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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 Group
Month DD, Year | Slide 1
LAC Drives, May 2015

Cooling tower direct drive


CTDD & ACS880 package
Cooling towers
General

 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)

© ABB Group
Month DD, Year | Slide 3
Traditional cooling tower solution
General

 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.

© ABB Group
Month DD, Year | Slide 4
Cooling tower direct drive solution
General

 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

© ABB Group
Month DD, Year | Slide 5
Cooling tower direct drive
Why does people care?

 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

© ABB Group
Month DD, Year | Slide 6
Cooling tower market
Cooling towers
Common industries and applications

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)

© ABB Group
Month DD, Year | Slide 8
Cooling tower RPM-AC PM motor
Cooling tower installations

 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

© ABB Group
Month DD, Year | Slide 9
Cooling methods
Wet cooling towers

 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

© ABB Group
Month DD, Year | Slide 10
Mechanical draft towers
Wet 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
Cross flow induced draft
 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

Counter flow induced draft

© ABB Group
Month DD, Year | Slide 11
Cooling tower types
Wet cooling towers

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

© ABB Group
Month DD, Year | Slide 12
Air-cooled condenser (ACC)
Dry cooling towers

ACC Cooling tower  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

© ABB Group
Month DD, Year | Slide 13
Air cooled heat exchanger (ACHE)
Dry coolers

 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

© ABB Group
Month DD, Year | Slide 14
Gearbox solution vs CTDD motor solution

Gearbox solution

Cooling tower
direct drive solution

© ABB Group
Month DD, Year | Slide 15
Traditional cooling tower solution
Maintenance issues
 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
© ABB Group
Month DD, Year | Slide 16
stresses when started across the line
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
NO SPACE  Easy to use with simplified parameter set
HEATERS REQUIRED
 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

© ABB Group
Month DD, Year | Slide 18
Cooling tower direct drive
Direct drive technology
Benefits
Conventional tower design

 Eliminates gearbox, drive shafts,


disc couplings and existing motor
Fan
 Runs quieter & saves energy
 Increases safety due to fewer
components AC Motor Disc
Coupling
Drive Shaft Disc
Coupling
Gear Box

 Improves reliability and reduces New direct drive tower design


maintenance
 Lower installation cost by
eliminating alignment issues of
mechanical components
Fan
 Reduces cooling water
contamination from gearbox oil
and leakage

AC Motor

© ABB Group
Month DD, Year | Slide 20
Possible cooling tower environment

 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

© ABB Group
Month DD, Year | Slide 21
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)

© ABB Group
Month DD, Year | Slide 22
CTDD motor type matrix up to 11 000 Nm
Rough motor table

IEC160 IEC180 IEC225 IEC250 IEC280 IEC355


Speed
500 FL2562 FL2570 FL2578 FL2578 FL2882 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4058 FL4440 FL5818
475 FL2562 FL2570 FL2578 FL2882 FL2882 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4421 FL4440 FL5820
450 FL2562 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4429 FL4440 FL5820
425 FL2562 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3698 FL3614 FL4046 FL4429 FL4440 FL5820
400 FL2562 FL2570 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4429 FL5818 FL5822
375 FL2562 FL2570 FL2882 FL2882 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4440 FL5820 FL5822
350 FL2562 FL2578 FL2882 FL2890 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4440 FL5820 FL5824
325 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3614 FL3614 FL4046 FL4058 FL4440 FL5822 FL5824
300 FL2570 FL2578 FL2882 FL2890 FL2898 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL5818 FL5822 FL5826
275 FL2570 FL2578 FL2890 FL2898 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4421 FL5820 FL5824 FL5828
250 FL2570 FL2882 FL2890 FL2898 FL3698 FL3698 FL3614 FL3614 FL4034 FL4058 FL4429 FL5822 FL5826 FL5830
225 FL2578 FL2882 FL2890 FL3698 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4429 FL5822 FL5828 FL5832
200 FL2578 FL2882 FL2898 FL3698 FL3698 FL3614 FL3614 FL4034 FL4046 FL4421 FL4440 FL5824 FL5830
175 FL2578 FL2890 FL2898 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4429 FL4440 FL5828 FL5832
150 FL2882 FL2898 FL3698 FL3698 FL3614 FL4022 FL4034 FL4046 FL4421 FL4440 FL5820 FL5830
125 FL2882 FL2898 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4429 FL5820 FL5824
100 FL2890 FL3698 FL3698 FL3614 FL4034 FL4046 FL4058 FL4421 FL4440 FL5822 FL5828
HP 10 15 20 25 30 40 50 60 75 100 125 200 250 300
kW 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

