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.
Connect Collaborate Differentiate
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
C = Cost
Connect Collaborate Differentiate
Sp = perceived Service
T = Time
History
Baldor 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

Gear
Drive
Drive Shaft & Disc Coupling
Third party testing (CTI)
 Confirmed Performance data
Motor & Controls
Connect Collaborate Differentiate
CTDD Motor Installed Base
Row Labels
Sum of GLOBAL_TOT_SALES
250-Frame
280-Frame
440-Frame
5800-Frame
Sum of NET_UNITS
250-Frame
280-Frame
440-Frame
5800-Frame
Total Sum of GLOBAL_TOT_SALES
Total Sum of NET_UNITS
2009
$
2010
2011
$ 9,857 $ 93,446
$ 17,831 $ 78,920
9,350 $ 165,002 $ 772,880
$ 238,280
2012
$
9,303
$ 198,612
$ 442,538
$ 2,718,903
2013 Grand Total
$ 11,391
$ 209,726
$ 321,772
$ 3,878,354
$ 123,997
$ 505,089
$ 1,711,541
$ 6,835,537
16
16
37
$
20
3
3
42
10
22
21
69
2
61
25
21
146
8
61
90
159
9,350 $ 192,691 $ 1,183,526 $ 3,369,356 $ 4,421,243 $ 9,176,165
2
69
99
111
135
416
$123,997 , 1%
$4,500,000
$505,089 , 6%
$4,000,000
$3,500,000
$3,000,000
250-Frame
$2,500,000
$1,711,541 ,
19%
280-Frame
$2,000,000
440-Frame
$1,500,000
5800-Frame
$1,000,000
$500,000
$0
2009
2010
2011
2012
2013
Connect Collaborate Differentiate
250-Frame
280-Frame
440-Frame
$6,835,537 ,
74%
5800-Frame
Product Migration – w/motor solution for commercial and ACS880 for
Industrial
Today
Short Term
ACH550
Special Motor
Design need to
allow for this
Future
ACH580
Building Automation
Networks
Pre-Package Options
Simple Startup
Latest Generation
VS1CTD
Sensorless Control
Calculated Motor Model
Basic Interface
Trickle Current motor heating
Anti- Wind Mill Features
Building and Automation Networks
Aging product
Connect Collaborate Differentiate
ACS880
Industrial Networks
ID run
CodeSys Application
Software
Global Reach
Latest Generation
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)
Connect Collaborate Differentiate
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
Connect Collaborate Differentiate
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
Connect Collaborate Differentiate
Updated CT Frame Matrix
Speed
500
475
450
425
400
375
350
325
300
275
250
225
200
175
150
125
100
HP
FL2554
FL2562
FL2562
FL2562
FL2562
FL2562
FL2562
FL2562
FL2570
FL2570
FL2570
FL2570
FL2578
FL2873
FL2882
FL2890
FL3698
10
FL2562
FL2562
FL2570
FL2570
FL2570
FL2570
FL2570
FL2578
FL2578
FL2873
FL2882
FL2882
FL2890
FL3698
FL3698
FL3698
FL3698
15
FL2570
FL2570
FL2578
FL2578
FL2578
FL2578
FL2882
FL2882
FL2882
FL2882
FL2890
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
20
FL2578
FL2578
FL2873
FL2882
FL2882
FL2882
FL2882
FL2890
FL2890
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
25
FL2882
FL2882
FL2882
FL2882
FL2890
FL2890
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
FL3698
FL3614
30
RPMAC Cooling Tower Product Matrix
FL2890 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3698
FL3698 FL3698 FL3698 FL3614
FL3698 FL3698 FL3698 FL3614
FL3698 FL3698 FL3614 FL4034
FL3698 FL3698 FL3614 FL4046
FL3698 FL3614 FL4046 FL4421
FL3614 FL4034 FL4413 FL4429
FL3614 FL4413 FL4429 FL5812
FL4413 FL4429 FL5812 FL5814
40
50
60
75
Connect Collaborate Differentiate
FL3698
FL3698
FL3698
FL3698
FL3698
FL3614
FL3614
FL3614
FL4034
FL4046
FL4413
FL4421
FL4429
FL4402
FL5814
FL5816
FL5818
100
FL3698
FL3614
FL3614
FL3614
FL3614
FL4034
FL4046
FL4046
FL4421
FL4421
FL4429
FL4440
FL5814
FL5816
FL5816
FL5818
FL5822
125
FL3614
FL3614
FL4034
FL4046
FL4046
FL4413
FL4421
FL4429
FL4429
FL4440
FL5814
FL5814
FL5816
FL5818
FL5820
FL5822
FL5824
150
FL4413
FL4421
FL4421
FL4429
FL4429
FL4440
FL4440
FL5814
FL5814
FL5816
FL5818
FL5818
FL5820
FL5822
FL5824
FL5828
FL5832
200
FL4429
FL4440
FL5814
FL5814
FL5814
FL5816
FL5816
FL5818
FL5818
FL5820
FL5820
FL5822
FL5824
FL5826
FL5828
FL5832
250
8/28/2013
FL5814
FL5814
FL5816
FL5816
FL5816
FL5818
FL5818
FL5820
FL5822
FL5822
FL5824
FL5826
FL5828
FL5830
300
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
Connect Collaborate Differentiate
Environmental Effects
• High Mechanical Maintenance
More 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
Connect Collaborate Differentiate
Reducer/Torque Tube
Torque tubes and reducers do degrade over time. This is typical of having to
operate in this environment.
Connect Collaborate Differentiate
Eliminate High Maintenance Components
Conventional Tower
Design
Pillow Block Bearing
AC Motor
Coupling
Drive Shaft
Coupling
Fan
Gear Box
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
Connect Collaborate Differentiate
New Direct Drive Tower Design
Fan
AC Motor
Direct Drive Cooling Tower Install
• 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
Connect Collaborate Differentiate
New Direct Drive Tower Design
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
Connect Collaborate Differentiate
TCO Benefits
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
Connect Collaborate Differentiate
EPC






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)