Agenda 1. Cooling tower information 2. Cooling tower market 3. Cooling tower direct drive and ACS880...

Agenda

1. Cooling tower information

2. Cooling tower market

3. Cooling tower direct drive and ACS880 +N5350

4. Cooling tower direct drive

5. ACS880 +N5350 CTD

6. Package selection

7. Energy Efficiency

8. Need more information?

© ABB GroupMonth DD, Year | Slide 1

Cooling tower direct drive CTDD & ACS880 package

LAC Drives, May 2015

A cooling tower is a heat exchange system that removes waste heat from a process system fluid

The mechanical components of a cooling tower fan are made up of motor, gearbox, driveshaft, disc couplings and fan impeller

The motor speed is usually 1500 rpm, where as fan speeds are much slower (around 90 to 450 rpm)

Cooling towersGeneral


Traditional cooling tower uses a 1500rpm induction motor connected to a driveshaft that connects to a gearbox which connects to the fan.

These parts require continual maintenance which slows down the production. Gearbox maintenance is time consuming and oil leaks are common.

Spare parts may have long lead times. A broken driveshaft can disable the fan until spares can be received.

Traditional cooling tower solutionGeneral


Cooling tower direct drive replaces the gearbox, driveshafts and induction motor

This results in less parts, less maintenance and reduced risks

High-torque and slow-speed synchronous RPM™ AC salient pole permanent magnet motor is designed for cooling tower applications

Cooling tower motor is based on the existing RPM AC motor platform

Industrial drive ACS880 supports the cooling tower direct drive motor

Cooling tower direct drive solutionGeneral


Cooling tower direct drive

Reliable and less maintenance

No gears, no oil leaking

Reduced cooling water contamination from gearbox oil leakage

No drive shafts or coupling

No bearing problems

Eliminates startup current peaks and stress from across the line startup

Higher system efficiency and better process control

Lower operating noise levels and vibration

Increase safety due to fewer rotation components

Why does people care?


Cooling tower market

Cooling towers

Cooling tower industries:

HVAC, power ranges 7.5 to 100 kW

Universities, hospitals, conference centers, large office complexes

Industrial processing, power ranges 10 to 185 kW

Petro-chemical, steel, paper and others

Heavy industrial, larger powers up to 260 kW

Power generation, petro-chemical

ACC (Air Cooled Condensers), power ranges 150 to 260 kW

Power generations

Cooling tower applications

Wet and dry cooling towers

ACC (Air Cooled Condensers)

ACHE (Air Cooled Heat Exchangers)

Common industries and applications


Cooling tower RPM-AC PM motor

Cooling tower RPM-AC PM motor is designed to replace gearbox solutions

Fan diameters usually start at around 1.8m where mechanical speed reduction is required

In some cases the motor is designed to drop directly into existing gearbox mounting patterns

Some applications may require a base plate to match the existing gearbox bolt hole pattern

RPM-AC PM motors can be offered in conventional foot mounted designs that can replace the belt and sheave applications where more vertical mounting space is available

Cooling tower installations


Wet cooling towers operate on the principle of evaporative cooling

Two main categories:

1. Natural draft towers used only in power stations for larger water flows

2. Mechanical draft towers which uses power-driven fan motors to force or draw air through the tower

Cool water absorbs heat from the hot process streams which need to be cooled or condensed

Warm water returns to the top of the cooling tower and evaporates when it contacts the air

Remaining water returns back to the tower and further cools down when it floats through the fill material (usually plastic or ceramic)

Small amount of fresh water is supplied to the tower basin to compensate the loss of evaporated water

Cooling methodsWet cooling towers


Mechanical draft towers are available in the following airflow arrangements:

1. Counter flow induced draft

2. Counter flow forced draft

3. Cross flow induced draft

Typically induced draft tower requires smaller fan motor for the same capacity then forced draft tower

In the cross flow induced draft design, the water enters at the top and passes over the fill. The air is introduced at the side either on one side or opposite sides.

