http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/RSS.ashxRefrigeration and Air Conditioning PagesMon, 14 Jan 2008 16:52:23 +0100http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=1MAKING MODERN LIVING POSSIBLE2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=2MAKING MODERN LIVING POSSIBLE FPO Great partners create the coolest ways to control hot energy costs—that’s EnVisioneering . SM High energy costs make everyone sweat—even ice machine makers. That’s why an industry-leading ice-machine manufacturer looked to Danfoss for an innovative solution. They liked what they saw: a unique combination of engineering innovation, . energy e ciency, and environmental responsibility that we call EnVisioneeringSM As an EnVisioneering partner, Manitowoc Foodservice Group leveraged our experience in helping industry leaders meet critical challenges. By applying custom-engineered Danfoss lter driers, compressors, expansion valves and solenoid valves, Manitowoc’s S-Series ice machines now lead the way with 25% more energy e ciency, plus greater reliability. Don’t sweat the details of your next HVAC&R challenge. Get a fresh perspective at www.envisioneering.danfoss.com ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=3MAKING MODERN LIVING POSSIBLE CONTENTS Experts speak out on energy efficiency’s bottom line . 2 EnVisioneering Appliance Control or A Case Study in Fast Food . 6 Volume 6, Issue 2 Jeff Duncan North America Motion Controls Jan Petersen North America Refrigeration and Air–Conditioning DANFOSS ENVISIONEERING SOLUTIONS is published for the benefit of Danfoss customers. Information in the DANFOSS ENVISIONEERING SOLUTIONS may be republished only with permission of editorial and always with credit to DANFOSS ENVISIONEERING SOLUTIONS. Comments, suggestions, and contributions are welcome. Getting More for Your Money: How One Repair Reduced Energy Costs at a W. Virginia Plant . 10 Pressure control – you get what you ask for . 14 Product News. 16 Dear Readers, 2007 was a year of change. ere were changes in e ciency standards that raised the bar in the HVAC-R and motion control industries. ere were changes that put more focus on climate change and sustainability and brought the issues to the forefront of public concern and business practices. And there were changes in the economy that also have had an impact on the way we do business. It has been a year to test the old saw that “change makes us stronger”. In many ways we have passed the test, with new and better technologies to meet the latest environmental and economic challenges. Perhaps the greatest outcome has been collaboration between industry, government and consumers to come up with answers to new and complex problems. At Danfoss we have been part of that collaborative e ort. is includes organizing symposia to encourage dialogue among industry leaders, politicians, and other decision-makers about important, and di cult issues. It also includes our partnerships with customers to develop new technologies to increase e ciency, productivity, and environmental responsibility. is issue of EnVisioneering Solutions takes a look at some of the ways we are tackling change. Inside you’ll nd interviews with experts on energy and environmental issues as well as pro les on new technology and applications. We hope you enjoy reading the magazine, and wish you great success for the New Year. THE EDITORS, solutions@danfoss.com *This publication should not take the place of appropriate technical or legal advice related to company-specific circumstances. DANFOSS ENVISIONEERING SOLUTIONS does not assume any liability of any kind whatsoever for the use or reliance upon the information contained in this publication. Design by Arista Advertising & Design, Inc. www.AristaAdvertising.com WWW.ENVISIONEERING.DANFOSS.COM Vol. 6 Issue 2 2007 12008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=4COVER STORY Experts speak out on ENERGY EFFICIENCY’S BOTTOM LINE Every time we pick up a newspaper or turn on the radio or TV, we get messages about climate change and the need to reduce the world’s natural resource consumption and emissions. S ometimes it can feel like “green overload.” Yet, attention on these topics is deserved. Energy consumption is projected to grow by 71 percent from 2003 to 2030. As demand outpaces supply, energy costs continue to rise. High fossil fuel consumption is also causing environmental problems, including climate change and global warming. Take these issues down to the business level and there is huge potential to cut costs and enhance business performance, while doing the right thing for the environment. These issues were in focus at Danfoss’ 5th EnVisioneeringTM symposium “Making Dollars and Sense of Energy Efficiency,” held in Long Beach, California, on June 5, 2007. The event was hosted by John Galyen, president, Danfoss Refrigeration & Air-Conditioning North America. The dialogue among the participants focused on advanced global strategies to launch a new era in energy efficiency. Two of the keynote speakers at the event discussed energy efficiency with EnVisioneering Solutions. 