ABSTRACT

Traditional centrifugal compressors use roller bearings and hydrodynamic bearings, both of
which consume power and require oil and lubrication system. This can be overcome by the
introduction of new compressor technology called frictionless compressor technology. The
frictionless compressor technology is compressor with the application of magnetic bearings and
permanent magnet synchronous motor. In frictionless compressor instead of roller bearings and
hydrodynamic bearings, magnetic bearings are used. Magnetic bearings consume less power and
there is no need for oil and lubrication systems. Permanent magnet brushless synchronous motor
has permanent magnet instead of copper windings.

After 10 years of development, magnetic bearing compressors offer economic, energy, and
environmental benefits. Chief among them are increased energy efficiency, the elimination of oil
and oil management and considerable less weight, noise, and vibration. This is initial mid-range
package offers centrifugal compression efficiencies previously reserved for large tonnage
systems only. This compressor has high reliability, efficiency, less maintenance cost and staff.
With the help of digital control system the controlling and monitoring of work is very easy. The
frictionless compressor technology makes new revolutions in the field of air conditioning,
refrigeration etc.
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1. INTRODUCTION
A new compressor technology introduced during the 2008 International Air Conditioning
Heating Refrigerating Exposition (AHR Expo), held at January in Chicago, may have a
significant effect on the future of mid-range chillers and rooftop applications in water cooled,
evaporative cooled, and air-cooled chilled water and direct-expansion (DX) systems.

Designed and optimized to take full advantage of magnetic-bearing technology, the compressor
was awarded the first AHR Expo Innovation Award in the energy category, as well as Canada’s
Energy Efficiency Award for its potential to reduce utility-generated greenhouse-gas emissions.
The compressor is key to a new water cooled centrifugal-chiller design, with Air Conditioning
and Refrigeration Institute (ARI) tests indicating integrated part-load values (IPLVs) not
normally seen with conventional chillers in this tonnage range.

Frictionless Compressor Technology is one of the fast growing Technology in the mechanical
engineering field. In the case of Traditional centrifugal compressors, we use roller bearings &
hydrodynamic bearings, both of them consume power & require oil & lubrication system. This
can be overcome by introduction of the new compressor technology which is called as
frictionless compressor technology.

1.2. GAS COMPRESSOR

A gas compressor is a mechanical device that increases the pressure of a gas by reducing its
volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can
transport the fluid through a pipe. As gases are compressible, the compressor also reduces the
volume of a gas. Liquids are relatively incompressible, so the main action of a pump is to
transport liquids.

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Types of Compressors

The main types of gas compressors are illustrated and discussed below:

Compressor Types

Positive
Dynamic
Displacement

Reciprocating Rotary Centrifugal Axial

Single
Diaphgram
Acting
Liquid
Double Acting Lobe Screw Scroll Vane
Ring

Centrifugal compressors

Centrifugal compressors use a rotating disk or impeller in a shaped housing to force the gas to
the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section
converts the velocity energy to pressure energy. They are primarily used for continuous,
stationary service in industries such as oil refineries, chemical and petrochemical plants and
natural gas processing plants. Their application can be from 100 hp (75 kW) to thousands of
horsepower. With multiple staging, they can achieve extremely high output pressures greater
than 10,000 psi (69 MPa).

Many large snow-making operations (like ski resorts) use this type of compressor. They are also
used in internal combustion engines as superchargers and turbochargers. Centrifugal
compressors are used in small gas turbine engines or as the final compression stage of medium
sized gas turbines.

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Diagonal or mixed-flow compressors

Diagonal or mixed-flow compressors are similar to centrifugal compressors, but have a radial
and axial velocity component at the exit from the rotor. The diffuser is often used to turn
diagonal flow to the axial direction. The diagonal compressor has a lower diameter diffuser than
the equivalent centrifugal compressor.

