new cooling tower concept: ec solutions - ebm-papst sea€¦ · 12/8/2020 new cooling tower...

New Cooling Tower Concept:EC Solutions

Keith Tan, 12th August 2020

Overview

Presentation Content

Case Study

Advantages of EC Technology in Cooling Towers

Range of Products & Applications

What is EC Technology?

Company History & Introduction

2

1.

2.

3.

4.

5.

6.

Testing Methods for the EC fan in Cooling Towers

12/8/2020 New Cooling Tower Concept: EC Solutions

Company History & Introduction1

3

Milestones in our corporate development

EstablishmentElektrobau MulfingenGmbH & Co. KG (ebm) by Gerhard Sturm and Heinz Ziehl

PAPST Motoren GmbHbecomes part of the group

1975 Alcatel SEL AG in Landshutbecomes part of the group

1992

1997

Re-naming of thethree brands ebm, PAPST and mvlto become ebm-papst

2003

2013

Enhanced electronics expertiseGreenTech

our symbol for environmental protection. GreenTech includes forward-looking development, environmentally friendly production, maximum energy efficiency and the greatest possible customer benefit.

ebm-papst neoDigital products need new business models

OpeningDevelopment Center Osnabrück

GreenIntelligenceThe systematic further development of GreenTech

2016

2017

Production of the first electronically commutated DC external rotor motorBirth of EC technology

Zeitlauf GmbH becomes part of the group

20092019

1963


48 sales offices

29 production sites

ebm-papstin figures

14,638 Employees

114.3million euros R&D expenditure

2,188 million euros sales


ebm-papst SEA headquarter is in Singapore. Our premises include an office, showroom, lab and warehouse. We support Indonesia, Malaysia, Philippines, Thailand and Vietnam.

Range of Products & Applications2

6

Innovativeaerodynamics and drive engineeringPerfect system solutions for our markets

Mulfingen St. Georgen Landshut

Industrial Air Technology

Industrial & Ventilation Technology

Automotive HouseholdAppliances

Heating Technology

Refrigeration & Air Conditioning

Industrial Drive Technology


Commercial & Industrial Buildings Air Purifiers Air Handling Units Air Curtains Air-Conditioning Systems for Facades

Residential Buildings Centralised Ventilation Units Decentralised Ventilation Units

Agriculture

Applications in Ventilation Technology

Industrial & Ventilation Technology


Condensers Evaporators Display Cases & Bottle Coolers Condensing Units Cooling Towers

Applications for Commercial & Retail

Refrigeration


What is EC Technology?3

10

What is an EC Motor?

• EC means “Electronically Commutated”

• Brushless (thus, no dust) & Variable speed control

• Compact direct drive & External rotor

• Synchronous, Lower noise & Soft start

• High efficiency motor (including electronics of up to 90%)

• Plug & Play

• Control system from a single source

• RS 485 MODBUS-RTU ready11

• Built in Integrated PFC, motor protection, Direct AC main supply but electronics convert AC to DC

• Master or slave options available

• Wide voltage range for 1~AC or 3~AC

• Suitable for 50, 60Hz system and wide voltage range

• Permanent magnet


Distinct Features of the EC Fan

12

• Aerodynamics of impeller reduce turbulence andthus, noise and vibration

• Minimal losses, as doesn’t involve belt & pulleylosses, mis-match losses, and VFD losses

• Harmonics are kept below 35% with PFC

• Maintain high static efficiency even at low speeds

• 2 plane balancing; G6.3 or better

• External rotor construction aids cooling

• Components are optimized for each other

• Integrated electronics filter reduce noise fromelectronics


IE Classes for Standard AC Motors (4-pole, 50Hz)

Most Efficient Motor Technology

ebm-papst EC motors with high efficiency

IEC 60034-30-1 defines the following efficiency classes for induction motors:

• IE1 Standard Efficiency• IE2 High Efficiency• IE3 Premium Efficiency• IE4 Super Premium Efficiency


Flow of Power through Motors

14

Comparison of AC & EC Motor (3050 W)

EC motor saves 340 W

Total lossAC = 620 W EC = 280 W

Inverter lossAC = 160 W EC = 80 W

Slip & Friction lossAC = 60 W EC = 0 W

Copper lossAC = 200 W EC = 120 W

Lamination lossAC = 200 W EC = 80 W

*standard squirrel cage motor (90L frame)


EC - Soft Start

15

AC motor inrush current = 3.5 times higher than F.L.A.

