Upload
trinhbao
View
219
Download
2
Embed Size (px)
Citation preview
© 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
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
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