Axial-flow compressors

Axial-flow compressors are dynamic rotating compressors that use arrays of fan-like aero foil to
progressively compress the working fluid. They are used where there is a requirement for a high
flows or a compact design.

The arrays of aero foil are set in rows, usually as pairs: one rotating and one stationary. The
rotating aero foil’s, also known as blades or rotors decelerate and pressurize the fluid.

The stationary aero foil is, also known as a stators or vanes, turn and decelerate the fluid;
preparing and redirecting the flow for the rotor blades of the next stage. Axial compressors are
almost always multi-staged, with the cross-sectional area of the gas passage diminishing along
the compressor to maintain an optimum axial Mach number. Beyond about 5 stages or a 4:1
design pressure ratio, variable geometry is normally used to improve operation.

Axial compressors can have high efficiencies; around 90% polytrophic at their design conditions.
However, they are relatively expensive, requiring a large number of components, tight tolerances
and high quality materials. Axial-flow compressors can be found in medium to large gas turbine
engines, in natural gas pumping stations, and within certain chemical plants.

Reciprocating compressors

Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or
portable, can be single or multi-staged, and can be driven by electric motors or internal
combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp) are
commonly seen in automotive applications and are typically for intermittent duty. Larger
reciprocating compressors up to 1000 hp are still commonly found in large industrial

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applications, but their numbers are declining as they are replaced by various other types of
compressors. Discharge pressures can range from low pressure to very high pressure (>5000 psi
or 35 MPa). In certain applications, such as air compression, multi-stage double-acting
compressors are said to be the most efficient compressors available, and are typically larger,
noisier, and more costly than comparable rotary units.

Rotary screw compressors

Rotary screw compressors use two meshed rotating positive-displacement helical screws to force
the gas into a smaller space. These are usually used for continuous operation in commercial and
industrial applications and may be either stationary or portable. Their application can be from 3
hp (2.24 kW) to over 500 hp (375 kW) and from low pressure to very high pressure (>1200 psi
or 8.3 MPa). They are commonly seen with roadside repair crews powering air-tools. This type is
also used for many automobile engine superchargers because it is easily matched to the induction
capacity of a piston Engine

Rotary vane compressors

Rotary vane compressors consist of a rotor with a number of blades inserted in radial slots in the
rotor. The rotor is mounted offset in a larger housing which can be circular or a more complex
shape. As the rotor turns, blades slide in and out of the slots keeping contact with the outer wall
of the housing.[1] Thus, a series of decreasing volumes is created by the rotating blades. Rotary
Vane compressors are, with piston compressors one of the oldest of compressor technologies.

With suitable port connections, the devices may be either a compressor or a vacuum pump. They
can be either stationary or portable, can be single or multi-staged, and can be driven by electric
motors or internal combustion engines. Dry vane machines are used at relatively low pressures
(e.g., 2 bars) for bulk material movement whilst oil-injected machines have the necessary
volumetric efficiency to achieve pressures up to about 13 bars in a single stage. A rotary vane
compressor is well suited to electric motor drive and is significantly quieter in operation than the
equivalent piston compressor.

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Scroll compressors

A scroll compressor, also known as scroll pump and scroll vacuum pump, uses two interleaved
spiral-like vanes to pump or compress fluids such as liquids and gases. The vane geometry may
be involutes, Archimedean spiral, or hybrid curves. They operate more smoothly, quietly, and
reliably than other types of compressors in the lower volume range. Often, one of the scrolls is
fixed, while the other orbits eccentrically without rotating, thereby trapping and pumping or
compressing pockets of fluid or gas between the scrolls.

Diaphragm compressors

A diaphragm compressor (also known as a membrane compressor) is a variant of the

conventional reciprocating compressor. The compression of gas occurs by the movement of a
flexible membrane, instead of an intake element. The back and forth movement of the membrane
is driven by a rod and a crankshaft mechanism. Only the membrane and the compressor box
come in touch with the gas being compressed. Diaphragm compressors are used for hydrogen
and compressed natural gas (CNG) as well as in a number of other applications.