2 Vol. 6 Issue 2 2007 ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=5Experts Say Businesses Face Higher Costs and Reliability Issues EnVisioneering Solutions: How critical is the energy efficiency issue to businesses today? In what ways is it affecting the immediate bottom-line, company liability, security, etc? Kent Peterson: Energy efficiency is a very critical issue for businesses today. Energy drives world economies and we are beginning to see global energy availability as a global concern. Energy prices are continuing to rise due to the increase in world demand. World energy consumption is projected to grow by 71 percent from 2003 to 2030. Oil is forecasted to remain the dominant energy source with coal forecasted as the primary fuel for generating electricity. Energy use is also shifting away from developed countries and becoming more carbon-intensive. Kent Peterson, president ASHRAE Mark Bernstein: Energy efficiency will continue to grow in importance. Even though for most businesses, the cost of energy is small relative to other costs, it is the one cost item that has been rising substantially over the past few years, and expectations are that costs will continue to rise. In some places businesses can also expect to face reliability issues. Companies should be looking to reduce their exposure in energy markets, and one of the ways to do this is by reducing demand through energy efficiency. Many efficiency projects have very short payback times – less than two years – and companies can show significant returns on the investment. ES: What about energy and climate change – is that an issue pressing on the business community, or something that is still really more a concern of governments? Mark Bernstein, visiting professor University of Southern California, Future Fuels and Energy Initiative of Southern California WWW.ENVISIONEERING.DANFOSS.COM Vol. 6 Issue 2 2007 32008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=6COVER STORY EXPERTS SPEAK OUT Kent Peterson: Future energy costs are a real concern for businesses today. Both the public and state and federal government are beginning to evaluate human impact on climate change. It will likely become a pressing issue for our government due to pressure from many other countries. continued no question that as the world population is forecasted to increase from 6 billion people today to 10 billion people in 2050 that total demand for global energy will increase. The solutions we need to seek will include more efficient use of energy and additional sources of renewable energy. “Climate change is an issue that will impact everyone, and is as much a concern of the business community as it is for government.” Once it becomes a pressing issue for our government, you can be assured it will be an issue the business community will need to be prepared to deal with. California has already passed AB 32, The Global Warming Solutions Act, which will require businesses to reduce their greenhouse gas emissions in the future. Other states have or are considering implementing similar carbon reduction legislation. may also impact other factors as well, in particular water. Water costs are likely to rise substantially in the near future and could perhaps rise faster and farther than energy. Put together the cost impacts will be critical to a company’s bottom line. Climate change may also impact the market for a company’s output. Mark Bernstein: Yes, we are THE ANSWER LIES IN A PORTFOLIO OF SOLUTIONS ES: Will the answer come in terms of energy efficiency, or alternative and renewable energies, or a combination of both? Kent Peterson: I believe the answer will come with a combination of energy efficiency and alternative and renewable energies. Energy efficiency cannot solve the problem alone. having a hard time just keeping pace – but I believe that we can get ahead of the curve – with the right commitments, visions and policies. But it will take being proactive in making changes and we will need cooperation and innovation from many different sources to keep out in front. There may be realities that help push the system. ES: As businesses grapple with the many regulations and codes, how do they stay on top of what’s happening out there? Mark Bernstein: The answer will be a portfolio of solutions – from efficiency to renewables, to more efficient and lower polluting conventional fuels. There is not a single bullet solution. Our energy future will be based on a robust portfolio of alternatives. Mark Bernstein: Climate change is an issue that will impact everyone, and is