EC motor current ramps up slowly to F.L.A.

Inru

sh

F.L.

A.

F.L.

A.

No sequenced start-up required


GreenTech EC Motor And Drive Electronics

without PFCPower Factor λ= 0,85Current IRMS = 958 mA

with PFCPower Factor λ= 0,99Current IRMS = 628 mA


Reducing line – Harmonics by PFC

Imains [mA]

Harmonic currents, harmonics w and w/o active PFC, same duty-point @ 230V50Hz

0

100

200

300

400

500

600

700

1 3 5 7 9 11 13 15 17 19

withoutPFC


GreenTech EC Fan vs. AC/PM Fan with VFD

• Fan Laws

• P ~ n³

• The grey bars show power consumption of AC fans, which are switched on gradually as required

• Air performance drops by 50% if half of the fans are switched off

• The blue curve shows power consumption with in-built variable speed control in EC fans, resulting in approximately 37% in energy savings


GreenTech EC Fan vs. AC/PM Fan with VFD

• Fan Laws• Lp [dB] = 50 x lg (n1/n2) • Switching off half the AC fans

only reduces noise generation by approx. 3 dB.

• In contrast, a reduction of 15dB can be achieved with continuous speed adjustment.


Speed Control with AC fan

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EMC filter400 V / 50 HzL1

L2

L3

Line filter VFD

Motor sine filter

Motor protectionBMS/DDC

AC fanTemp sensor


Speed Control with EC fan

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Motor sine filter

380 - 480 V 50/60 Hz

L1

L2

L3

BMS/DDCPressure or temp sensor

EC fan

EMC filterLine filter

VFD

Motor protection


Advantages of EC technology in Cooling Towers

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4

Advantages of EC technology in Cooling Towers (1)

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Part Load Operating RangeEC AC

• Able to run as low as 10% of full speed or 5Hz in frequency

• Good for night load, whereby temperature of wet bulb is usually very low < 28°C

• Lowest speed to operate using VFD at 25~30 Hertz

• Can’t run lower than 25Hz due to harmonic distortion at night or during cold days (e.g. raining)

Power Savings and Noise ReductionEC AC

• Optimum selection (using FanscoutSoftware), based on airflow and static pressure requirements

• Compact• EC fans ramp down together. There is no

need to perform staging. • via Fan law, energy savings of

approximately 37% can be achieved

• Limited options• Always oversized• AC fans perform staging to achieve

power savings



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Minimal MaintenanceEC AC

• EC fan solution is maintenance free, only visual check on wiring and vibration is needed

• Oil leaks, due to broken oil seals, are common in AC systems

• Checks will be needed

Operational Redundancy Option AvailableEC AC

• EC Fan solution offers multiple fans in parallel operation. Therefore, redundancy advantages apply.

• No redundancy advantage. When 1 fan fails, the tower has to be shut down.



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Operational Redundancy Option Using EC Fans (District Cooling Plant)

Multiple fans offer better and uniform air suction out from the infills. Thus, the coverage is wider, improving thermal efficiency.

• ‘Multiple fans’ option offers better operation stability

• For AC systems, if the fan breaks down, it means the cell will need to be shut down.

• For EC systems, if one fan breaks down, the remaining fans can speed up to make up for the airflow loss.

