baldor 2014 cooling tower update

Baldor 2014Cooling Tower Update

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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.


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


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


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


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


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)


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


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


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


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


• 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


Reducer/Torque Tube

Torque tubes and reducers do degrade over time. This is typical of having to operate in this environment.


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


• 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


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


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

baldor 2014 cooling tower update

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