baldor 2014 cooling tower update
DESCRIPTION
Baldor 2014 Cooling Tower Update. Our mission is to be the best (as determined by our customers) marketers, designers and manufacturers of industrial electric motors, drives and mechanical power transmission products. Our Strategy. - PowerPoint PPT PresentationTRANSCRIPT
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Our mission is to be the best (as determined by our customers)
marketers, designers and manufacturers of industrial electric motors, drives and
mechanical power transmission products.
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Our Strategy
To produce the highest-quality, energy-efficient products available in the marketplace and sell
them to a broad base of value-minded customers.
Vp = perceived Value Qp = perceived Quality Sp = perceived Service
C = Cost T = Time
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HistoryBaldor RPM-AC Direct Drive CT Motor/Drive Initiative
July 2005 Began Evaluation of CT Industry regarding new Gear box Solution
Gearbox most problematic with oil leakage, environment contamination and high maintenance
Developed Solution / Concept July 2007
Beta Testing Presented Solution to Clemson
University Nov 2007 Installed Solution June 2008 as
retro-fit on existing Clemson tower
Third party testing (CTI) Confirmed Performance data
Motor & Controls
Drive Shaft & Disc Coupling
Gear Drive
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CTDD Motor Installed Base
Row Labels 2009 2010 2011 2012 2013 Grand TotalSum of GLOBAL_TOT_SALES
250-Frame 9,857$ 93,446$ 9,303$ 11,391$ 123,997$ 280-Frame 17,831$ 78,920$ 198,612$ 209,726$ 505,089$ 440-Frame 9,350$ 165,002$ 772,880$ 442,538$ 321,772$ 1,711,541$ 5800-Frame 238,280$ 2,718,903$ 3,878,354$ 6,835,537$
Sum of NET_UNITS250-Frame 16 20 3 3 42 280-Frame 16 10 22 21 69 440-Frame 2 37 61 25 21 146 5800-Frame 8 61 90 159
Total Sum of GLOBAL_TOT_SALES 9,350$ 192,691$ 1,183,526$ 3,369,356$ 4,421,243$ 9,176,165$ Total Sum of NET_UNITS 2 69 99 111 135 416
$0
$500,000
$1,000,000
$1,500,000
$2,000,000
$2,500,000
$3,000,000
$3,500,000
$4,000,000
$4,500,000
2009 2010 2011 2012 2013
250-Frame
280-Frame
440-Frame
5800-Frame
$123,997 , 1% $505,089 , 6%
$1,711,541 , 19%
$6,835,537 , 74%
250-Frame
280-Frame
440-Frame
5800-Frame
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Product Migration – w/motor solution for commercial and ACS880 for Industrial
ACH580Building Automation
Networks
Pre-Package Options
Simple Startup
Latest Generation
ACS880Industrial Networks
ID run
CodeSys Application Software
Global Reach
Latest Generation
Commercial
IndustrialVS1CTDSensorless Control
Calculated Motor Model
Basic Interface
Trickle Current motor heating
Anti- Wind Mill Features
Building and Automation Networks
Aging product
ACH550
Today Short Term Future
Special Motor Design need to allow for this
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Palmetto Sales Collateral
DMMG to take lead on package in US DMDR to teak lead on package in ROW Sales Collateral to be developed as part of
Palmetto:› Standard Specification Template (Internal &
External Versions)› Training Content (Product & Cert S/U)› Brochure (BR411) Update› Application Notes› Selection via CT Wizard› Pricing via BUS Configurator (both Motor &
Drive)› Installation, Operation and Maintenance
Manual (Simplified User’s Guide) – MN799› Submittal package (Wizard Update)
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Service & Warranty
Service and warranty › Service through DSS Network› Warranty for Motor, Drive and Motor/Drive Package – Five
Years (+P934 Drive Care Variant Code) Replacement / Spare parts
› Same as ACS880 ABB Global Drive Service and Support via Drive Care
Package› ABB Drive Support Worldwide› 5-Year Drive Care Warranty› Preventative Maintenance included with Drive Care Package
at 3 Years
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CT Motor Improvements Now with slinger over Inpro seal (440- & 5800-Frames)
› V-Ring Slinger on smaller frames With E-Coating New end bracket draft design (no pooling of water) Assembled “wet” Synthetic grease Improved paint system
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Updated CT Frame Matrix
