© ABB Group May 13, 2013 | Slide 1

Cooling Tower Motor Solutions With Direct Drive Technology Baldor

Matt Nichols, ABB Technology Show, May 2013

Founded in St. Louis, Missouri 1920

Headquarters moved to Fort Smith,

Arkansas in 1967

History of acquisitions which allowed us

to become vertically integrated and

support niche markets

2007 acquisition of Reliance motors

and Dodge mechanical power

transmission products

Dodge Founded in 1878

Reliance Founded in 1883

Acquired by ABB Ltd in 2011

Became part of Discrete Automation

and Motion Division

| © Baldor Electric Company

About Baldor

May 13, 2013 | Slide 3

Cooling Tower Motor Solutions With Direct Drive Technology

What is a Cooling Tower

History of the Cooling Tower Initiative

Industry Segments

Beta Test Site

Results

Baldor Solution Features and Benefits

Present WIN’s - Installations

A cooling tower is a heat exchange

system that removes waste heat from a

process

system fluid, usually water.

Cooling towers are used in both

commercial and industrial applications.

The mechanical components of a cooling

tower fan are made up of Motor, gearbox

& fan impeller.

The motor speed is usually 1,450 rpm’s.

Fan speeds are much slower and are

determined by the diameter of the Fan to

keep the blade tip subsonic, typically

around 90 to 230 rpm’s.

In cooler climates the fans can be

reversed to prevent freezing during the

winter months.

Average cells are 14 to 28 feet in

diameter. But can go as large as 40 feet.

What is a Cooling Tower

HVAC Commercial/Institutional

HVAC towers are paired with a water-cooled chiller or water-cooled condenser

Used by HVAC systems to increase efficiency of the heat transfer process

Range: 10 - 150 Hp (typical range 25 – 75 Hp)

Applications:

Industrial Processing & Power Plants

Remove heat absorbed in circulating water cooling systems from various sources such as machinery or process materials

Cool discharge water back to lakes, rivers or oceans at a safe environmental level

Typical range: Industrial: 75 – 200 Hp Power Plants: 250 – 350 Hp

Applications:

Power Plants

Petro Chemical

Petroleum Refineries

Petroleum Refineries

Natural Gas

Food Processing

Office Buildings

Convention Centers

Shopping Malls

Hospitals

University Buildings

Cooling Towers - Typical Applications

High Mechanical Maintenance

More components to fail over time:

Gearbox failures

Oil leaks & contamination

Failed & misaligned drive shafts

Excessive vibration

Additional replacement time due to large mounting frame

Conventional Cooling Tower Control

Lightly loaded majority of the time

Peak load for short durations

Started across the line

High inrush currents

Mechanical stresses

Seal and bearing wear when fan “windmills”

Conventional Mechanical Issues

July 2005 Began Evaluation of CT Industry regarding new Gear Box Solution

Baldor was going to supply a better mouse trap to the industry

Existing gearboxes within Industry

Marley Amarillo

Two Leaders Within Market

Baldor New Gearbox Solution

Gear

Development

Project

Goals

Better Sealing

Lower Maintenance

Higher reliability

Beginning of Cooling Tower Initiative

During Evaluation CT Industry Response is lukewarm.

Gearbox most problematic with oil leakage, environment

contamination and high maintenance & low reliability

They have heard it all before with big promises and product under

performance

Industry calls for changing the playing field by removing existing

problem components

Evaluation Results

PM Technology

Finned Frame Technology

Insulation Technology

Technology Expansion Begins Cooling Tower Initiative 3 areas of development

Induction – squirrel cage motor PM – surface

Same: stator, rotor diameter, 3 phase power

Different: Induction has slip, PM is synchronous

PM has no rotor losses, therefore – more efficient

Induction is line start, PM requires drive or other

means to start

How do PM motors differ from Induction motors?

Optimized motor speed

Traditional cooling towers are designed for the “Worst Case” (highest air flow) scenario

Running the fan at reduced speed saves energy and cost of operating the tower

Allows for optimized control of the cooling of return water; increasing the efficiency of compressor operation and this components life

IPM Motor Highest Industry Efficiency

Permanent Magnet Motors provide the

highest efficiency levels of any motor in

the industrial market

IPM Motors are fully one band higher

than premium efficient motors

Optimized Efficiency

Interior PM Rotors Have Saliency

Saliency Means the Inductance of the Motor Varies with Rotor Position

Allows the accurate control of speed without feedback

Magnet demagnetization occurs at above 210 deg C; temps measured today

around 140 deg C.

Interior PM Development

Addition of Cooling Fins Increases the Surface Area for Heat

Dissipation

Typical Power Increase from 20-25% Over Smooth

Lamination 58 lams /inch

Improvements in Motor Technology Finned-laminated frame construction

75 Hp @ 1800 rpm, TEFC 360T 9.00”

280T 7.00”

250T 6.25”

Shaft ht.