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3. THE EMERGING TECHNOLOGY IN CENTRIFUGAL COMPRESSOR

The Frictionless compressor is the world’s first totally Oil-Free compressor specifically
designed for the Heating, Ventilation, Air Conditioning and Refrigeration (HVACR) industry.
The convergence of aerospace and industrially proven magnetic bearings, variable-speed
centrifugal compression and digital electronic technologies enables the frictionless compressors
(nominal 60-150 ton capacity range) to achieve the highest compressor efficiencies, cost
effectively, for middle-market, water-cooled, evaporative-cooled and air-cooled HVACR
applications.

The well-proven energy performance advantages of variable-speed centrifugal

Compressors are now brought to mainstream middle-market applications through the use of
High-speed, two-stage centrifugal compression with integral variable-speed drive. Compressor
speed is reduced as the condensing temperature and/or heat load reduces.

Optimizing energy performance through the entire operating range from 100% to 20% or
below of rated capacity. Operations to near zero loads are achievable via an optional, digitally
controlled, load balancing valve.

Centrifugal compressors tend to be more efficient than screw or scroll compressors, and
take advantage of speed control more effectively, but they are usually only available in larger
sizes. By using the smaller shaft, they are able to take advantage of the centrifugal compressor
technology in a smaller size than is normally available.

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4. FRICTIONLESS COMPRESSOR TECHNOLOGY

Frictionless Compressor Technology is one of the fast growing Technology in the

mechanical engineering field. In the case of Traditional centrifugal compressors, we use roller
bearings & hydrodynamic bearings, both of them consume power & require oil & lubrication
system. This can be overcome by introduction of the new compressor technology which is called
as FRICTIONLESS COMPRESSOR TECHNOLOGY. The frictionless compressor technology
is the compressor with which the application of the magnetic bearings & permanent magnet
synchronous motor. In the frictionless compressor instead of the roller bearings & hydrodynamic
bearings, magnetic bearings will be use. Magnetic bearings consume less power & there is no
need for the oil and lubrication systems. Permanent magnet brushless synchronous motor has the
permanent magnet instead of the copper windings. This compressor has the high efficiency,
reliability, less maintenance cost & the staff. With help of the digital control system, controlling
& monitoring of the work is very easy. The frictionless compressor technology makes new
revolutions in the field of air conditioning, refrigeration etc.

They Are Different because

1. Magnetic bearings.

2. Oil-free design.

3. VFD control.

4. Smaller and lighter than conventional compressors.

5. Less noise

Problems with Traditional Technology

1. Oil-lubricated equivalent wastes more on friction and irreversible loss.

2. Oil fouling costs more due to higher ∆T.

3. On / off control costs more.

4. Part-load inefficiency costs more for traditional chillers.

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Solutions with Frictionless Compressor

1. Frictionless oil-free using magnetic bearings.

2. Soft start and Ramp up.

3. Power Management.

4. No COP deterioration with time.

5. Low noise and smooth Operation.

6. Low maintenance costs as there are no wearing parts.

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5. MAIN COMPONENTS

The components in Frictionless Compressor can be mainly classified into two categories as
Mechanical components and Electrical components:

MECHANICAL COMPONENTS

1. Magnetic bearings and bearing sensors

 Composed of both permanent and electromagnets

 Enables precisely controlled frictionless compressor
shaft rotation on a levitated magnetic cushion
 Bearing sensors, located at each magnetic bearing,
feedback rotor orbit and thrust/axial information in real time.

2. Permanent-magnet synchronous motor

 Powered by PWM (pulse width modulated) voltage

supply

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 High-speed variable frequency operation affords high efficiency, compactness and soft
start capability

3. Touchdown bearings
 Carbon-lined radially and axially located bearings support the rotor when the compressor
is not energized
 Prevents contact between the rotor and other metallic surfaces.

