ANSÖKAN OM FORSKNINGSSTÖD Datum Dnr 1 (7) Projektnr Sökande Företag/organisation Organisationsnummer KTH, Kungliga Tekniska Högskolan 202100-3054 Institution/avdelning Postgiro/Bankgiro/Bankkonto Energiteknik, Avd. Tillämpad Termodynamik och Kylteknik PG: 1 56 53-9, BG: 895-9223 Postadress Brinellvägen 68 Postnummer Ort Länskod Kommunkod Land 10044 Stockholm 01 80 Sverige Projektledare (förnamn, efternamn) Joachim Claesson, Hatef Madani Telefon 08 790 8653 08 20 41 61 E-postadress Hatef.madani@energy.kth.se Eventuell medsökande (ange organisation) Fax Webbplats http://www.kth.se/itm/inst/energiteknik Projektet Ansökan avser nytt projekt Fortsättning på tidigare projekt, ange projektnummer: Projekttitel (på svenska) Smart Felidentifiering och diagnos för värmepumpsystem Projekttitel (på engelska) Smart Fault Detection and Diagnosis (SFDD) for heat pump system Sammanfattning (på svenska). Sammanfattningen skall omfatta max 250 ord och skall skrivas både på svenska och på engelska. Sammanfattningen skall skrivas så att den i ämnet oinvigde med lätthet förstår projektets innehåll och syfte. Det är inte ovanligt att värmepumpssystem presterar sämre systemeffektivitet än det som uppmätts vid standardprover i laboratorier. Dessutom har många värmepumpar rapporterats som felaktiga eller defekta till försäkringsbolagen under många år. Ett Smart Felidentifierings och Diagnostiseringssystem (SFDD) kan vara en lösning till att motverka försämrande prestanda över tiden, minska underhållskostnaderna samt att reducera antal fel som behöver reklameras. FDD kan också öka de svenska tillverkarnas möjligheter till global export genom stärkta konkurrensfördelar. Projektet syftar att: 1. Skapa en omfattande feldatabas med de mest förekommande felen som uppstår under installation och under drift och underhåll. 2. Skapa ett smart felidentifierings och diagnossystem som agerar under tre faser: Installation, drift, och underhåll 3. Upprätthålla kontakt med liknande projekt utomlands (t ex IEA QI/QM) STEM038 ver.n-1.1, 2005-09-14 Det framtagna verktyget fokuserar alltså inte bara på vanliga fel under drift, men också vid systemets installation. Det finns speciella typiska installationsfel, felaktigt dimensionerade komponenter, fel på styrningen, under- eller överfyllning av systemen etc. Till sist kommer projektet i slutänden vara den viktigaste kunskapsbasen att ta avstamp från vid en framtida generisk inbyggd FDD i framtidens Sekretariatet EFFSYS+ Institutionen för Energiteknik Avdelningen Tillämpad termodynamik och kylteknik Kungliga Tekniska Högskolan 100 44 Stockholm Besöksadress Brinellvägen 68 Telefax 08-204161 E-post effsysplus@energy.kth.se
2 (7) svensktillverkade värmepumpar. Sammanfattning på engelska enligt ovan (max 250 ord). Most of the heat pump systems operate with much lower system efficiency than the typical efficiencies measured at standard conditions in manufacturers laboratories. Furthermore, there have been several heat pump failures reported to the insurance companies during the recent years. A Smart Fault Detection and Diagnosis procedure (SFDD) is suggested as the solution to decrease the performance degradation during operation, and reduce the maintenance cost and the number of reported damages. FDD system may also improve the chances of Swedish heat pump manufacturers to export globally by adding a new competitive edge. The project aims at: 1. Making a comprehensive database of the most common faults during the installation and operation and service processes. 2. Designing a fault detection and diagnosis system at three different phases: commissioning, operation, and maintenance. 3. Providing an appropriate source for collaboration with international organizations with similar projects, e.g. IEA QI/QM The designed SFDD system focuses not only on the common faults during the heat pump operation, but also analyze the commissioning phase which covers common installation faults, incorrectly sized equipment, control errors, and refrigeration undercharge and overcharge conditions. Moreover, at the end, the project will be the main knowledge base for commercializing a generic built-in SFDD product for heat pumps manufactured in Sweden. Enskilt projekt Datum för projektstart Forskningsprogram, ange vilket: EFFSYS+ 2012-07-01 2014-06-01 Totalt sökt belopp 950 kkr Tidpunkt då projektet beräknas vara genomfört