• Replacement is relatively easy, plug and play

• The fast replacement process can be done when the tower is in operation, meaning there is no disruption (With all the safety measures being considered)

12/8/2020

EC Multiple Fans solutionAC Conventional system

Controllability of EC fans (1)

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PLC R

D

Master

RSBRSA

Fan 1 Fan 2 Fan 3

Integration with Building Management System (BMS) Setting options

for speed controlOn demand operation with continuous speed control

Monitoring and control


Controllability of EC fans (2)

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If a fan breaks down:

Operational Redundancy: The cooling tower will continue with the same cooling capacity as before because the other fans will speed up to compensate for the reduced airflow.

PLC R

D

Master

RSBRSA

Fan 1 Fan 2 Fan 3


Testing Methods for the EC fan in Cooling Towers

28

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Testing methods at ebm-papst for EC fans

29

Salt fog test HALT Vibration andshock testTCR test

Temperature Change Rain Test (1)

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• Temperatures between -10 °C and +60 °C

• Direct water impact• Fan on/off• 6 months 5 cycles per day

• 900 cycles on one product


Temperature Change Rain Test (2)

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Time [min]

Tem

pera

ture

[°C]

Rel

ativ

e hu

mid

ity[%

]

Actual temperatureTemperature set pointRelative humidityRain

Items under test ON

Items under test ON

Items under test OFFOFF OFF


Salt Fog Test


• Simulation of highly corrosive environment

• At least 1000h of salt fog test for every product

HALT – Highly Accelerated Lifetime Test

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• Testing beyond specifications, in thermal vibration chamber

• Detection of weaknesses• Improvement during development• Test conditions: -100 °C to

+200 °C at 70 K/min und 50 gRMS(10 Hz to 10 kHz)

• With the HALT/HASS systems (Highly Accelerated Life Testing / Highly Accelerated Stress Screening) you put your samples under a maximum exposure to stress. In addition to the vibration in three axis directions, a very high temperature change rate is achieved using liquid nitrogen making it possible to test your products in extreme situations


Vibration and Shock Test


Test Results of ebm-papst‘s Products for Cooling Towers

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ebm-papst products for cooling towers havethe environment rating H2+A or H2+C


• Implementation of these test to prove sustainability of ebm-papst’s products

• H2 = Basic Class• + = Additional Stress• Protection against highly corrosive environment,

permanent steam, concentration of minerals and cleaning agents

Case Study6

36

Case Study

37

• EC fan Part number is W3G910GF0536 + AxiTop

• 8 Cells per tower, 1 EC fan per Cell• Total (2 towers, 16 Cells) = 16 EC fans• Airflow per cell, 32,000CMH, total airflow for

1 tower is 256,000CMH• Rated power per cell is 3.7kW

Robust & Advanced-looking

Comparison

New Counter Flow EC System Old Cross Flow System


Case Study

38

Cooling Tower Replacement, Conventional Crossflow type Counterflow EC fan type, 900HRT per tower

• Managed to cut down the labour required for installation on-site• Included new tower CKD erection on site ground level and hoist up to the existing beam • Replacement process only took 4 to 5 hours

• All units of the fans are controlled via BMS and touchpad HMI (local)• Each HMI is able to support 8 EC fans and link to BMS to display parameters such as fan

status, running speed and input power• EC fans are able to ramp down to as low as 10% for speed

• This is ideal for night load or cold weather, whereby the wetbulb temperature is low• This enables user to gain more savings

• Compared to Crossflow, Counterflow tower is lower in drift loss due to the design• Algae formation is lower too as the infill is well covered inside the panel. This means less

exposure to sunlight, which leads to growth of algae• We are still in the midst of collecting data to compare the actual savings and this process may

take up to 6 months. However, initial results show…• Energy savings is approx. 20% to 25% from the motor input power• Noise level is lower by 3dB (High speed) to 6dB (Low speed)

• Maintenance for EC system is minimal, only visual check on the abnormal vibration or any loose wirings is needed.


39Date

Thank you for your attention

ebm-papst SEA Pte. Ltd.Contact person

Keith TanSales [email protected] Changi South Street 2, #01-01/02, Singapore 486596

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new cooling tower concept: ec solutions - ebm-papst sea€¦ · 12/8/2020 new cooling tower...

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