Shaft height comparison

200 HP, 120 RPM, 8753 lb-ft Both Motors Direct Drive – no gearbox

Motor Type Height (in.)

Width (in.)

Wt. (lbs.)

Cast Iron Frame Induction

61 54 18685

Finned, Laminated Frame Permanent Magnet

50.47 37 7900

Note Reduced Height and Weight of Finned, Laminated Frame PM Motor

Why we haven’t done it before

Developed Solution / Concept and presented to CT OEM July 2007

Beta Testing

Presented Solution to Clemson University Nov 2007

Installed Solution June 2008 as retro-fit on existing Clemson tower

Utilized Johnson Controls Metasys-N2 HVAC communications platform via standard expansion board

Third party testing (CTI)

Clean Air Engineering Confirmed Performance data

Solution development project

On The Campus Of Clemson University Clemson, SC

Constructed In 1986

Two Identical Cells

Fan - 18'

Motor – 50 HP, 326T

Frame, 1765/885 RPM

Amarillo Gearbox – 155, 8.5:1

Ratio

Case Study

Existing Design

Amarillo 155 Gearbox

With Drive Shaft

Baldor Solution

Drop-In Replacement

No Pedestal

Modification

Hudson 5 blade

18 ft Dia Fan

Mounts directly to

Motor Shaft

Clemson Installation

2-Speed, 326T

Induction Motor

RPM AC, FL4493

PM Motor

Fan Load 41.5 Hp 41.5 Hp

Gearbox and couplings

Efficiency

90.2% N/A

Motor Horsepower 46.0 Hp 41.5 Hp

Motor Efficiency 90.0%* 93.1%

Drive N/A 98.8%

Input kW 38.1 33.6

Total Efficiency 81.2% 92.0%

Existing motor is 22 years old, new induction motor today is 93.6% efficient.

Gearbox manufacturer states gearbox efficiency at 96-98%, but test data indicates mechanical system (gearbox, couplings, driveshaft) is 90.2%.

Data verified by Clear Air Engineering on site at Clemson University

* Published Data

4.5 kW

Savings

Clemson Installation Test Data

Loaded Noise Levels

Average High Speed Low Speed

Induction NEMA

Motor Tower

82.3 dBA 74.4 dBA

Laminated Frame

IPM Tower

77.7 dBA 69.0 dBA

Data verified by Clean Air Engineering on site at Clemson

University

CTI Std – ATC 128

Clemson Installation Test Data

Benefits:

Eliminates gearbox, drive shaft, disc couplings and existing motor

Runs quieter & saves energy

Increases safety due to fewer rotating components

Improves reliability & reduces maintenance

Lower installation cost by eliminating alignment issues of mechanical components

Reduces cooling water contamination from gearbox oil leakage

Soft start reduces tower stressing

Conventional

Tower Design

New Direct Drive

Tower Design

Ultimate goal simplicity and low maintenance

Torque vs. acceleration time Direct drive pm / induction

0%

50%

100%

150%

200%

250%

300%

0 20 40 60Time (sec)

Torq

ue (

% R

ate

d) Induction

Motor Torque

PM Motor

TorqueVideo of soft start

Soft start torque impact

Higher System Efficiency

Soft Start Reduces Tower Stressing

Lower operating noise levels

Safety issues regarding wind milling removed

Gearbox Low Speed Lubrication Issues

Eliminated

No Driveshaft

No Couplings

No Guards

No Alignment

Vastly Simplified System Greatly Improves

Reliability and Maintainability

Testing conclusions

Baldor CT Solution Energy Savings

Affinity Fan Laws also apply to Cooling Towers

Air Volume is Directly Proportional to Speed

Pressure varies as Sq of Speed

HP varies as Cube of Speed

Example of a 40 Hp Cooling tower motor at full

speed vs. Required Hp at ½ speed

Hpn = Hpo x (RPMn/RPMo)3 x (dn/do)

Hpn = 40 x (1000/2000)3 x (0.075/0.075)

Hpn = 5 Hp

Baldor CT Solution Energy Savings Efficiency Evaluation

0 20 40 60 80 100

0

20

40

60

80

100

%RPM

%F

low

/Vo

lum

e

0 20 40 60 80 100

0

20

40

60

80

100

%RPM

%P

res

su

re/H

ea

d

0 20 40 60 80 100 0

20

40

60

80

100

%RPM %

Inp

ut

Po

we

r

Towers are designed for the “Worst Case” (highest air flow) scenario

Reduction of operating speed saves energy & lowers the cost to run

Optimizes cooling of return water

Lengthens component life

Increases the efficiency of compressor operation

Fan Application Cooling Tower example

Power Consumption

PM Motor/ASD vs. Two-Speed Motor/Gearbox

Data Taken 6/18/08

33.6

38.1

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

1:12:00 PM 2:24:00 PM 3:36:00 PM 4:48:00 PM 6:00:00 PM 7:12:00 PM 8:24:00 PM 9:36:00 PM 10:48:00 PM

Time

Po

we

r C

on

su

mp

tio

n (

kW

)

