Beruflich Dokumente
Kultur Dokumente
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
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
motor driven systems. 59% of this goes to pumps, fans, blowers and
compressed air systems.
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
to save energy.
Stronger attempt to quantify savings and present to management
in financial terms.
13c/kWh
9c/kWh
5c/kWh
6c/kWh
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
(Expert Systems for Diagnosis of the Condition and Performance of Centrifugal Pumps)
Major causes:
Oversized pump & system not designed to run near
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.
impossible.
65% of control valves <50% open, with many <30% open and 15% at
startup.
kWh
Energy meter
Summary of Benefits
Energy Savings
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
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
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
High Speed
Low Speed
Induction NEMA
Motor Tower
82.3 dBA
74.4 dBA
Laminated Frame
IPM Tower
77.7 dBA
69.0 dBA
gearbox ratings.
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
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
tower
Elimination of drive shaft improves noise level.