Cooling Tower Motor Solutions With Direct Drive Technology Baldor

Transcription

1 Matt Nichols, ABB Technology Show, May 2013 Cooling Tower Motor Solutions With Direct Drive Technology Baldor ABB Group May 13, 2013 Slide 1

2 About Baldor 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

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 May 13, 2013 Slide 3

4 What is a Cooling Tower 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.

5 Cooling Towers - Typical Applications 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: Hp (typical range Hp) Applications: Office Buildings Convention Centers Shopping Malls Hospitals University Buildings 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: Hp Power Plants: Hp Applications: Power Plants Petro Chemical Petroleum Refineries Petroleum Refineries Natural Gas Food Processing

6 Conventional Mechanical Issues 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

7 Beginning of Cooling Tower Initiative 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 Baldor New Gearbox Solution Gear Development Project Marley Amarillo Two Leaders Within Market Goals Better Sealing Lower Maintenance Higher reliability

8 Evaluation Results 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

9 Technology Expansion Begins Cooling Tower Initiative 3 areas of development PM Technology Finned Frame Technology Insulation Technology

10 How do PM motors differ from Induction motors? Same: Different: stator, rotor diameter, 3 phase power 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 Induction squirrel cage motor PM surface

11 Optimized Efficiency 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

12 Interior PM Development 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.

13 Improvements in Motor Technology Finned-laminated frame construction Addition of Cooling Fins Increases the Surface Area for Heat Dissipation Typical Power Increase from 20-25% Over Smooth Lamination 58 lams /inch

14 Shaft height comparison Shaft ht rpm, TEFC 360T T T 6.25

15 Why we haven t done it before 200 HP, 120 RPM, 8753 lb-ft Both Motors Direct Drive no gearbox Motor Type Cast Iron Frame Induction Finned, Laminated Frame Permanent Magnet Height (in.) Width (in.) Wt. (lbs.) Note Reduced Height and Weight of Finned, Laminated Frame PM Motor

16 Solution development project 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

17 Case Study 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

18 Clemson Installation 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

19 Clemson Installation Test Data 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 Total Efficiency 81.2% 92.0% 4.5 kw Savings 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

20 Clemson Installation Test Data Loaded Noise Levels Average High Speed Low Speed Induction NEMA Motor Tower Laminated Frame IPM Tower 82.3 dba 74.4 dba 77.7 dba 69.0 dba Data verified by Clean Air Engineering on site at Clemson University CTI Std ATC 128

21 Ultimate goal simplicity and low maintenance 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 New Direct Drive Tower Design Conventional Tower Design

22 Torque (% Rated) Soft start torque impact 300% 250% 200% 150% 100% Induction Motor Torque PM Motor Torque Video of soft start 50% 0% Time (sec) Torque vs. acceleration time Direct drive pm / induction

23 Testing conclusions 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

24 Baldor CT Solution Energy Savings

25 Baldor CT Solution Energy Savings Efficiency Evaluation 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 ( / ) Hpn = 5 Hp

26 %Flow/Volume %Pressure/Head %Input Power Fan Application Cooling Tower example 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 %RPM %RPM %RPM

27 Power Consumption (kw) Speed (RPM) Case Study Test results power consumption Power Consumption PM Motor/ASD vs. Two-Speed Motor/Gearbox Data Taken 6/18/ 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 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 PM Motor/ASD kw Two-Speed Motor/Gearbox kw PM Motor/ASD Fan Speed Two-Speed Motor/ASD Fan Speed

28 Cooling Tower installation comparison Energy Savings 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%

29 Example of energy savings Intel facility Conventional Cooling Tower Design (Single Speed Motor) 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 Avg. Operating hours Fan Speed Baldor Solution with Drive Motor Hp Motor Rating kw Power Usage kwh Energy cost CA Industrial 11.2 c/kwh 5110 Full speed $ 21, Off Total Totals $ 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 $ 5, % $ 2, % $ 1, % $ % $ % $ Off Totals $ 11,312 Total Yearly Savings $ 10,036 Per Tower We have not added maintenance costs savings associated with the Baldor Solution Total Yearly % Savings 47% Per Tower

30 Common questions and benefits Sealing design 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

31 Common questions and benefits Motor bearings and grease 100% grease fill rate Eliminates voids Mobil SHC460 & 220 Synthetic Grease except for 5800 frame which uses Klubersynth BH 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

32 Field installations North American CTD sites MAP LEGEND Commercial Buildings Universities Paper Products Power Generation Petrochemical Pharmaceutical Food & Beverage Chemicals & Fertilizer Metal Processing

33 Field installations European CTD sites MAP LEGEND Commercial Buildings Universities Paper Products Power Generation Petrochemical Pharmaceutical Food & Beverage Chemicals & Fertilizer Metal Processing

34 Field installations Smithsonian 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

35 Field installations Disney (40hp 219rpm FL4485; FLA-43) 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 2 nd system - installed and commissioned April 2011

36 Field installations University of Florida Baldor CTPM solution Failed Drive Shaft 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 Baldor CT Solution

37 What is a Cooling Tower Questions? May 13, 2013 Slide 37

38 Questions?

39 ABB Group May 13, 2013 Slide 39