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RT GREEN SYSTEMS

1 Kenwood Circle Franklin, MA 02038


1-800 -343-1182 www.rtgreensystems.com

Energy Savings Initiative


Presented for Review To
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DATE

Target Industries
o Manufacturing
o Processing
o Water / Wastewater
o Commercial Agriculture
o Universities / Schools
o Hospitals
o Ski Industry
o Golf Courses
o Water parks

Target Applications
o Fans & Blowers
o Pumps
o Mixers
o Compressors
o Conveyors
o Cranes & Hoists
o Web HandlingBrake Unwind
o Centrifuges
o Erected Cooling Towers

Energy Savings Opportunities


Why is it important?
Source: Department Of Energy (DOE - 1994)
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 Environment
Industry 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!

Energy Savings Opportunities


Motor Energy Consumption by Application
Type Of Application

Motor System
Electricity
Consumption
(kWh/year)

% Of Total
Manufacturing Sector
Motor System Energy

Pump Systems

149,000,000,000

27%

Compressed Air
Systems

100,000,000,000

18%

Fan Systems

77,000,000,000

14%

Material
Movement/Handling

33,000,000,000

06%

133,000,000,000

24%

Industrial Refrigeration

33,000,000,000

06%

Other

28,000,000,000

05%

553,000,000,000

100%

Other Material
Processing

Total Manufacturing

From Motors to System Solutions


In 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 requirements
Operating equipment at optimal speeds

Utility & Government Sponsored Rebates


Many 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 $400
Motor 20hp x $8/hp = $160
VFD 20hp x $40/hp = $800

States with Rebate Programs


(generally vary by electric utility)

13c/kWh

9c/kWh

5c/kWh

6c/kWh

Blue = motor and/or drive program


Source CEE 2007

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


Finnish study of 1690 pumps at 20 process plants

(Expert Systems for Diagnosis of the Condition and Performance of Centrifugal Pumps)

Average pumping efficiency is below 40%


Over 10% of pumps run below 10% efficiency

Major 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 Valves


Oversized valves make good process control nearly

impossible.

65% of control valves <50% open, with many <30% open and 15% at
startup.

VFDs and Pumps

A VFD will provide significant energy savings when:


Centrifugal Pumps are operated at low flow rates
Existing system has bypass control
Local electricity costs are high
Any one item will often provide payback within 2
years.
Additional Benefits
Elimination of expensive valves and valve control

Reduces power surges and stress associated with

across the line starting


Provides accurate flow control
Longer Pump and seal life
Reduced wear & noise

Energy Savings Estimator - ROI

Energy and Power Metering

We can keep track of the savings


Power consumed, operating costs per hour,
power up time log and maintenance flags are all
standard features providing free Asset
Management tools

kWh
Energy meter

Summary of Benefits
Energy Savings

kWh savings (especially variable torque loads)


Improve power factor AC drives above 0.95 power factor
Reduce peak demand surcharges

Process Improvements
Match 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).

Comfort
Reduced fan / pump noise
Reduce water hammer and air duct rumble
No light dimming on start up

THREE SIMPLE STEPS

1.Schedule a free Energy


Evaluation.
2.Review evaluation report to
determine costs and ROI.
3.Place your order for equipment
upgrades and process your rebate.

Present Day Drive Shaft Issues


Inspect Drive Shaft and

Coupling Hardware Monthly


Inspect Coupling Flex
Element for Buckling and
fatigue damage
Replace as Required
Each time a blade passes
near an obstruction, such as
a drive shaft or structural
support the blade load
Drive Shaft Coupling
fluctuates

Baldor Solution Eliminates These Issues

Beta Site Location


On the campus of Clemson University in Clemson, SC

Clemson Installation

Existing Design
Amarillo 155 Gearbox
With Drive Shaft

Baldor Solution
Drop In Replacement
No Pedestal Modification

Hudson 5 blade
18 ft Dia Fan
Mounts directly to
Motor Shaft

Clemson Installation Test Data


2-Speed, 326T
Induction Motor

RPM AC, FL4493


PM Motor

41.5 Hp

41.5 Hp

90.2%

N/A

Motor Horsepower

46.0 Hp

41.5 Hp

Motor Efficiency

90.0%*

93.1%

Drive

N/A

98.8%

Input kW

38.1

33.6

81.2%

92.0%

Fan Load
Gearbox and
couplings Efficiency

Total Efficiency

4.5 kW
Savings

Existing 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 Data

Clemson Installation Test Data


Loaded Noise Levels
Average

High Speed

Low Speed

Induction NEMA
Motor Tower

82.3 dBA

74.4 dBA

Laminated Frame
IPM Tower

77.7 dBA

69.0 dBA

Data verified by Clean Air Engineering on site at Clemson University

VS1CTD Cooling Tower Drive Features


Designed around proven H2 Technology
Utilizes unique sensorless algorithms to

accomplish smooth, low speed operation


Power matched drive and motor
Presently preparing white paper on the need for a

packaged system with Baldor V*S Drive

Motor and VS1CTD drive can replace multiple

gearbox ratings.

Final Installation at Clemson University

Summary RPM-AC Direct Drive CT Motor


Laminated Frame Interior PM motor technology enables direct drive

gearless system.
Gearbox low speed lubrication issues are eliminated.
No drive shaft
No couplings
No guards
No alignment
Minimizes 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 ASHRAE
Std 90.1 variable speed requirements

Direct Drive motor reduces noise level of cooling

tower
Elimination of drive shaft improves noise level.

THREE SIMPLE STEPS

1.Schedule free Evaluation.


2.Review evaluation report to
determine costs and ROI.
3.Place your order for equipment
upgrades and process your rebate.

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