as much a concern of the business community as it is for government. A changing climate will impact the corporate bottom line, and companies have a role in helping to figure out how to reduce greenhouse gas emissions. Climate change will be one of the factors leading to increasing energy costs, but climate change ES: Demand just continues to grow worldwide – realistically can we do more than just play “catch up”, or is it possible to really change things and reach sustainability? Kent Peterson: ASHRAE is helping businesses stay in touch with current and proposed energy legislation at the following link, http://www.ashrae.org/advocacy. The U.S. Department of Energy also has useful sites for energy legislation at the following link: http://www.eia.doe.gov/oiaf/ legislation.html Mark Bernstein: I don’t see energy and environmental regulations being any different than tax or safety regulations or other policies that businesses face. However, businesses can be more proactive here as well and help Kent Peterson: As engineers and scientists, we are trained to solve problems. There is 4 Vol. 6 Issue 2 2007 ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=7shape policy directions by providing meaningful suggestions for achieving reductions in energy use and investments in renewable energy. Mark Bernstein: There is capital pouring into the energy sector – mostly for new and innovative technologies. There are many good business opportunities for technology commercialization, though investors should be cautious that this energy boom does not mirror the dot.com experience. INTEGRATED BUILDING DESIGN Integrated building ES: What about incentives for energy efficient technologies, such as tax breaks and state funding programs? Kent Peterson: Tax breaks and utility incentives are proven methods for promoting energy efficient decisions. Some businesses understand the importance of life cycle review of improved energy efficient technologies. The incentives are effective in helping bring new technologies to the market. ES: Do we also face a growing need for experts in the fields of energy, in areas like energy science and engineering? Kent Peterson: There is definitely a growing need for experts to assist businesses with the successful implementation of energy efficient technologies and renewable energy sources. This need will grow as more states begin to adopt carbon reduction legislation that will require businesses to improve their energy performance. Mark Bernstein: This really varies by location. Federal policies have been inconsistent. Some state policies have worked and have driven innovation and investments. These will continue and will continue to play and important role. Mark Bernstein: Yes, we are facing a shortage of experts. Universities scaled back or dropped programs in the late 1980’s and early 1990’s when energy was not an issue. Things are just being ramped back up, and business has a significant role to play in supporting educational and research programs at Universities. GLOBAL ENERGY CRISES DRIVES SOLUTIONS ES: How is the energy problem driving business opportunities, for example in development of new technologies? Kent Peterson: I believe we are at a pivotal point in the history of the built environment that is exciting, daunting and challenging. This global energy crisis will drive numerous business opportunities for both energy efficient technologies and alternative energy sources. “This global energy crisis will drive numerous business opportunities for both energy efficient technologies and alternative energy sources.” design (IBD) is a collaborative process that can help provide the strategies to achieve high-performance, lowenergy, sustainable buildings by considering all design variables together. IBD looks beyond the immediate building to how the building and it's systems can be integrated with supporting systems on it's site and in its community and at how materials, systems, and products of a building connect, interact, and a ect one another. Kent Peterson says he has reviewed numerous buildings that consume 50 percent less energy than allowed by current building energy codes. “In most cases, the solutions are simple and elegant,” he says. WWW.ENVISIONEERING.DANFOSS.COM Vol. 6 Issue 2 2007 52008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=8EnVisioneering Appliance TM or A Case Study in Fast Food Delfield 4400 Series prep tables meet the demands of fast food kitchens. Delfield Refrigeration is an industry leader that has been building commercial refrigeration equipment since 1949. Their products include prep tables that have refrigerated pans on their top surface with tomatoes, onions, and sandwich meat, or pizza toppings, depending on the type of restaurant, and a refrigerated cabinet below. Other Delfield products are the reach-in refrigerators and freezers used for storage of foods supplies. All of these are self-contained, meaning that each appliance has a complete refrigeration system with evaporator, compressor, A t Danfoss, the tradition of continual innovation brings new products to the markets we serve. But solutions for challenges often arise from innovative application of existing products. 