4. Shaft and impellers

 Only one major moving compressor component
 Acts as rotor for permanent-magnet synchronous motor
 Impellers are keyed directly to the motor rotor

5. Compressor cooling
 Liquid refrigerant flow is controlled electronically,
cooling electronic, mechanical and Electromechanical
compressor components to assure maximum efficiency
and safe operation

6. Inlet guide vane assembly

 Trims compressor capacity and is digitally integrated
 With the variable-speed control, to optimize energy
 Efficiency and compressor performance

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ELECTRICAL COMPONENTS

1. Soft start module

 Significantly reduces high in-rush current at startup
 The startup inrush current is only 2 amps vs. typically up to 500-600 amps
 Experienced by traditional screw compressors in this tonnage range – truly redefining
soft start

2. Variable frequency drive

 IGBT (Insulated Gate Bipolar Transistor) is an inverter that converts a DC voltage into an
adjustable three-phase AC voltage
 Signals from the motor/bearing controller determine the inverter output frequency,
voltage and phase, thereby regulating the motor speed converts mechanical energy back
into electrical energy.
 In case of power failure, this patented control scheme allows for a normal deLevitation
and shutdown.

3. Three-phase terminal block

 Connection point for primary power supply

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4. Rectifier

 Converts AC line power into a high-voltage DC power source for motor, bearings and
control operations.

5. Capacitors

 Energy storage and filter for smooth DC voltage

 Provide power to the magnetic bearings, along with
motor rotation, to ensure rotor shaft levitation through
compressor coast down in the event of an external
power loss.

6. DC-DC converters

 Supplies and electrically isolates the high and low DC voltages required for the control
circuits.

7. Controls connection

 Network connection for external control and monitoring

8. Bearing sensor feed through

 Hermetically sealed connections enabling the transfer of

power to the electromagnetic bearings and shaft position
and rotation signals to the control modules

9. Driver Board/EXV Control

10. Compressor and bearing controller

 Central processor of the compressor system

 Continuously updated with critical data from the motor/bearing and external sensors that
indicate the compressor and chiller/rooftop package Operating status
 Software enabled, it responds to changing conditions and requirements to ensure
optimum system performance

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 Computes the required shaft position signals that control the magnetic bearings
 Processes motor current information to control motor
speed

11. PWM amplifier

 Supplies power to the electromagnetic bearings

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6. THE BEARINGS
Traditional centrifugal compressors use roller bearings and hydrodynamic bearings, both
of which consume power and require oil and a lubrication system. Recently, ceramic roller
bearings, which avoid issues related to oil and reduce power consumption, were introduced to the
HVAC industry. The lubrication of these bearings is provided by the refrigerant itself.

Magnetic-bearing technology is significantly different. A digitally controlled magnetic

bearing system, consisting of both permanent magnets and electromagnets, replaces conventional
lubricated bearings. The frictionless compressor shaft is the compressor’s only moving
component. It rotates on a levitated magnetic cushion. Magnetic bearings—two radial and one
axial— hold the shaft in position.

When the magnetic bearings are energized, the motor and impellers, which are keyed
directly to the magnetic shaft, levitate. Permanent-magnetic bearings do the primary work, while
digitally controlled electromagnets provide the fine positioning. Four positioning signals per
bearing hold the levitated assembly to a tolerance of 0.00002 in. As the levitated assembly
moves from the center point, the electromagnets’ intensity is adjusted to correct the position.
These adjustments occur 6 million times a minute. The software has been designed to
automatically compensate for any out-of-balance condition in the levitated assembly.

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7. SHUTDOWNS AND POWER FAILURES

When the compressor is not running, the shaft assembly rests on graphite-lined, radially
located touchdown bearings. The magnetic bearings normally position the rotor in the proper
location, preventing contact between the rotor and other metallic surfaces. If the magnetic
bearings fail, the touchdown bearings (also known as backup bearings) are used to prevent a
compressor failure. The compressor uses capacitors to smooth ripples in the DC link in the motor
drive. Instantaneously after a power failure, the motor becomes a “generator,” using its angular
momentum to create electricity (sometimes known as back EMF) and keeping the capacitors
charged during the brief coast down period. The capacitors, in turn, provide enough power to
maintain levitation during coast down, allowing the motor rotor to stop and delimitate. This
feature allows the compressor to see a power outage as a normal shutdown.

