.Liquid R134a refrigerant is used in Smardt chillers to coolcritical electronic and electromechanical components toassure maximum efficiency and safe operation.3
This standard design 1140 TR water-cooled chiller uses a flooded shell and tube evaporator withshell and tube condenser with both pressure vessels using high performance copper tube profiles.The approach of less than 1 deg K allows very high part-load efficiencies.This simple comparison uses generic industry performancedata for 250 TR water-cooled chillers (data source: AHRI)to plot the relative efficiencies of different compressormodalities as they unload.Water‑cooled chiller range60 tr through 1200 trLowest lifetime operating costsSmardt works hard to minimize complexity in chiller designand operation – Smardt simplicity is reflected in low Smardtoperating costs. The thinking makes simple sense – with nooil, flooded shell-and-tube evaporation, soft start, low powerconsumption, low maintenance costs and high reliability withonly one main moving part.Operational flexibility means further savingsMultiple compressor design enables efficient capacity turndown to 5-10% and major turn-down in chilled water andcondenser water flows. This means lower chiller energy usageand lower pump power requirementsSmardt field reliability has been outstanding – not surprisingwhen you consider that some 80% of all chiller problemsin the field are due to failures in compressor oil return. AndSmardt chillers use no oil.The worldwide fraternity of Smardt-trained engineers andtechnicians suggests that total maintenance costs for oil-freechillers run at well under half the costs of traditional lubricatedchillers. This may be very conservative.ServiceabilityAlways important in minimizing operating costs, serviceaccess is swift and simple, as is access to operating historythrough remote monitoring. Operating history, compressorand chiller set points are all accessible remotely by trainedand authorized service personnel.4Simple BAS integrationIntegration with Modbus, Bacnet and LONworks buildingmanagement systems is standard, as is connectivity with mostindustry-standard protocols.Custom design and problem solvingThe group’s design engineers are happy to resolve specialequipment design challenges for you, but please allowsome extra time and, possibly, some extra cost for these.For example, high-efficiency heat recovery and free coolingapplications can all be supplied competitively. Marine waterboxes, corrosion protection and other options are availableand can be explored on request.RedundancyUse of multiple compressors allows unusual redundancysafeguards; and if multiple circuits are indicated, these canbe designed in and supplied. Smardt’s redundancy potentialcan offer system designers unique opportunities to eliminatemultiple chillers, multiple controls and multiple pumps. Moresavings for owners.Multiple compressors also allows system designers to saveon low-load or pony chillers, because with a VFD integratedinto each compressor control, a chiller which uses multiplecompressors can be efficiently driven right down below 10%or even 5% load.
Over only 5 days, 400 TR ofhigh-efficiency cooling was installed,commissioned and running at a fullytenanted downtown Toronto complex, usingaccess only through standard doorways,stairs and elevators. Access savings –demolition, carnage and the costs of closinga busy downtown street – were enormous.YOUR PLANT ROOM ACCESS PROBLEMS SOLVED– ONLY SMARDT OFFERS TWO EASY OPTIONSCompact Modular and Split chiller ranges;60 TR through 900 TRSmardt’s Compact Modular and split-vessel chillers elevatethe modular chiller into the high-efficiency, low-operating-costworld. No longer does modularity have to be compromisedby efficiency sacrifices.Now you can use the modularity concept to upgrade plantoperating efficiency while minimizing plant room accesscosts – saving high costs of demolition, rigging and cranage.Savings can be enormous, because the Smardt CompactModular range is designed to move through a standardelevator and a standard door, through to a footprint smallerthan any other high-efficiency chiller.Split designs: one step up from modularin first-cost efficiencySmardt’s Split chiller range (patent pending) minimizes chillerfirst cost as well as operating cost as well as access cost.Each Split chiller, once factory-tested as a complete chiller,becomes a special disassembled kit so you need only usestandard doors, standard elevators (and standard peopleinstead of demolition crews and cranes) and optimizingstandard capex budgets.Need a knocked down kit?If access is a challenge to your chiller replacement project,Smardt can help with solutions all along the way. Modularor split chillers often solve the problem, but not always. Oncethe chiller is built and factory-tested, we can offer not onlysimple removal of compressors and control panel but alsocomplete disassembly.This standard 90 TR Compact Modular chiller can be doubled up with thesame footprint, then expanded by up to 5 further modular steps, allowinga wide range of high-efficiency modular options.5
Air-cooled packaged chiller range60 tr to 600 TRThe Smardt air-cooled range offers the smallest footprint,the quietest operation and the highest air-cooled operatingefficiencies on the market.Condenser coils use a V configuration to optimize heatrejection and footprint. Coils are baked and double-coatedas standard with sealed edges as standard, to extend thecoil’s physical protection from environmental corrosion.dry bulb (95 deg F or 35 deg C) towards ambient wet bulb(say 75 deg F or 24 deg C). In warmer, dryer climates, Smardtreference sites show further savings of over 30% comparedwith normal Smardt air-cooled operation.Remote air-cooled condensingRemote location of the condenser can be a preferred optionin some applications. Smardt can supply a full package ifdesired, or on a condenser-less basis.“QUIETEST IN THE INDUSTRY!”Standard Smardt air cooled chillers are over 70% lower insound power than a standard screw machine. Even lowersound levels are deliverable when you need them.EVAPORATIVE PRE-COOLING FURTHER DROPSPOWER CONSUMPTIONUse of evaporative pre-cooling to lower the incident airtemperature on the coil can dramatically reduce energyconsumption, effectively shifting heat rejection from ambientUse of evaporative pre-cooling to minimize air-cooled power consumption can bevery efficient from an operating cost perspective.SMARDT FREE-COOLING CAN DRIVEEFFICIENCIES OFF THE PLANETAdding a Smardt Free Cooling package (special bypasscircuitry, controls and safeguards) can drive air cooled chillerefficiencies to spectacular levels with appropriately lowambient temperatures. Payback periods can be very short.6Service access isoutstandingly simple.Smardt air-cooled performance at thisFlorida university delivered the expected40% energy savings.