6 Vol. 6 Issue 2 2007 ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=9Control and condenser. All are front breathing, meaning that the air that cools the compressor is drawn in from the bottom front, and the heat removed from the condenser is rejected, or exhausted there. All Delfield refrigerators and freezers, then, must perform reliably in an excruciatingly demanding environment. In a fast food restaurant, they stand next to fast food fryers, ovens, broilers, and griddles. The refrigeration appliances are opened and closed hundreds of times each day in a hot and humid restaurant kitchen ambient atmosphere, but they must withstand that great thermal stress and still maintain steady, healthy temperatures around the clock. As customers became more and more demanding, Delfield managers knew that if they could achieve tighter temperature control in their undercounter line of refrigerators and freezers, they would have a significant advantage in the marketplace. And though tighter temperature control was the key to the market, energy savings would be a welcome plus. That challenge, and hope for a speedy solution, came into acute focus with the arrival at Delfield of a new engineering manager who had previously worked at another major restaurant appliance maker whom Danfoss had provided advantageous solutions when other suppliers had failed. Soon, a Delfield engineer began to work with the regional Danfoss sales engineer to analyze Delfield equipment and find a solution that would offer the desired temperature control. In time the result of this cooperation became a case study in EnVisioneering. Danfoss had for some time offered an electronic control for refrigeration appliances, type ETC1H. Because this unique control is completely electronic, it is able to provide a much tighter operating band around the setpoint (say 30°F) than a traditional mechanical thermostat. The temperature maintained in the appliance cabinet is much more stable because there is no drift as with mechanical controls. And the Danfoss ETC1H came with an array of additional functions that were very promising, too. Though the Delfield prep tables had two evaporators in each cabinet, and the Danfoss control’s Danfoss ETC1H electronic refrigeration appliance control. WWW.ENVISIONEERING.DANFOSS.COM Vol. Issue2 12007 2007 Vol. 66Issue 72008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=10Delfield builds its refrigeration systems with Danfoss compressors and components. software was engineered for single evaporators, both companies were hopeful that the solution for better temperature control had been found. But field testing soon proved that improvements were needed. Quickly, the Danfoss sales engineer involved engineers at the Danfoss factory. What he proposed was that a special version of software be written for the Delfield solution. It wouldn’t be a problem. Not only were the dual-evaporator routines added to the control, but other functions as well. When the new ETC1H (Delfield version) were delivered, they achieved gratifying success. And application of new defrost routines and other innovations (a smaller compressor, redesigned evaporator, and optimized airflow) yielded impressive energy savings on the order of 30 percent and more, an extremely attractive incentive for Delfield’s customers. Danfoss seeks to save energy in an environmentally friendly way with each of its products. With the ETC1H as it is used in Delfield Refrigeration products, some of the energy-efficient advantage comes from: • There is less compressor run time because of fan control. • Fan startup is delayed after defrost to allow all water to drip from the evaporator. This means that when the compressor is turned on, there is no water to freeze on the evaporator, hastening the need for a subsequent defrost. • Defrosts are started and stopped by logic. Because the ETC1H incorporates timers, and since the compressor runs on demand when cabinet temperature rises, a defrost can be initiated after a certain compressor run time. But the ETC1H offers an even better solution. When an evaporator needs defrost, it is covered with ice. That makes it inefficient at cooling because the ice insulates the evaporator. So Danfoss can program the ETC1H to start defrost based on compressor run time OR on high evaporator temperature. And finally, defrost is terminated not after a certain time, but when evaporator temperature reaches the level at which all ice is melted. So there is no electric energy