In the counter flow induced draft design, hot water enters at the top, while the air is introduced at the bottom and exits at the top

Induced draft towers are considered to be less susceptible to recirculation which can results in reduced performance

Mechanical draft towersWet cooling towers


Cross flow induced draft

Counter flow induced draft

Package type

Factory preassembled and shipped to the site

Typically belt driven but some larger units do have gear driven units

Capacity is limited and used in facilities with low heat rejection requirements such as in F&B, textile plants, chemical plants or in buildings

Field erected type

Fabricated on site

Typically uses gearbox, drive shafts, disc couplings and motor

Facilities such as power plants, steel processing plants, petroleum refineries or petrochemical plants

Cooling tower typesWet cooling towers


Air-cooled condenser (ACC) is another type of heat rejection device used for refrigeration and air conditioning systems

Dry coolers advantages:

Does not rely on water, no evaporation or steam plumes in lower temperatures

No chemicals needed

Cost-efficient with less maintenance

Big fans with power ranges 150 – 260 kW

Big market potential due to known maintenance issues

Used in different industries such as in P&P, power plants, chemical industries, water and wastewater treatment plant, F&B, biogas plant

Cooling tower direct drive motor requirement is the biggest FL58xx force ventilated motor frame with in-line blower cooling, usually with shaft down

Air-cooled condenser (ACC)Dry cooling towers


ACC Cooling tower

Air cooled heat exchanger (ACHE) is also called “fin fan” cooler since finned tubes are used in the cooler

Usually smaller units for roof top installation, including commercial buildings

Usually driven by a motor and a belt system

Market potential in petrochemical industries, oil & gas, process and power generation applications

Estimated 420 000 units installed globally

Smaller powers with revenues around $5 - 20 k/cell

Air cooled heat exchanger (ACHE)Dry coolers


Gearbox solution vs CTDD motor solution


Gearbox solution

Cooling tower direct drive solution

Traditional cooling tower solution

Gearbox maintenance (manufacturer’s recommendations):

Inspections for leaks? Daily

Check oil level frequency? Weekly

Drain water condensation? Weekly or monthly

Oil change frequency? Every 6 months (some boxes requires 95l or more)

Drive shaft and coupling inspection? Monthly

Windmilling problems

Components to fail over time:

Gearbox failures

Oil leaks and contamination

Failed and misaligned drive shafts

Vibration

Long replacement lead-times on components

Conventional cooling tower control causes peak loads and mechanical stresses when started across the line

Maintenance issues


CTDD & ACS880

Cooling tower direct drive & ACS880 +N5350

Cooling tower direct drive motor (CTDD)

Slow-speed and high-torque PM motors up to 11 000 Nm/650 rpm

5 years warranty, 3 years for the biggest frame

New option codes for ACS880-01 single drives and ACS880-04 drive modules

+N5350 cooling tower control program

Easy to use with simplified parameter set

Cooling tower application features such as trickle current and de-ice functions

Warranty

Standard warranty is 24 months and 36 months as option (outside US)

Available for all voltages


NO SPACE HEATERS

REQUIRED

Eliminates gearbox, drive shafts, disc couplings and existing motor

Runs quieter & saves energy

Increases safety due to fewer components

Improves reliability and reduces maintenance

Lower installation cost by eliminating alignment issues of mechanical components

Reduces cooling water contamination from gearbox oil and leakage

Direct drive technology


AC Motor DiscCoupling

Drive Shaft DiscCoupling

Gear Box

Fan

AC Motor

Fan

Conventional tower design

New direct drive tower design

Benefits

Torque tubes and reducers degrades over a time

Corrosion is typical in cooling tower environment

Some users pressure wash units to clean scale off boxes

Possible removal of paint during cleaning

Possible cooling tower environment


CT motor improvements

Cooling tower motor is designed for outdoor severe duty service to handle the extremes of 100 % humidity and chemical environments

Inpro/Seal® combination slinger and labyrinth non-contact shaft seal protects motor from water ingress and contamination

E-coating prevents corrosion

New end bracket draft design – no pooling water

Assembled “wet” - motor is assembled while the paint is still wet preventing any voids where condensation or corrosion can occur

High performance synthetic grease and paint system

Class H VPI (vacuum pressure impregnation) insulation system (same class is used in navy motors, off shore oil drilling and submersible motors)