8. OIL-FREE DESIGN

Oil management, particularly as it pertains to the lubrication of compressor bearings, is a critical

issue in refrigeration system design. But with magnetic bearings, this issue is avoided. Only a
very small amount of oil is required to lubricate other system components, such as seals and
valves; often, however, experience shows that even this small amount of oil is not needed.
Avoiding oil-management systems means avoiding the capital cost of oil pumps, sumps, heaters,
coolers, and oil separators, as well as the labor and time required to perform oil related services.
Reports indicate that for many installations, compressor-maintenance costs have been cut by
more than 50 percent.

Magnetic bearings eliminate the need for these systems and oil management in general. In fact,
the only required regular maintenance of the compressor is the quarterly tightening of the
terminal screws, the annual blowing off of dust and cleaning of the boards, and the changing of
the capacitors every five years. Complete service agreements and extended maintenance
contracts can be provided by the manufacturer.

9. THE MOTOR

Most hermetic compressors use induction motors cooled by either liquid or suction-gas
refrigerant. Induction motors have copper windings that, when alternating current is run through

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them, create the magnetic fields that cause the motor to turn. These copper windings are bulky,
adding size and weight to the compressor. Two-pole, 60-Hz induction motors operate at
approximately 3,600 rpm. A higher number of revolutions per minute can be obtained by
increasing the frequency. Compressors that require higher shaft speeds tend to use gears. While
gears are a proven technology, they create noise and vibration, consume power, and require
lubrication. The magnet-bearing compressor features a synchronous permanent-magnet brushless
DC motor with a completely integrated variable-frequency drive (VFD). The stator windings
found conventional induction motors are replaced with a permanent-magnet rotor. Alternating
current from the inverter energizes the armature windings. The stator (excitation) and rotor
(armature) change places. The motor and key electronic components are internally refrigerant
cooled, so no special cooling is required for the VFD or the motor.

The use of permanent magnets instead of rotor windings makes the motor smaller and lighter
than induction motors. Using magnetic-bearing technology, a 75-ton compressor weighs 265
lb.—about one-fifth the weight of a conventional compressor. A variable-speed drive (VSD) is
required for the motor to operate.

The VSD varies the frequency between 300 and 800 Hz, which provides a compressor-speed
range from 18,000 to 48,000 rpm. This avoids a gear set. The VSD is integrated into the
compressor housing, avoiding long leads and allowing key electronic components to be
refrigerant-cooled. The VSD also acts as a soft starter; as a result, the compressor has an
extremely low startup in-rush current: less than 2 amps, compared with 500 to 600 amps for a
traditional 75-ton, 460-v screw compressor with a cross-the-line starter. With the integration of
the motor, VSD, and magnetic-bearing system, the capacitors required for the motor and drive
can be used as a backup power source for the bearings in the event of a power outage or
emergency shutdown.

10. CAPACITY AND EFFICIENCY

Among the key parameters affecting performance are capacity (tons) and efficiency (kilowatts
per ton). The compressor’s capacity ranges from 60 to 90 tons, depending on the operating
conditions. Plans call for that range to be extended to 150 tons water-cooled and 115 tons air-

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cooled by the end of 2004 with the use of R-134a refrigerant. An R-22 version is planned for
retrofit applications.