wasted by an overlong defrost. • Product integrity is improved by using only the amount of defrost needed, rather than relying on a timer or thermostat alone. Too much defrost not only makes recovery more expensive, but also shortens product life. 8 Vol. 6 Issue 2 2007 ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=11• In a traditional refrigeration appliance, the fans run constantly. In the future, Delfield may take advantage of another ETC1H feature. The control’s intelligent software and multiple control outputs can turn the fan off when the compressor is not running. Not only is the energy required to run the fan saved, but also the energy required to remove the heat blown into the cabinet by the fan bringing in ambient air while the compressor is off. Maintenance savings are hard to quantify, but the ETC1H also protects the compressor from overvoltage or under-voltage, a very important feature where mains power varies, and particularly important in areas subject to brownout. Alarms activated or error codes displayed when established parameters are exceeded. Each alarm can be associated with a time delay, so, for instance, a high temperature alarm will not be generated until temperature has been above the danger level for a user-defined time. Delfield has begun using both the ETC1H digital display and alarms for its larger reach-in refrigerators and freezers. The Danfoss ETC1H is a small, but very capable control. Able to fit easily in the palm of your hand, it provides outstanding control for commercial refrigeration appliances, and an extensive array of very flexible features. The partnership between Danfoss as supplier and Delfield as customer has been one that has certainly benefited both. Delfield’s customers are excited about the tight temperature control on their prep table, undercounter, and reach-in refrigeration appliances, and they are also getting the benefit of 30 percent energy savings and more, a saving that provides bottom line improvement that is critical in the hyper-competitive fast food industry. ETC1H controls, first used in Delfield prep tables and undercounter refrigeration, are now being built into larger reach-in appliances. Delfield has added the Danfoss digital display to those, and their customers praise the alarm and error code display capability as well as the ability to monitor temperature from a large, bright LED display. The real story here is about people. Dedicated, tenacious, incisive people at Delfield and at Danfoss, melding ideas and applying innovative engineering for efficient solutions. As customers became more and more demanding, Delfield managers knew that if they could achieve tighter temperature control in their undercounter line of refrigerators and freezers, they would have a significant advantage in the marketplace. And though tighter temperature control was the key to the market, energy savings would be a welcome plus. Delfield reach-in commercial refrigeration for fast food kitchens. WWW.ENVISIONEERING.DANFOSS.COM Vol. 6 Issue 2 2007 92008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=12How One Repair Reduced Energy Costs at a West Virginia Plant Getting Money: For Your More ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING 10 Vol. 6 Issue 2 20072008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=13hen the Moundsville Wastewater Treatment Plant, located in the Northern Panhandle of West Virginia, encountered a centrifugal blower failure in 2003, a plant employee attending a training session earlier that year recalled remarks made by Danfoss representative Mr. Stu Harper of S. R. Harper, Inc. about the advantage of positive displacement blowers and how running them at a slower speed can save on energy costs. When it came to addressing this repair, Moundsville staff members were particularly concerned about VFDs and the dissolve oxygen sensor, said Larry Bonar, superintendent of the Moundsville plant. “These two items can be a maintenance headache,” he said. “Harper recommended Danfoss VFDs and DO [dissolved oxygen] sensors along with Kaeser blowers. We installed the equipment ourselves and saved quite a bit of money. Other than routine maintenance on the Danfoss VFD and the sensor in the tank, we have not had a problem with either one.” The Moundsville plant, which is owned by the City of Moundsville with a population of approximately 10,000 people, has a design flow of 2.34 million gallons per day, said Bonar. In addition to serving Moundsville, the plant also serves Glen Dale, W. Va., a neighboring community of approximately 2,500 people, and also takes flow from areas outside our city limits. W With the addition of another Danfoss drive controlling a 100 HP positive displacement blower connected to the primary aeration tanks, the Moundsville plant has now optimized overall operation while maximizing