Smardt chiller controllers have beendeveloped from the ground up using primarycompressor performance maps, maximizingthe performance potential within these, thenoptimizing the whole chiller’s operation tominimize energy consumption.User-friendly controlsSmardt’s Kiltech controller is very user-friendly, highly intuitiveand allows optimization of both single compressor operationand multiple compressor operation while enabling a richarray of communication options.The compressor’s onboard digital controller proactivelymanages compressor operation while allowing externalcontrol and web-enabled monitoring of performance andreliability information.The PowerPax PLC-based microprocessor system has beenused on well over 1500 chiller sites, and that installationexperience has been used to generate the state-of-theart controls software that is used to maximize operatingefficiencies and minimize maintenance and operating costs.Two tiers of control options are available.This system provides several access levels for plant operatorsand commissioning, and offers a wide variety of options forflexible operation and optimization of power consumption,maximizing time spent operating at compressor sweet spots.7
Especially when using multiple chillersin a chilled water plant, very largeenergy savings can be reliably achievedwhen the whole system is optimizedby a Kiltech CPECS installation usingall-variable-speed drives.INTEGRATED VARIABLE SPEED CHILLED WATER PLANTSKiltech CPECS optimizes total integrated energy efficiency25-75% total improvement in both new and existing plantsAfter many years’ observing and testing variable primary flowsystems in chilled water cooling plants across a wide rangeof environments and applications, Smardt’s associate Kiltechinfotech group developed a proprietary suite of functionalalgorithms which constantly minimize the total energyconsumption of the chilled water cooling system. Not just thechillers, or the cooling towers, or the pumps, but the wholesystem. Perhaps surprisingly, optimizing the whole system canmean running an individual component machine away fromits own optimum.Optimizing Operating Speed of a Total Variable PrimaryFlow System Aggregates Multiple SavingsThere are two simple but absolutely key concepts involved:Reducing Operating Speed by X Reduces Operating EnergyConsumption by X3When each item of your variable speed equipment (e.g. yourSmardt chiller) is operating at part load, you save the cube ofthe differential of the load.Obviously, it pays you to minimize the load on your variablespeed equipment at all times.8A quick comparison between red and yellow bands above shows the consistent savingsacross a whole year achieved by a CPECS optimization system compared with astandard plant control.
Switching on the CPECS Optimization Control Drives Major System-Management Savings. Instantly.Each member piece of equipment in this chilledwater plant either has an in-built variable speeddrive function (like the Smardt chillers) or has hada VSD added to it. That is, the system’s primaryflow is inherently variable.However, it is not until you actually engage thesystem’s controller that you can see the very largeand year-round impact on system savings.The data above comes from the Westwood HighSchool in Phoenix, AZ during 2010.SETS NEW BENCHMARK IN WHOLE-PLANT ENERGY SAVINGSThe Kiltech CPECS uses complex algorithms generatedby over ten years of experimentation and research acrossthe globe.When the CPECS is switched on, and your chilled watercooling system optimized for energy efficiency, the dashboardlooks like this:9
SMARDT OIL-FREE CENTRIFUGAL TECHNOLOGY DRIVES CHILLER SYSTEMCOST SAVINGS ACROSS THE WORLD, PROBABLY SOMEWHERE NEAR YOUIN HOTELSVery quiet operation with unmatched part-load efficiencies acrossthe Smardt chiller range enables leading hotel groups across theworld to maintain optimum indoor environmental comfort yearround while also optimizing financial efficiency. Managingenergy costs can be an ongoing challenge as seasons vary andoccupancy levels fluctuate, but Smardt’s flexibility and reliabilityprovides hotel owners and operators with lowest total lifetimecosts for theirchillers.IN HOSPITALSHealthcare administrations across the globe find that theirSmardt chillers make a critical contribution to the physicalenvironment required for optimum patient comfort and qualitycare across all facilities including operating and data rooms.Unmatched redundancy from multiple compressors providespeace of mind while outstanding part-load efficienciesmean better operational performance and financial results.10Some hospitals put special value on Smardt’s seismiccertification while others derive special benefits from Smardt’sacoustic performanceor the outstandingsavings which canbe delivered by heatrecovery chillers.IN OFFICE BUILDINGSEnergy savings throughout the year are a feature of all Smardtchiller installations, while reductions of maintenance costs ofover 50% are routine, compared with lubricated standardchillers. Smardt’s quiet operation and built-in redundancy arealso valuable, butfor most ownersandmanagersof Smardt-cooledoffice buildings it isthe chillers’ overalllowest lifetime costthat means most.