CTDD motor type matrix up to 11 000 NmRough motor table


IEC160 IEC180 IEC225 IEC250 IEC280 IEC355Speed

500 FL2562 FL2570 FL2578 FL2578 FL2882 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4058 FL4440 FL5818475 FL2562 FL2570 FL2578 FL2882 FL2882 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4421 FL4440 FL5820450 FL2562 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4429 FL4440 FL5820425 FL2562 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3698 FL3614 FL4046 FL4429 FL4440 FL5820400 FL2562 FL2570 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4429 FL5818 FL5822375 FL2562 FL2570 FL2882 FL2882 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4440 FL5820 FL5822350 FL2562 FL2578 FL2882 FL2890 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4440 FL5820 FL5824325 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3614 FL3614 FL4046 FL4058 FL4440 FL5822 FL5824300 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL5818 FL5822 FL5826275 FL2570 FL2578 FL2890 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4421 FL5820 FL5824 FL5828250 FL2570 FL2882 FL2890 FL2898 FL3698 FL3698 FL3614 FL3614 FL4034 FL4058 FL4429 FL5822 FL5826 FL5830225 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4429 FL5822 FL5828 FL5832200 FL2578 FL2882 FL2898 FL3698 FL3698 FL3614 FL3614 FL4034 FL4046 FL4421 FL4440 FL5824 FL5830175 FL2578 FL2890 FL2898 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4429 FL4440 FL5828 FL5832150 FL2882 FL2898 FL3698 FL3698 FL3614 FL4022 FL4034 FL4046 FL4421 FL4440 FL5820 FL5830125 FL2882 FL2898 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4429 FL5820 FL5824100 FL2890 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4421 FL4440 FL5822 FL5828HP 10 15 20 25 30 40 50 60 75 100 125 200 250 300kW 7.5 11 15 18.5 22 30 37 45 55 75 90 150 186 225

To be noted that there is no NEMA or IEC standards on the cooling tower motors that replace gearboxes

Motor is sized by the fan torque requirements

ACS880 +N5350 CTD

ACS880 +N5350 cooling tower control program

CTDD startup assistants

Motor data and ID run

CTDD setup

Simplified (“hidden”) parameter set for CT applications

Advanced features available by unlocking full parameter set

Custom CTDD features

Trickle current for preventing the rotation of fan during standby while keeping the motor warm and dry

De-ice function for preventing ice build-up on the fan blades

Defaults and ranges present for CTDD applications

Standstill ID run (requires CEMF voltage which is on the rating plate)

Standstill autophasing

No resolver or encoder is required

Note that ACS880 +N5350 will only support RPM-AC PM cooling tower motors

Features



Trickle current

Primary purpose is to prevent rotation of fan during standby (anti-windmill feature) which can be caused by exterior wind conditions or by another tower’s airflow

It will produce a low level DC voltage across the windings of the direct drive motor which will inhibit rotation of the fan blades

It will also produce enough heating in the motor preventing condensation (eliminates the need of space heaters)

Operates while the tower is in a power on but in standby mode

Trickle current is disabled as a factory default

De-ice mode

Primary this function is to prevent ice build-up in towers located in colder climates

In this mode the fan runs at a low speed but in the opposite direction

De-ice mode consists of a setting for the speed and a time value

More information can be found from user’s guide

CTDD features – trickle current & de-ice mode


NO SPACE HEATERS

REQUIRED

User’s guideACS880 +N5350 cooling tower drive



1. Motor data & ID run

Basic startup (language, date, time)

International (SI) or US standard (imperial)

CT motor data (back EMF, current, base frequency, rpm etc)

Standstill ID run

2. CTDD setup

Speed limits

Ramp times

Drive name

Operating mode

Trickle current

De-ice function

Both startup assistants can be run independently

Two startup assistants


Package selection

Application sizing & considerations

Define mounting including weight, structure limitations, mounting base construction and mounting foot print

Define shaft requirements from fan hub size

Possible vibration switch or sensor mounting dimensions

Size motor by fan torque requirements

Fan torque = (kW * 9550)/Fan speed

Use CT wizard to determine frame and to get motor performance data and dimensional data for both motor and drive