control and flexibilty. WWW.ENVISIONEERING.DANFOSS.COM Vol. 6 Issue 2 2007 112008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=14A wastewater treatment plant in Moundsville, West Virginia, uses variable frequency drives to improve aeration control and lower costs. The plant personnel and Harper back-calculated the air requirements for the individual tanks and came up with the idea to put a new valve in the line to the secondary aeration tanks with a new 50 HP rotary positive displacement blower. To operate the blower at optimum efficiency, a Danfoss drive was installed along with a dissolved oxygen meter, allowing the system to respond to actual conditions in the aeration tanks. With the new arrangement, the drive was programmed to maintain a dissolved oxygen level of 2.2 PPM and a minimum of 40 percent blower speed. After four days, the plant’s pinfloc problem ceased. Employees of the plant believe this resulted from better control of the dissolved oxygen levels. The 50 HP blower was generally observed to be operating at 40–50 percent of full speed or 20 to 25 HP. After a year of operation, it was apparent that with one 75 HP blower operating full time and one blower operating at a rough average of 22 HP, they had saved about $24,000 in power costs. The plant then performed further studies with a dissolved oxygen meter in the two remaining tanks and found that excess air was being introduced. Since then, with the addition of another Danfoss drive controlling a 100 HP positive displacement blower connected to the primary aeration tanks, the Moundsville plant now has optimized overall operation with maximized control and flexibility. The original centrifugal blowers are now being maintained as backups for the new blowers, which also run much more quietly. “We have not only saved a substantial amount of money in electric cost but [the repair] has also helped with reducing solids in our effluent by giving us the ability to control the amount of dissolve oxygen in the tanks,” said Bonar. After two years of service, the new blower arrangement is saving approximately $50,000 to $60,000 per year in energy costs. 12 Vol. 6 Issue 2 2007 ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=15Aeration Improvements at Moundsville WWT Plant After a study with an online DO meter the plant determined that DO levels varied fr from about 0.5 PPM to 5 or 6.0 PPM throughout oughout the day. The plant personnel along with the Kaeser representative and Danfoss sales rep equirements for the individual tanks and representative back calculated the air requirements came up with the idea to put a new valve in the line to the secondary aeration tanks with a new 50 HP blower DO meter and VFD as shown below: 75 HP centrifugal blowers New 100 HP blower N ew New e val valve l ve New 50 HP blower VFD VFD WWW.ENVISIONEERING.DANFOSS.COM Vol. 6 Issue 2 2007 132008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=16Pressure control— you get what you ask for The extent of automation in both mobile and stationary applications is increasing dramatically. More and more, electronic controls make possible efficient machine and system management. Sophisticated controls require ever more information with greater accuracy. Pressure sensing is an area where many technologies have been used, and there are still quite a number of options available to the engineer that must select controls for critical applications. A dvances in electronic controls allows some very attractive features, and corresponding benefits - all at competitive cost. It’s important to take care to select the best transmitter for the application. Mechanical pressure switches have been available for many years. They act to turn a system on or off when pressure reaches set point of the user’s choice, much like a thermostat cycles the heating and cooling unit on and off in a home. The age of electronics, though, brought more sophistication to pressure sensing and control. Various technologies have been used. The two most common principles used in industrial cartridge pressure transmitters are strain gauge Wheatstone bridge sensing and capacitive sensing. In Wheatstone bridge sensing, gauge elements are placed on the flexible diaphragm in such a way that they are stretched or compressed under pressure. The physical change thus caused in turn causes a change in resistance, and the output, basically, varies in proportion to the pressure. Even among these simple pressure sensing devices, though, there are varieties dependent upon the materials used—whether the sensing material is thick, or thin, or functions by twisting (by the piezoelectric effect). In capacitive sensing, pressure forces two conductive plates to change their distance from each other, thereby changing the capacitance between them. The result, once again, is read as an electric signal. There are varieties of this type, of which ceramic is the most widely used. in industrial applications. The science behind different technologies in pressure sensors In almost all pressure sensors (called most often transmitters or transducers) today, varying pressure is sensed by a diaphragm, and the diaphragm is deformed temporarily, more or less, by the changing pressure. Pressure on the diaphragm is transformed into an electrical signal that is read by an electronic circuit. 