© ABB Group
Month DD, Year | Slide 23
ACS880 +N5350 CTD
ACS880 +N5350 cooling tower control program
Features

 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

© ABB Group
Month DD, Year | Slide 25
ACS880 +N5350 cooling tower control program
CTDD features – trickle current & de-ice mode

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
NO SPACE which will inhibit rotation of the fan blades
HEATERS REQUIRED
 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

© ABB Group
Month DD, Year | Slide 26
User’s guide
ACS880 +N5350 cooling tower drive

© ABB Group
Month DD, Year | Slide 27
ACS880 +N5350 cooling tower control program
Two startup assistants

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

© ABB Group
Month DD, Year | Slide 28
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

© ABB Group
Month DD, Year | Slide 30
Package selection with CT wizard
Wizard input data

 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
CT Wizard
 Voltage
 Ambient (default 40°C)
 Height restriction (can be left blank)
 Altitude
 Air flow

© ABB Group
Month DD, Year | Slide 31
Request for motor quote

 Fan diameter
 Fan speed
 Motor power
 Gear size, type and ratio (fan
torque)
 Voltage
 Height restrictions
 Shaft requirements
 Drive location

© ABB Group
Month DD, Year | Slide 32
Energy efficiency
Comparative performance data

PM Premium Efficiency® Energy Efficient Premium Efficiency® PM


IEEE 841 Energy Efficient 98
98
97
96

96

% EFFICIENCY
% EFFICIENCY

94

95
92

94
90

88 93

86 92
1 10 100 1000 0 20 40 60 80 100 120
HP % LOAD

 Consistently best across a wide range of powers and loads

© ABB Group
Month DD, Year | Slide 34
Cooling tower direct drive
Advantages and energy savings

 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
© ABB Group
Month DD, Year | Slide 35
Technology comparison

IE2 induction IE3 induction VSD + IE3 VSD + direct


motor + gearbox motor + gearbox induction motor + drive PM motor
gearbox
Base efficiency +1.4% efficiency 57.7% efficiency 59.9% efficiency
improvement improvement improvement
Gearbox Gearbox Gearbox Eliminates
maintenance maintenance maintenance gearbox
required required required maintenance

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

© ABB Group
Month DD, Year | Slide 36
Example of energy savings
DOL vs VSD
Conventional cooling tower design DOL

Operating Fan speed Motor Power usage Energy cost Example does not
Motor hp
hours rpm rating kW kWh 0.12€/kWh take into effect
ambient and wet bulb
5110 Full speed 225 50 37.3 190603 22,872 € temperature changes
3650 Off 0 0 0 0 0€
tot 8760 190603 22,872 €

CTDD solution with VSD CTDD solution shows


Operating Fan speed Motor Power usage Energy cost a 5.5% efficiency
Motor hp
hours rpm rating kW kWh 0.12€/kWh gain due to the
1460 Full 225 47.25 35.2 51463 6,176 € removal of the
730 90% 202.5 34.4 25.7 18758 2,251 € mechanical losses
730 80% 180 24.2 18 13174 1,581 €
730 70% 157.5 16.2 12.1 8826 1,059 €
The full speed
730 60% 135 10.2 7.6 5558 667 € operating hours have
730 50% 112.5 5.9 4.4 3216 386 € been updated for
3650 Off 0 0 0 0 0€ variable speed
tot 8760 100995 12,119 € capabilities

 Total yearly savings 10 753 € per tower


 Total year savings 47 % per tower
 In addition maintenance cost savings

© ABB Group
Month DD, Year | Slide 37
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

© ABB Group
Month DD, Year | Slide 39
External ABB web pages

© ABB Group
Month DD, Year | Slide 40
Press releases
Cooling tower direct drive solution

 http://www.baldor.com/mvc/Download  http://www.baldor.com/mvc/DownloadCen
Center/Files/Solutions1009 ter/Files/FM1462

© ABB Group
Month DD, Year | Slide 41