Professional Documents
Culture Documents
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LAC Drives, May 2015
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Month DD, Year | Slide 3
Traditional cooling tower solution
General
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Cooling tower direct drive solution
General
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Cooling tower direct drive
Why does people care?
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Cooling tower market
Cooling towers
Common industries and applications
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Cooling tower RPM-AC PM motor
Cooling tower installations
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Month DD, Year | Slide 9
Cooling methods
Wet cooling towers
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Mechanical draft towers
Wet cooling towers
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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
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Air-cooled condenser (ACC)
Dry cooling towers
No chemicals needed
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Month DD, Year | Slide 13
Air cooled heat exchanger (ACHE)
Dry coolers
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Gearbox solution vs CTDD motor solution
Gearbox solution
Cooling tower
direct drive solution
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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
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Month DD, Year | Slide 16
stresses when started across the line
CTDD & ACS880
Cooling tower direct drive & ACS880 +N5350
Warranty
Standard warranty is 24 months and 36 months as option (outside US)
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Month DD, Year | Slide 18
Cooling tower direct drive
Direct drive technology
Benefits
Conventional tower design
AC Motor
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Month DD, Year | Slide 20
Possible cooling tower environment
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Month DD, Year | Slide 21
CT motor improvements
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Month DD, Year | Slide 22
CTDD motor type matrix up to 11 000 Nm
Rough motor table
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
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Month DD, Year | Slide 23
ACS880 +N5350 CTD
ACS880 +N5350 cooling tower control program
Features
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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
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Month DD, Year | Slide 26
User’s guide
ACS880 +N5350 cooling tower drive
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Month DD, Year | Slide 27
ACS880 +N5350 cooling tower control program
Two startup assistants
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Month DD, Year | Slide 28
Package selection
Application sizing & considerations
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Month DD, Year | Slide 30
Package selection with CT wizard
Wizard input data
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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
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Month DD, Year | Slide 32
Energy efficiency
Comparative performance data
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
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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
Variable speed control assumption, average 75% of maximum speed over duty cycle
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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 €
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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
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Month DD, Year | Slide 39
External ABB web pages
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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
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Month DD, Year | Slide 41