14 Vol. 6 Issue 2 2007 ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=17http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=17Characteristics and abilities vary for the various pressure transmitter technologies. The important differences are in how they handle variables such as: • pressure range • temperature range • zero displacement due to overpressure • long term thermal drift both at zero and over span • ability to measure absolute or gauge pressure To meet the full range of customer needs today, seems to be a trend toward sensor manufacturers developing broad product portfolios in order to offer more than one sensor technology. It’s important to know exactly what to ask for. The table below represents a performance evaluation of the majority of transmitter types on the market today, and gives an idea of the complexity found in selecting one that just meets the demands of the application it is being selected for. For instance, it must be accurate enough for a given application, but the user doesn’t want to spend more money to get a transmitter more accurate than required. The same goes for the pressure range, the ambient conditions the sensor can tolerate, and so on. Monolithic piezoresistive semiconductor 0.1– 600 bar 1.5 – 8700 psi ++ ++ ++ +++ +++ ++ +++ ++ +++ ++ ++ Bonded piezoresistive semiconductor 5 – 3000 bar 70 – 43,500 psi + ++ ++ ++ ++ ++ +++ +++ ++ ++ Ceramic capacitive Pressure range Accuracy Operating temperature span Long term stability Pressure peak resistance Over pressure safety Burst pressure safety Resistance to chock / vibration Hermetical tight pressure port (No seals) Absolute Gauge Low cost 0.01– 60 bar 0.15 – 900 psi ++ + ++ + ++ ++ ++ +++ ++ +++ Ceramic thick film 4 – 60 bar 60 – 900 psi + + + + + ++ + ++ +++ Thin-film 10 – 2000 bar 150 – 30,000 psi +++ +++ +++ ++ + ++ +++ ++ ++ ++ *typical figures. There are products on the market in which special action has been taken to exceed the range limits shown. +++ = very good ++ = good This article was adapted from an in-depth presentation and white paper, presented at + = satisfactory Sensors Expositon earlier this year. For a copy of the full presentation, contact the Industrial Automation Division at Baltimore 410-931-8250. = less satisfactory or not applicable WWW.ENVISIONEERING.DANFOSS.COM Vol. 6 Issue 2 2007 152008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=18http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=18P R O D U C T N E W S Product Highlight New Packaged Solutions Optimize and Simplify HVAC Operations Combine with popular VLT® HVAC Drives to provide unparalleled flexibility, performance and protection in HVAC applications MILWAUKEE, WI -- Danfoss Drives introduces VLT® HVAC Packaged Drive Solutions. Completely new designs for Electronically Controlled Bypass (ECB) and Electro-Mechanical Bypass (EMB) are available. ECB packages allow the user to program advanced bypass control features directly from the VLT HVAC drive keypad, including automatic bypass, advanced firefight’s override, coordinated run-permissive in both drive and bypass, and serial control while in bypass operation. The EMB packages are designed for users that prefer the traditional control provided through selector switches and pilot devices. “By combining the advanced features of the VLT HVAC Drive with the advanced performance of these Packaged Solutions, Danfoss is uniquely positioned to provide complete, advanced solutions to the HVAC market that to date have simply been unavailable,” says Ed Smith, HVAC Product Manger. “All packages allow the customer to match the capabilities of the Packaged Solution with the specific needs of the application,” he says. All packages provide improved protection and operation through a first-of-its-kind bypass 24VDC switch mode power supply. Contactor operation is maintained in harsh conditions, and drive operation can be maintained at a reduced output with an input voltage as low as 70% of nominal voltage, or with one input phase missing. This improves operation over standard transformer power supplies or power supplies that only operate off of two legs of input power. The unique power supply acts as a backup power source to the drive logic for ECB packages when power is removed form the drives input terminals. This allows operation of all control features to remain active in