Energy Savings Initiative Presented for Review To

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1 Kenwood Circle • Franklin, MA 020381-800 -343-1182 www.rtgreensystems.com

RT GREEN SYSTEMS

Target Industrieso Manufacturing o Processingo Water / Wastewatero Commercial Agricultureo Universities / Schoolso Hospitalso Ski Industryo Golf Courseso Water parks

Target Applicationso Fans & Blowerso Pumpso Mixerso Compressorso Conveyorso Cranes & Hoistso Web Handling–Brake Unwindo Centrifugeso Erected Cooling Towers

Energy Savings OpportunitiesWhy is it important?

Money, Lots of Money >13.5m electric motors 1Hp or greater in US industrial process

operations.

Industry spends >$33b annually on electricity for motor driven systems.

Industrial motors system electricity accounts for 24% of all electricity sold.

Our Environment Industry consumed 691b kWh in process motor driven systems plus an

additional 68b kWh per year on HVAC.

In the US industrial sector, 70% of all electricity consumption involves motor driven systems. 59% of this goes to pumps, fans, blowers and compressed air systems.

Because we can make a difference!

Source: Department Of Energy (DOE - 1994)

Energy Savings Opportunities Motor Energy Consumption by ApplicationType Of Application Motor System

Electricity Consumption (kWh/year)

% Of Total Manufacturing Sector Motor System Energy

Pump Systems 149,000,000,000 27%

Compressed Air Systems

100,000,000,000 18%

Fan Systems 77,000,000,000 14%

Material Movement/Handling

33,000,000,000 06%

Other Material Processing

133,000,000,000 24%

Industrial Refrigeration 33,000,000,000 06%

Other 28,000,000,000 05%

Total Manufacturing 553,000,000,000 100%

From Motors to System Solutions In the early to mid 90’s the public and private sector focused

on lighting & motor efficiency as primary means to save energy.

In the past 4 years the market is shifting to more of a system solution. Some of the activities being undertaken are: Increased focus on process, system, and overall solution as means

to save energy. Stronger attempt to quantify savings and present to management

in financial terms.These have led towards increased use of variable speed drives

and motion controls to achieve process improvements, improve quality & reduce costs. better matching of pumps & motors to the load requirements Operating equipment at optimal speeds

Utility & Government Sponsored RebatesMany utilities & states promote energy

efficiency through rebates.Programs provide rebates for pumps, motors and

/ or Variable Frequency Drives (VFDs).Example Rebates are $3-$10 per hp for Premium

Efficient motors and $30-$50 per hp for VFDs. Contact your electric utility for details.

Example: Duke Energy will provide following on a 20hp pump application – using one application.

Pump $400 Motor 20hp x $8/hp = $160 VFD 20hp x $40/hp = $800

States with Rebate Programs(generally vary by electric utility)

Blue = motor and/or drive program

Source CEE 2007

13c/kWh

5c/kWh

6c/kWh

9c/kWh

Pumps Typically sized for

maximum flow with multiple levels of safety-factor added.

Systems typically operate far below maximum capacity.

Flow control is normally achieved using an output control (throttling) valve or bypass which routes output back to the input.

Energy savings is achieved when flow is controlled with a VFD

Pumping Systems Efficiency

Average pumping efficiency is below 40% Over 10% of pumps run below 10% efficiency

Major causes:Oversized pump & system not designed to run near

pump’s best efficiency point (BEP). Pump draws too much power - results in added vibration, bearings

run hot with substantially reduced life, packing has short life, high rate of mechanical seal failure.

Over-use of Bypass Valves & Throttling ValvesOversized valves make good process control nearly

impossible. 65% of control valves <50% open, with many <30% open and 15%

at startup.

Finnish study of 1690 pumps at 20 process plants (Expert Systems for Diagnosis of the Condition and Performance of Centrifugal Pumps)

VFDs and PumpsA VFD will provide significant energy savings

when:Centrifugal Pumps are operated at low flow ratesExisting system has bypass controlLocal electricity costs are highAny one item will often provide payback within 2

years.Additional Benefits

Elimination of expensive valves and valve controlReduces power surges and stress associated with

across the line startingProvides accurate flow controlLonger Pump and seal lifeReduced wear & noise

Energy Savings Estimator - ROI

kWh

Energy and Power MeteringWe can keep track of the savingsPower consumed, operating costs per hour,

power up time log and maintenance flags are all standard features providing free Asset Management tools

Energy meter

Summary of BenefitsEnergy Savings

kWh savings (especially variable torque loads)Improve power factor – AC drives above 0.95 power

factor Reduce peak demand surcharges

Process ImprovementsMatch speed to need & eliminate the starts & stops

Maintenance Less stress on mechanical equipment including belts

& couplings.Controllable via a BMS, PLC or fieldbus (Ethernet,

Metasys, DeviceNet, Profibus, Modbus, & others).Comfort

Reduced fan / pump noise Reduce water hammer and air duct rumbleNo light dimming on start up

THREE SIMPLE STEPSTHREE SIMPLE STEPS1.Schedule a free Energy Evaluation.2.Review evaluation report to determine costs and ROI.3.Place your order for equipment upgrades and process your rebate.

Present Day Drive Shaft Issues Inspect Drive Shaft and

Coupling Hardware Monthly Inspect Coupling Flex

Element for Buckling and fatigue damage

Replace as RequiredEach time a blade passes

near an obstruction, such as a drive shaft or structural support the blade load fluctuatesDrive Shaft Coupling

Baldor Solution Eliminates These Issues

Beta Site LocationOn the campus of Clemson University in Clemson, SC

Clemson Installation

Existing DesignAmarillo 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 Test Data2-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%, 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

VS1CTD Cooling Tower Drive FeaturesDesigned around proven H2 TechnologyUtilizes unique sensorless algorithms to

accomplish smooth, low speed operationPower matched drive and motor

Presently preparing white paper on the need for a packaged system with Baldor V*S Drive

Motor and VS1CTD drive can replace multiple gearbox ratings.

Final Installation at Clemson University

Summary RPM-AC Direct Drive CT Motor Laminated Frame Interior PM motor technology enables direct

drive gearless system. Gearbox low speed lubrication issues are eliminated. No drive shaft No couplings No guards No alignment Minimizes blade load fluctuation.

Motor can be configured / drop in replacement for gearbox (Ref Clemson University Beta site) Clemson was 6 hour conversion.

The Baldor Lamination Frame Technology / Interior Permanent Magnet Design along with Magnet performance improvements have allowed Baldor to lead with this new Innovative Disruptive Solution.

Summary (cont’d)Vastly simplified system greatly improves reliability

and maintainability.Significant improvements in overall system

efficiency can be realized.Elimination of gearbox provides biggest

improvement in overall fan drive system efficiency.Although a Baldor V*S drive is required, the

majority of cooling towers are being retrofitted with VFDs.Ref ASHRAEStd 90.1 variable speed requirements

Direct Drive motor reduces noise level of cooling tower

Elimination of drive shaft improves noise level.

THREE SIMPLE STEPSTHREE SIMPLE STEPS1.Schedule free Evaluation.2.Review evaluation report to determine costs and ROI.3.Place your order for equipment upgrades and process your rebate.