Efficiency improvements stem from a combination of the centrifugal compressor, permanent

magnet motor, and magnetic bearings. Within the compressor, efficiency is affected by the
Compressor isentropic efficiency (the efficiency of the wheels), the motor, and the bearings.
Traditional induction motors of this size typically are in the 92-percent efficiency range. This
compressor’s permanent-magnet motor has an efficiency of 96 to 97 percent. Efficiency is
further enhanced with the use of magnetic bearings, which avoid the friction of rubbing parts
associated with traditional oiled bearings. Conventional bearings can use as much as 10,000 w,
while magnetic bearings re- quire only 180 w. That amounts to 500 times less friction loss.

Current development projects are expanding the range and duty of the compressor wheels and
promise to offer even greater efficiency for water-cooled and air-cooled duties and different
capacities.

11. SOUND AND VIBRATION

Because the rotating assembly levitates, there essentially is no structure-borne vibration. The
magnetic bearings create an air buffer that prevents the only major moving part the motor rotor
from transmitting vibration to the structure. Similarly, sound levels are extremely low, primarily
because of refrigerant-gas movement through the compressor and the rest of the refrigeration
system. There are no tonal issues, such as those found with some screw compressors, and the
noise occurs in the higher octave bands, where it is easier to attenuate. When two magnetic
bearing compressors were integrated into a chiller, the sound pressure was 77 dB at 3.3 ft. under

ARI Standard 575-94, Method of Measuring Machinery Sound within an Equipment Space.

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12. ADVANTAGES

 Easy to work with

It features the same standard suction, discharge and economizer ports as conventional
compressors. It mounts in the standard way. It can use the same power wiring with a
single control and monitoring connection.

 Easy on product cost

This frictionless magnetic bearing design needs no oil management system. And because
there’s no oil to coat the heat transfer surfaces, the unit’s high efficiency can be
maintained over the lifetime of the product. The outstanding efficiency of the compressor
gives equipment manufacturers the option to offer the highest efficiency/lowest
emissions, cost effective performance in its tonnage range.

 Easy on the ears

A sound level less than 70 dB, with virtually no structure-borne vibration, eliminates the
need for expensive attenuation accessories.

 Easy to handle

265 pounds (120 kg) is less than 20% of the weight of competitive compressors with an
approximate 50% smaller footprint.

 Easy refrigerant choice

Since the compressors are optimized for HFC -134a, a well-known, environmentally
responsible, refrigerant.

 Easy to control

Onboard digital electronics make the compressor “the compressor” with a brain. Inside,
the compressor is totally self-correcting and incorporates a system of sophisticated self-
diagnostics, monitoring and control. Outside, you can tap into this intelligence by using
control outputs in various for including web-enabled monitoring and control.

 Easy on energy

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The compressor enables chiller and rooftop manufacturers to achieve the necessary
product efficiency levels to meet and exceed ASHRAE 90.1 and the California Title 24
requirements for energy efficiency.

13. APPLICATIONS

Water-cooled chiller applications

Rooftop and packaged system applications

Air-cooled chiller applications

Multiple compressor applications

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CONCLUSION

Frictionless Compressor Technology is one of the fast growing Technology in the mechanical
engineering field. In the case of Traditional centrifugal compressors, we use roller bearings &
hydrodynamic bearings, both of them consume power & require oil & lubrication system. This
can be overcome by frictionless compressor technology And it offer economic, energy and
environmental benefits. Chief among them are energy efficiency, eliminating oil and control oil
and much less weight, noise and vibration. This is the initial intermediate package offers the
efficiency of centrifugal compression previously intended only for large systems. This
compressor has a high reliability, efficiency, lower maintenance costs and staff. Using digital
control and monitoring management system of operation is very simple. Frictionless compressors
make new revolutions in air-conditioning, refrigeration and so Frictionless. Compressor
technology is one of the fastest growing technologies in the field of engineering. The design of
these compressors is clearly innovative, elegant, and efficient, and all indications are that it is a
quality product. The idea of using magnetic bearings is provocative, but it turns out that this
feature in itself is rarely enough to justify considering the 50-70% price premium you are likely
to pay for a frictionless compressor. However, with associated benefits, it may be well worth
considering.

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