Build any rating so long as it make torque for that frame size

Select and size drive by current rating from CT wizard

Drives are pre-selected by motor frame size

Request for quote input sheet


Use the CT wizard for easy and proper frame size selection

Size the motor by fan torque requirements

Select IEC or NEMA from settings

Power (kW or HP)

Fan speed

Voltage

Ambient (default 40°C)

Height restriction (can be left blank)

Altitude

Air flow

Package selection with CT wizardWizard input data


CT Wizard

Fan diameter

Fan speed

Motor power

Gear size, type and ratio (fan torque)

Voltage

Height restrictions

Shaft requirements

Drive location

Request for motor quote


Energy efficiency

Comparative performance data


86

88

90

92

94

96

98

1 10 100 1000

HP

% E

FF

ICIE

NC

Y

PM Premium Efficiency®

IEEE 841 Energy Efficient

Consistently best across a wide range of powers and loads

92

93

94

95

96

97

98

0 20 40 60 80 100 120

% LOAD

% E

FF

ICIE

NC

Y

Energy Efficient Premium Efficiency® PM


Biggest energy savings are reached when the system can take advantage of adjustable speed/airflow to reduce the overall motor kW requirements for the fan

50 - 60 % energy savings are typical

Old retrofits can show significant energy savings if the original gear and motor are low in efficiency to start with

10 – 15 % energy savings are possible

There is minimal energy savings of the direct drive PM cooling tower system compared to an efficient newer installation if the tower can not take advantage of the variable speed to minimize the kW consumed to drive the fan

+/- 2% energy savings is the expectation

Efficiency of the PM motors at the very low speeds of the fan is not very high and also drive losses have to be considered

Simplified installation and reduced maintenance are the major selling points

Advantages and energy savings


Technology comparison


IE2 induction motor + gearbox

IE3 induction motor + gearbox

VSD + IE3 induction motor + gearbox

VSD + direct drive PM motor

Base efficiency +1.4% efficiency improvement

57.7% efficiency improvement

59.9% efficiency improvement

Gearbox maintenance required



Eliminates gearbox maintenance

Variable speed control assumption, average 75% of maximum speed over duty cycle

Example of energy savingsDOL vs VSD


Conventional cooling tower design DOL

Operating hours

Fan speed rpm

Motor hpMotor

rating kWPower usage

kWhEnergy cost 0.12€/kWh

5110 Full speed 225 50 37.3 190603 22,872 €3650 Off 0 0 0 0 0 €

tot 8760 190603 22,872 €

CTDD solution with VSDOperating

hoursFan speed

rpmMotor hp

Motor rating kW

Power usage kWh

Energy cost 0.12€/kWh

1460 Full 225 47.25 35.2 51463 6,176 €730 90% 202.5 34.4 25.7 18758 2,251 €730 80% 180 24.2 18 13174 1,581 €730 70% 157.5 16.2 12.1 8826 1,059 €730 60% 135 10.2 7.6 5558 667 €730 50% 112.5 5.9 4.4 3216 386 €3650 Off 0 0 0 0 0 €

tot 8760 100995 12,119 €

Example does not take into effect ambient and wet bulb temperature changes

CTDD solution shows a 5.5% efficiency gain due to the removal of the mechanical losses

The full speed operating hours have been updated for variable speed capabilities

Total yearly savings 10 753 € per tower

Total year savings 47 % per tower

In addition maintenance cost savings

Need more information?

CTDD marketing materials

Web pages:

Abb.com > Offers > Drives > Cooling tower

ABB brochure

FAQ-list

User’s guide

CT Wizard tool for easy package selection

Marketing materials from Baldor:

External pages:

http://www.baldor.com/brands/baldor-reliance/products/motors/ac-motors/variable-speed-ac/cooling-tower-motors

http://www.baldor.com/brands/baldor-reliance/customer-resources/energy-savings/cooling-tower-controls








External ABB web pages


Press releasesCooling tower direct drive solution


http://www.baldor.com/mvc/DownloadCenter/Files/Solutions1009

http://www.baldor.com/mvc/DownloadCenter/Files/FM1462







Agenda 1. Cooling tower information 2. Cooling tower market 3. Cooling tower direct drive and ACS880...

Documents

Transcript of Agenda 1. Cooling tower information 2. Cooling tower market 3. Cooling tower direct drive and ACS880...