Energy Savings Initiative Presented for Review ToENTER COMPANY NAMEDATE1 Kenwood Circle Franklin, MA 020381-800 -343-1182 www.rtgreensystems.com RT GREEN SYSTEMS

Target IndustriesManufacturing ProcessingWater / WastewaterCommercial AgricultureUniversities / SchoolsHospitalsSki IndustryGolf CoursesWater parks

Target ApplicationsFans & BlowersPumpsMixersCompressorsConveyorsCranes & HoistsWeb HandlingBrake UnwindCentrifugesErected 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 EnvironmentIndustry 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 Application

Type Of ApplicationMotor System Electricity Consumption (kWh/year)% Of Total Manufacturing Sector Motor System EnergyPump Systems149,000,000,00027%Compressed Air Systems100,000,000,00018%Fan Systems77,000,000,00014%Material Movement/Handling33,000,000,00006%Other Material Processing133,000,000,00024%Industrial Refrigeration33,000,000,00006%Other28,000,000,00005%Total Manufacturing553,000,000,000100%

From Motors to System SolutionsIn the early to mid 90s 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 requirementsOperating 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 $400Motor 20hp x $8/hp = $160VFD 20hp x $40/hp = $800

States with Rebate Programs(generally vary by electric utility)Blue = motor and/or drive programSource CEE 200713c/kWh5c/kWh6c/kWh9c/kWh

FansTypically sized for maximum flowSystems typically operate at less than designed levelsFlow control is normally achieved using either an output damper or inlet guide vanesEnergy savings is achieved when flow is controlled with a VFD

Flow Rate (%)Input Power (%)101020304050607080901002030405060708090100110120130140DamperInlet Guide VanesDisc ThrottleIdeal Fan ControlVariable PitchAxial FanVFD

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% efficiencyMajor causes:Oversized pump & system not designed to run near pumps 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

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

kWhEnergy 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 SavingskWh savings (especially variable torque loads)Improve power factor AC drives above 0.95 power factor Reduce peak demand surchargesProcess 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).ComfortReduced fan / pump noise Reduce water hammer and air duct rumbleNo light dimming on start up

THREE SIMPLE STEPSSchedule a free Energy Evaluation.Review evaluation report to determine costs and ROI.Place your order for equipment upgrades and process your rebate.

Present Day Drive Shaft IssuesInspect Drive Shaft and Coupling Hardware MonthlyInspect Coupling Flex Element for Buckling and fatigue damageReplace as RequiredEach time a blade passes near an obstruction, such as a drive shaft or structural support the blade load fluctuatesBaldor Solution Eliminates These Issues

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

Clemson InstallationExisting DesignAmarillo 155 GearboxWith Drive ShaftBaldor Solution Drop In ReplacementNo Pedestal ModificationHudson 5 blade 18 ft Dia FanMounts directly to Motor Shaft

Clemson Installation Test DataExisting 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 Data4.5 kW Savings

2-Speed, 326T Induction MotorRPM AC, FL4493PM MotorFan Load41.5 Hp41.5 HpGearbox and couplings Efficiency90.2%N/AMotor Horsepower46.0 Hp41.5 HpMotor Efficiency90.0%*93.1%DriveN/A98.8%Input kW38.133.6Total Efficiency81.2%92.0%

Clemson Installation Test DataData verified by Clean Air Engineering on site at Clemson University

Loaded Noise LevelsAverageHigh SpeedLow SpeedInduction NEMA Motor Tower82.3 dBA74.4 dBALaminated Frame IPM Tower77.7 dBA69.0 dBA

VS1CTD Cooling Tower Drive FeaturesDesigned around proven H2 TechnologyUtilizes unique sensorless algorithms to accomplish smooth, low speed operationPower matched drive and motorPresently preparing white paper on the need for a packaged system with Baldor V*S DriveMotor and VS1CTD drive can replace multiple gearbox ratings.

Final Installation at Clemson University

Summary RPM-AC Direct Drive CT MotorLaminated Frame Interior PM motor technology enables direct drive gearless system.Gearbox low speed lubrication issues are eliminated. No drive shaftNo couplingsNo guardsNo alignmentMinimizes 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 (contd)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 requirementsDirect Drive motor reduces noise level of cooling towerElimination of drive shaft improves noise level.

THREE SIMPLE STEPSSchedule free Evaluation.Review evaluation report to determine costs and ROI.Place your order for equipment upgrades and process your rebate.

****************The benefits are significant:-

Most efficient operation of the motor and enhanced savings.High accuracy and repeatability with low maintenance.Constant power factor regardless of load.Reduced audible noise.Reduced cavitation in pumps and enhanced pump life.Reduced resonance in duct systems.Soft start every time - increased motor life, reduced max demand.Fully integrated system control from any modern control systems.*********