0.00

50.00

100.00

150.00

200.00

250.00

Sp

ee

d (

RP

M)

PM Motor/ASD kW

Two-Speed Motor/Gearbox kW

PM Motor/ASD Fan Speed

Two-Speed Motor/ASD Fan Speed

Over This 8 Hour Time Period, The PM

Motor/ASD Consumed Less Than 1/2 The

Energy As The Two-Speed

Motor/Gearbox Solution Would Have

Case Study Test results – power consumption

Denmark NL Pharmacutical application

Cell 5: average = 35,06 kW Traditional solution

Cell 4: average = 31,14 kW Baldor Solution

Saving 3,92 kW = 11,2 %

Cargill – Turkey

Analysis - Avg over 2 month period

21kW vs 25kW which will be around a 16%

Cooling Tower installation comparison Energy Savings

Conventional Cooling Tower Design (Single Speed Motor)

Baldor Solution with Drive

Avg.

Operating

hours

Fan

Speed Motor Hp

Motor

Rating

kW

Power

Usage kWh

Energy cost CA

Industrial 11.2

c/kWh

5110 Full speed 225 50 37.3 190603 $ 21,348

3650 Off 0 0 0 0 0

8760 Total Totals 190603 $ 21,348 Based on avg of 7 months of operation

Avg.

Operating

hours

Fan

Speed Motor Hp

Motor

Rating

kW

Power

Usage kWh

Energy cost CA

Industrial 11.2

c/kWh

1460 Full 225 47.25 35.2 51463 $ 5,764

730 90% 202.5 34.4 25.7 18758 $ 2,101

730 80% 180 24.2 18.0 13174 $ 1,476

730 70% 157.5 16.2 12.1 8826 $ 988

730 60% 135 10.2 7.6 5558 $ 622

730 50% 112.5 5.9 4.4 3216 $ 360

3650 Off 0 0 0 0 0

8760 Totals 100996 $ 11,312

The example does

not take into effect

ambient and wet

bulb temperature

changes

The Baldor solution

shows a 5.5%

system eff gain due

to the removal of the

mechanical loses

The full speed

operating hours

have been updated

for variable speed

capabilities

Total Yearly Savings 10,036$ Per TowerWe have not added maintenance costs savings associated with the Baldor Solution

Total Yearly % Savings 47% Per Tower

Example of energy savings Intel facility

Inpro Seal on Drive End of Motor

Only one Ingress point

Proven history on IEEE-841 Motors

Proven Performance in the Cooling Tower Industry

Shaft Flinger

Acts as umbrella over seal in the static condition

Throws contaminant away from seal in the dynamic condition

Will be made from stainless steel on future designs

Common questions and benefits Sealing design

100% grease fill rate

Eliminates voids

Mobil SHC460 & 220 Synthetic Grease except for 5800 frame which uses Klubersynth BH 72-422 which has a temp range of -20C to 220C

63 & 62 series ball bearings for smaller hp ratings

Ceramic coated OD of ODE to prevent current damage. Ceramic sleeve for 5800 frame motors

AC bearings for large hp ratings to increase bearing thrust capacity and increase L10 life

Bearing L10 life min 100,000 hrs

Re-lubrication interval Based on 17,500 hrs of operation 40C ambient & 750FPM Min airflow

Goal of lubed for life in future

Common questions and benefits Motor bearings and grease

MAP LEGEND

Commercial

Buildings

Universities

Paper Products

Power Generation

Petrochemical

Pharmaceutical

Food & Beverage

Chemicals &

Fertilizer

Metal Processing

Field installations North American CTD sites

MAP LEGEND

Commercial

Buildings

Universities

Paper Products

Power Generation

Petrochemical

Pharmaceutical

Food & Beverage

Chemicals &

Fertilizer

Metal Processing

Field installations European CTD sites

Baldor FL-2898, 40 Hp, 375 rpm, 460V

Commissioned Jan 2011

Added additional stack ring due to new fan height

New torque tube installed

Vibration switch mounted on torque tube beam

Drive mounted in control room NEMA-1 enclosure

Field installations Smithsonian

Installed March 2010

(4) units on site

Plus 4x enclosure due to mounting drives outside next to towers

One spare VFD was ordered

Based on performance Disney Ordered 2nd system - installed and commissioned April 2011

Field installations Disney (40hp 219rpm FL4485; FLA-43)

60Hp, 175rpm

Drive shaft failed June 2010

Damaged Fan & Gearbox

18 ft Hudson Fan

Amarillo double reduction gearbox 1110

Replaced with Baldor FL-4413 CT Direct Drive Motor & Drive Installed August 2010

Reconstructed Pedestal to match existing fan position

Replaced fan with Hudson Tuflite-II

Failed Drive Shaft

Field installations University of Florida – Baldor CTPM solution

Baldor CT Solution

Questions?

May 13, 2013 | Slide 37

What is a Cooling Tower

Questions?

© ABB Group May 13, 2013 | Slide 39