Speed 8/28/2013500 FL2554 FL2562 FL2570 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4413 FL4429 FL5814475 FL2562 FL2562 FL2570 FL2578 FL2882 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL3614 FL4421 FL4440 FL5814450 FL2562 FL2570 FL2578 FL2873 FL2882 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4034 FL4421 FL5814 FL5816425 FL2562 FL2570 FL2578 FL2882 FL2882 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4046 FL4429 FL5814 FL5816400 FL2562 FL2570 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4046 FL4429 FL5814 FL5816375 FL2562 FL2570 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3698 FL3614 FL4034 FL4413 FL4440 FL5816 FL5818350 FL2562 FL2570 FL2882 FL2882 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4046 FL4421 FL4440 FL5816 FL5818325 FL2562 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4046 FL4429 FL5814 FL5818 FL5820300 FL2570 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3698 FL3698 FL4034 FL4421 FL4429 FL5814 FL5818 FL5822275 FL2570 FL2873 FL2882 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4046 FL4421 FL4440 FL5816 FL5820 FL5822250 FL2570 FL2882 FL2890 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4413 FL4429 FL5814 FL5818 FL5820 FL5824225 FL2570 FL2882 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4034 FL4421 FL4440 FL5814 FL5818 FL5822 FL5826200 FL2578 FL2890 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4046 FL4429 FL5814 FL5816 FL5820 FL5824 FL5828175 FL2873 FL3698 FL3698 FL3698 FL3698 FL3698 FL3614 FL4046 FL4421 FL4402 FL5816 FL5818 FL5822 FL5826 FL5830150 FL2882 FL3698 FL3698 FL3698 FL3698 FL3614 FL4034 FL4413 FL4429 FL5814 FL5816 FL5820 FL5824 FL5828125 FL2890 FL3698 FL3698 FL3698 FL3698 FL3614 FL4413 FL4429 FL5812 FL5816 FL5818 FL5822 FL5828 FL5832100 FL3698 FL3698 FL3698 FL3698 FL3614 FL4413 FL4429 FL5812 FL5814 FL5818 FL5822 FL5824 FL5832HP 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300
RPMAC Cooling Tower Product Matrix
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CTDD Commercial Market Situation
VS1CTD Solution Available through 1Q14› Includes HVAC Building Automation Protocols
Use ACS880+N5350+P934 in general› No HVAC Protocols Available – Must use bridge to MODBUS-RTU
For high-volume/OEM Opportunities› ACH550 may be available for sale through your LSU in these situations› ACH550 includes built-in HVAC Protocols
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• High Mechanical MaintenanceMore 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– High ambient temperature– Peak loads– Started across the line
• High inrush currents• Mechanical stresses
Environmental Effects
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Reducer/Torque Tube
Torque tubes and reducers do degrade over time. This is typical of having to operate in this environment.
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Eliminate High Maintenance Components
AC Motor
Fan
Conventional Tower Design
New Direct Drive Tower DesignAC Motor Coupling Drive Shaft Coupling Gear Box
Pillow Block Bearing Fan
Benefits:• Eliminates gearbox, jack shaft, pillow block
bearings and couplings• Runs Quieter & Saves Energy• Increases safety due to fewer components• Improves reliability & reduces maintenance• Lower installation cost by eliminating
alignment issues of mechanical components• Reduces cooling water contamination from
gearbox oil and leakage
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• Installation process simplified– Basic assembly is smaller and easier to lift into place– Weight is center distributed to load making the installation process safer– One piece fit into existing cooling tower – Field tested (Clemson University conversion made in less than a day)
Conventional Tower Design New Direct Drive Tower Design
Direct Drive Cooling Tower Install
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Gear Box Manufacturers & Required Lubrication The following manufacturers have
provided gearboxes to the cooling tower industry:› Marley - Sumitomo› Amarillo - Phil
Gear› Hansen - Lufkin
Gear Drive Lubrication Check Oil Level Weekly Change Oil first 500 hrs or 4 weeks
from start up.› Some boxes require 25 gallons or
more Follow gear box O & M manual for oil
type and change out frequency.› Typically every 6 months› Filtration
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TCO BenefitsEPC
Reduced parasitic load Better heat rate with better control
of the overall process Sized for fan bhp, no mechanical
losses included in motor sizing Quicker & easier mechanical
installation and start-up Ability to integrate drives into an
E house for total integrated solution with switchgear, MCCs, transformers.
Reduced environmental impact (noise)
User Eliminate reducer replacement (cost $30K-
$100K) Eliminate drive shaft replacement (cost $3-5K) In & out costs Crane rental & availability ($3-5K) Availability of replacement items (wks or months) Oil replacement (T&M) , disposal, filtration, off
site testing, EPA concerns (?) Cleaning of components due to oil leaking (dry
cooling only) Cost of downtime during peak season- 20-50%
of reducers fail every year (wet). Could be down 3-5 days/avg.
GREEN solution. Eliminate CO2 footprint associated with elimination of oil.
Energy savings is sustainable where as the mechanical system degrades over time.
Reliability & Heat Rate improvement