IN SCHOOLS AND UNIVERSITIESComfortable classroom environments are essential prerequisites for optimum learning performance, according to thearray of modern academic studies available across the world.Minimising lifetime chiller costs is an essential goal of K12school administrations, where energy cost is usually the nextlargest variable after staff.In universities, commitment not only to energy efficiency butalso to minimizing greenhouse gases is important to studentsand faculty alike. Administrators specify Smardt because ofunmatched reliability and redundancy as well.in both operationalenergy efficiency andlower maintenancecosts are routinelydelivered.IN DATA CENTERSSmardt’s share of new data center chiller applications isreportedly increasing across the world, as owners andoperators better understand their mission-critical need notonly for uninterrupted uptime throughout the year but also foroptimum energy efficiency throughout the year. Depending onspecific applications, Smardt has deployed a large numberof different configurations in data centers – water cooled, aircooled and condenserless chillers partnered with evaporativecondensers.IN MANUFACTURINGSmardt chillers provide mission-critical cooling to leadingcompanies in a wide range of industries – includingpharmaceutical manufacturing and research, food andbeverage, automotive, chemical, petrochemical andaerospace. In additional to extraordinary reliability (no oil,so no oil system to need maintenance), extraordinary savings11
CertificationAll Smardt chillers are ETL-listed. Electrical safety forthe life of the chiller is a fundamental requirementthroughout the company. Smardt evaporators andcondensers naturally conform to the ASME pressurevessel codes.Their energy efficiency performance is certified according to AHRI standard 500/590, as is confirmed by AHRI on its websitewww.ahrinet.org. The IPLV performance of its chillers always exceeds minimum levels set out by ASHRAE standard 90.1, CSA 743,Eurovent, Australia’s MEPS, China’s CRAA and others, usually by a very considerable margin. Smardt, in company with the majorityof the HVACR industry’s leading engineers, considers the use of full‑load energy efficiencies to predict any chiller’s actual year-roundenergy-efficiency under US comfort-cooling conditions to be totally misleading, and therefore discourages the use of them.Witness tests can be arranged on appropriate notice and for an appropriate fee on Smardt’s AHRI-certified test stands in Montreal,Quebec and Melbourne, Victoria.Strong LEED contributionSmardt technology can be very useful in achieving LEED certification for your building, whether in existing buildings, core and shellor new construction, because it can help win critical points in the Energy & Atmosphere category. Market research by the US GreenBuilding Council finds that the streamlined LEED process is second only to rising energy costs as a driver for stronger adoption ofgreen building practices and the transformation of the built environment to sustainability. Smardt is a member of the USGBC.Strong support for the EPA’sResponsible Use visionThe EPA’s Responsible Use vision encourages manufacturers, system designers andowners to invest in products and technologies which document sustainability of the highestefficiencies in tandem with lowest emissions. Smardt is a strong supporter of the vision,and the EPA.For further information please contact:Smardt Chiller Group Inc.1840 TransCanada HighwayDorval, Quebec, Canada, H9P 1H7Smardt-OPK Chillers AGIm Kalten Brunnen 29,72666 Neckartailfingen, GermanySmardt Chillers Pty Ltd144 Colchester Road, Bayswater NorthVictoria 3153, AustraliaTel: 1 514 426 8989Fax: 1 514 683 6013Tel: 49 7127 9202 20Fax: 49 7127 9202 720Tel: 61 3 9761 7905Fax: 61 3 9761 6707Email: sales@smardt.comwww.smardt.comEmail: sales@smardt.comwww.smardt.comEmail: sales@powerpax.com.auwww.smardt.comSmardt Chillers, Inc.22 Colorado AvenuePlattsburgh, New York 12903, USASmardt Chillers (Asia-Pacific) Pte Ltd108 Pasir Panjang Road#04-10 Golden Agri PlazaSingapore 118535Guangzhou Smardt Chiller Manufacturing Co., LtdMei Xing Industrial Park, No. 30 Dong Zhong Road,ETDD Guangzhou, GuangdongEmail: sales@smardt.comwww.smardt.comTel: 65 6273 1120Fax: 65 6273 1129Email: sales.asia@smardt.comwww.smardt.comTel: 86 20- 8205 7161Fax: 86 20- 8200 1302Email: sales.china@smardt.comwww.smardt.com1/13Tel: 1 514 426 8989Fax: 1 514 683 6013
yOuR PLAnt ROOM ACCeSS PROBLeMS SOLveD - OnLy SMARDt OffeRS tWO eASy OPtIOnS Compact Modular and Split chiller ranges; 60 tr through 900 tr Smardt's Compact Modular and split-vessel chillers elevate the modular chiller into the high-efficiency, low-operating-cost world. no longer does modularity have to be compromised by efficiency sacrifices.