3 (7) Motivering; Energi-/miljö-/näringslivsrelevans, max 250 ord. Ange koppling till resultat från tidigare genomfört program eller projekt. After the success in the car industry, it seems logical to bring the Fault Detection and Diagnosis (FDD) technology to the heat pump markets because: It is not uncommon for heat pump systems to operate with lower system efficiencies than the efficiencies measured at the standard conditions in manufacturers laboratories. This considerable performance degradation, which costs a lot both economically and environmentally, may be caused by some minor errors during installation, refrigerant charge, incorrectly operating control units or by a malfunctioning component in the system. During recent years, there have been several heat pump failures reported to the insurance companies. For example, Folksam announced that 8 500 heat pump damages were reported during 2008 and 77% of the failed heat pump were less than 5 years old. Sweden is known as one of the leading countries in heat pump technology and it has one of the highest numbers of installed heat pump per capita. To maintain the high competency level, Sweden should not have a passive role in some of the advanced technologies such as SFDD which is predicted to be commercialized in the near future. A comprehensive SFDD system may mitigate the performance degradation to a large extent, save money, make the heat pumps more environmental friendly, reduce the number of damages, decrease the number of unnecessary visual inspections, components replacements as well as decrease maintenance costs, and finally improve the chance of Swedish heat pump manufacturers to export globally. Bakgrund; vad har gjorts tidigare?, vad är nytt i detta projekt?, forskargruppens verksamhet?, samarbeten? etc, max 1 A4-sida Fault Detection is the (automatic) process of determining that some fault(s) has occurred in the system. As soon as a fault is detected, the next step is to determine the kind of fault including the exact location (fault isolation), time, and magnitude of the fault (fault identification). A Diagnosis system should be able to guide the technicians to the best way to handle/remove the fault. During one of the projects within Effsys2 program called Dynamiska värmepumpsystem med kapacitetsreglering, a generic model of a heat pump system was developed. The model developed in the project consists of several sub-models such as detailed models of compressor, evaporator, condenser, pumps, heat sources, heat sinks, etc. Then, through discussing the issue with the project partners, it was concluded that, by combining the available models with a comprehensive database of the most common faults and errors in heat pump systems, it is possible and desirable to design a fault detection and diagnosis system for heat pumps, similar to the approach taken in the car industry. The present project will be the first official research project in Sweden which aims at designing a generic solution for Smart Fault Detection and Diagnosis in heat pump systems. The research group working on the project will consist of scientists from KTH with a vast experience in modeling of heat pump systems. Accomplishment of several research projects concerning modeling of heat pump systems together with several available models provide a great opportunity for KTH research group to design a complex model-based FDD system for heat pumps in a relatively short time. The project is co-financed by the largest heat pump manufacturers which keeps a comprehensive database of the faults occurring in their heat pumps. Furthermore, the insurance company Folksam, the insurer of every second family house in Sweden, will participates actively in the project. Therefore, it is possible to collect a significant amount of data regarding faults and problems in heat pump systems and
4 (7) make a comprehensive database of the most common faults, the frequency of fault occurrence and the approximate cost of the faults. The present project will be the main knowledge basis for a later commercializing of a generic built-in FDD product for the heat pumps manufacturer to use in Sweden. Designing a FDD system with a minimum number of sensors, detects as many significant faults as possible, and diagnoses with a high quality will provide a great opportunity for the heat pump manufacturers to commercialize a new product in a very short time. Mål; Ange enkla, tydliga och mätbara mål i exempelvis kwh, max 250 ord. The project aims at 1. Making a comprehensive database of the most common faults during the installation and operation processes. 2. Designing a smart fault detection and diagnosis system at three different phases: commissioning, operation, and maintenance. During the commissioning phase the SFDD system does the first system check a short time 1 right after installation to ensure the manufacturer that the system is installed correctly and operates properly. At this phase, the SFDD system finds installation errors, incorrectly sized equipment, control errors, undercharge and overcharge conditions and so on. During normal operation phase the SFDD system detects any performance degradation and faults during the operation to avoid poor performance of the system due to minor problems, unnecessary visual inspections, and small faults which can lead to serious system failure. During eventual maintenance, the FDD system simplifies and speeds up fault diagnosis or guidance during service in order to avoid unnecessary component replacements, minimize the maintenance cost, and reduce down-time. 1 The required time for this is a research question.