drive and bypass modes. Packages are available in either two contactor or three contactor configurations, from ½ HP through 350HP at 460 & 600VAC, or ½ HP through 60HP at 208 and 230VAC. NEMA/ UL Type 1 or Type 12 enclosures are available for all package configurations, and in many cases the physical size of the packaged solution does not change with the enclosure rating. All packages include drive-only input fusing. A wide range of optional power features are available including dual motors operation, contactor motor selection, input reactors, dV/dt filters, and selection between input disconnect, fused disconnect or circuit breaker. Danfoss is a leading manufacturer of precision mechanical and electrical components, with locations in more than 120 countries. Danfoss created the VLT name when they introduced the world’s first mass-produced VFD in 1968, and the name has set the standard for high performance quality variable frequency drives ever since. New Low Temp R-404A Compressors High EER, Lower Sound Levels Danfoss NTZ compressors are optimized for freezing applications— commercial freezers (including walk-ins), ice flakers, ice cream machines, and other low temperature applications including medical and scientific equipment. With EERs up to 4.2, and engineered to suit the special requirements of low temperature operation, the NTZ line offers capacities from 3,400 to 24,000 Btuh. The new low temperature compressors have a smaller footprint and a lower sound level. Motors are 100% suction gas cooled, so additional cooling components are unnecessary, and compressor reliability is enhanced, making the NTZ an economical choice for OEMs. “We believe that we have given the industry a range of hermetic low temperature compressors with significant advantages that mean there are savings for both OEMs and end users,” says Andres Lacassie, business development manager at Danfoss in Baltimore. For more information, contact 800-621-8806; salesinformation@danfoss.com; www.namc.danfoss.com. For more information, contact 410-931-8250. 16 Vol. 6 Issue 2 2007 ENGINEERING + E2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=19http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=19MAKING MODERN LIVING POSSIBLE G E E O O E E V E V O B L SM M E M P A E D D A D S M www.envisioneering.danfoss.com L ENGINEERING + ENERGY EFFICIENCY + ENVIRONMENT = ENVISIONEERING2008-01-14T16:52:23+01:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=20http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol6Issue2/?Page=20HOW TO CONTACT DANFOSS BALTIMORE, MD 7941 Corporate Drive Baltimore, MD 21236 410-931-8250 / Fax: 410-931-8256 www.danfoss.com/North_America Refrigeration & Air–Conditioning Industrial & Heating Controls 2 0 0 8 C A L E N D A R O F E V E N T S January 2008 AHR International Air-conditioning, Heating and Refrigeration Expo: January 22-24, 2008 Javits Convention Center, New York City. Visit Danfoss booth #521. TALLAHASSEE, FL Danfoss Turbocor 1769 Paul Dirac Drive Tallahassee, FL 32310 850-504-4800 www.turbocor.com Oil-Free Compressors for Refrigeration and Air-Conditioning GLENS FALLS, NY Danfoss Flomatic Valves 15 Pruyn's Island Drive Glens Falls, NY 12801 800-833-2040 / Fax: 800-314-3155 E-Mail: flomatic@flomatic.com www.danfossflomatic.com Water Controls LOVES PARK, IL Danfoss Drives 4401 N. Bell School Road Loves Park, IL 61111 815-639-8600 / Fax: 815-639-8000 www.namc.danfoss.com Drives; Industrial Sales MILWAUKEE, WI 8800 W. Bradley Road Milwaukee, WI 53224 414-355-8800 / Fax: 414-355-6117 www.namc.danfoss.com www.na.water.danfoss.com Danfoss Graham HVAC Danfoss Water & Wastewater Nessie Water Hydraulics MISSISSAUGA, ONT 6711 Mississauga Rd., Suite 410 Mississauga, Ontario L5N 2W3 905-285-2050 / Fax: 905-285-2055 www.na.heating.danfoss.com Heating Controls Motion Controls MOUNTAINSIDE, NJ Danfoss Hago Inc. 1120 Globe Ave Mountainside, NJ 07092 908-232-8687 / Fax: 908-232-7246 www.hagonozzle.com Components for Oil Burners SOMERSET, NJ Danfoss Bauer 31 Schoolhouse Road Somerset, NJ 08873-1212 732-469-8770 / Fax: 732-469-8773 www.danfoss.com/drives/us/ Gearmotors March 2008 CONEXPO-CON/AGG-IFPE 2008: March 11-15, 2008 Las Vegas, Las Vegas Convention Center. Visit Danfoss booth #13176. IIAR 2008 Ammonia Refrigeration Conference & Exhibition: March 16-19, 2008 Colorado Springs, Colorado. Visit Danfoss booth #301/303. CMX-CIPHEX 2008, National Trade Show & Learning Forum: March 27-29, 2008 - Metro Toronto Convention Centre, North Building, Toronto. April 2008 NA 2008: April 21-24, 2008 - I-X Center, Cleveland, OH. Visit Danfoss booth # 2732. For More Information Keep updated on all the latest news about Danfoss products and your industry at www.envisioneering.danfoss.com To find out more about Danfoss North America, contact us via-email at: solutions@danfoss.com2008-01-14T16:52:23+01:00