5 (7) Genomförande, max 250 ord. First, a comprehensive literature survey will be made in order to investigate all the available opportunities and most recent research studies in the field of fault detection and diagnosis, especially in heat pump and refrigeration applications. Second, a comprehensive database of the most common faults during the installation and operation of heat pump system will be compiled. Then, at least two different heat pump systems are selected to be modeled in details and a model-based FDD system is designed for them. The project will be mainly done at KTH and the project partners form an expert panel consisting of specialists and experts from different fields such as modeling, heat pump manufacturing, and Information Technology (IT). The KTH s team will coordinate the panel and have several individual and group meetings on a regular basis to have a direct impact on the project. Regarding the database on faults, KTH will collects further data already provided by installers and technical support departments of the heat pump manufacturers, beside Folksam s large database. It is important to note that these data will be treated as anonymous in the database and KTH will not share the confidential data of any project partner with the others. The project will provide an appropriate source for a close cooperation with an ongoing IEA HPP annex called Quality Installation / Quality Maintenance Sensitivity Studies - Avoiding Efficiency Degradation due to Poor Installations and Maintenance.
6 (7) Kostnader Projektets totala kostnad Projektets totala kostnader per år % av heltid KALENDERÅR 2012 2013 2014 Lönekostnader 2387500 596875 1193750 596875 Laboratoriekostnad 40000 10000 20000 10000 Datorkostnad 20000 10000 10000 Utrustning 30000 7500 15000 7500 Material 10000 2500 5000 2500 Resor 50000 12500 25000 12500 Övriga kostnader 10000 2500 5000 2500 Ev förvaltningskostnader 332500 83125 166250 83125 SUMMA 2880000 725000 1440000 715000 Finansiering inkl. samfinansiärer Andel i kronor och procent av projektets totala kostnader/år. Specificera bidrag som natura respektive kontanta. FINANSIÄR År 2012 År 2013 År 2014 År År Total (%) Energimyndigheten 240000 480000 230000 950000 33 Folksam 150000 300000 150000 600000 20.8 Thermia Danfoss 200000 400000 200000 800000 27.8 ETM Kylteknik 20000 40000 20000 80000 2.8 CTC Enertech 50000 100000 50000 200000 6.95 IVT Bosch Termoteknik 50000 100000 50000 200000 6.95 Nowab 15000 20000 15000 50000 1.7 SVEP SUMMA 725000 1440000 715000 2880000 100 Detta projekt är i sin helhet i vissa delar lika med ansökan till annan myndighet, ange vilken: Sökt stöd för dyr utrustning (Vetenskapsrådet, Wallenbergsstiftelsen e.d.) Gäller endast högskola. Namn på doktorand Namn på doktorand Namn på doktorand Namn på doktorand Övriga samarbetspartners (ange organisation och namn) Resultatredovisning (ange här om resultatet kommer att redovisas på något ytterligare sätt än det obligatoriska, se information). Regular progress reports will be submitted and the project will be presented in the form of scientific papers, articles in international magazines and journals, and oral presentation in international conferences.
7 (7) Bilagor Intyg med underskrifter från samfinansiärer Please see the attachment Gantt-schema 2012 2013 2014 July Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec Jan Feb Mar Apr May June 1. Literature survey 2. Installation and operational fault database 3. Modeling of five different HP units (at least one from each sponsors) 4. Design and development of of fault detection system 5. Design and development of the diagnosis system 6. Data dissemination including the scientific journal papers, technical reports, etc. Övriga bilagor Datum Datum 2012-01-11 2012-01-11 Behörig firmatecknares (prefekt motsv.) underskrift Projektledarens underskrift Namnförtydligande, titel och telefon Namnförtydligande och titel Björn Palm, 08 790 7453 Joachim Claesson, 08 790 7460 Hatef Madani, 08 790 8653
Confirmation of interest This letter certifies that CTC Enertech reported interest in participating in the Effsysplus project called Smart Fault Detection and Diagnosis for heat pump system. The project is going to be started July 2012 and it will be finished June 2014. The expected contribution from IVT will be 200 kkr over these two years. Kent Karlsson