TORQUE REPORT

TORQUE REPORT 1

TORQUE REPORT

OCTOBER 2005OCTOBER 2005

INSIDE THIS ISSUE:INSIDE THIS ISSUE:

* TECO Factories Upgraded ............ 2

* Dealers Electrical Drives Success ... 3

* Replacement Motor Program

Generates Plant Reliability .......... 3

* Hammond Visits TWMC South

Carolina Facility .......................... 3

* TWMC Engineers Earn Highest

Vibration Analyst Certifications ...... 4

* TECO Tech Tip ............................. 4

* CE Mark, ATEX Certification for

TWMC Products .......................... 4

* Mid-Plains Brings Motor

Showroom to Customers ........... 5

* 7200GS Sensorless Vector VFD ... 5

* Repair Partners Program ............ 5

* PSNY AC/DC MG Test Set ............ 6

In June of 2004 YorkInternational, a leadingcompany in the heating,ventilation, air condition-ing, and refrigeration( H V A C & R )market, wonthe world’s

largest air conditioningcontract of its type.

York will provide acooling capacity of118,000 tons for theexpansion project at

Dubai InternationalAirport, which islocated in the cityof Dubai on theNortheastern coast

of the United ArabE m i r a t e s . T E C O -

Westinghouse Motor Companywas chosen to supply 63 motorsfor the 107,250 HP needed for theairport expansion.

York’s multi-million dollar con-tract is part of the US $4.1 billionsecond phase of the expansionproject, which includes the con-struction of Terminal 3,Concourses 2 and 3, a cargo megaterminal, the Dubai FlowerCentre, and upgrades of existingTerminal 2 for the airport.

The TWMC motors range from1000 HP to 2000 HP and willdrive York’s centrifugal compres-sors that are used to chill waterfor the airport and flower centre’sHVAC&R systems. These motorswill operate at 3000 RPM and are3 phase, 50 hertz, 11,000 VAC.Enclosures for the motors areeither Open Drip Proof (ODP) orTotally Enclosed Water-to-Air-Cooled (TEWAC).

TWMC was chosen as themotor supplier based on aproven successful track recordwith HVAC&R motors used onYork’s chillers. Continued on page 2

TWMC Delivers Time-Efficient Turn-Around for Dubai Airport Expansion

StiStilll Making Wl Making Waavves: TWMC’es: TWMC’s Super Quiets Super QuietDCDC PrPropulsion Topulsion Technology Legacyechnology Legacy

TECO-Westinghouse Motor Companyhas a long history of supplying superquiet DC propulsion motors that datesback to the Second World War. InitialWestinghouse super quiet technology wasdeveloped for the U.S. Navy, who had amajor interest inmaking their sub-marines quiet. Thetechnology wasexpanded afterWe s t i n g h o u s eworked with theU.S. Navy onsuper quiet surfaceships used foroceanographicsurveillance andresearch duringthe years of theCold War. Westinghouse provided DCequipment for many of these ships thatcomfortably met the required contractualstructure-borne noise limits.

In the mid 1990’s it was recognizedthat the radiated noise from fisheriesresearch vessels was critical to theaccuracy of the collected data on fishpopulations. There were two vital aims fornoise reduction in these types of vessels.

The first aim wasto assure that thefish would notswim out of thepath of the vesselas it approached,and that theradiated noisewould not causea n a r t i f i c i a lconcentration offish below thevessel. The secondaim was to prevent

noise from contaminating the signal fromthe fish echoes received and processed byacoustic survey equipment.

Continued on page 2

TWMC built the super quiet DC propulsion system for theNorwegian GO Sars vessel (shown above) that has been inoperation for over a year.

TWMC motorswill drive York’scentrifugal compressorsthat are used to chillwater for the airport andflower center’s HVAC&R systems.

The International Congress ofExploration of the Seas (ICES), aworld wide research organization,undertook the task of determining theultimate noise signature for a researchvessel that met the two criteria definedabove. The result of this major studywas a recommended curve of under-water radiated noise. Acceptedby all of the major countries inthe world involved in fish-eries research, this standardis the basis for the design ofall new fisheries researchvessels. As fish populations aredwindling and there are concernswith over-fishing, many feel that it isimperative that countries utilize thesame sampling methods. New vesselsare being built for this purpose.

Capitalizing on this wealth of expe-rience, TWMC has successfully obtained

orders for a number of new state-of-the-art fisheries research vessels,including the propulsion system for

the Norwegian GO Sars vessel thathas been in operation for over a

year. TWMC will also supplypropulsion systems for the

English vessel “JamesCook,” being constructedin Norway, as well as aSpanish vessel that is

being built in the Friereshipyard in Spain. Most

recently, TWMC was chosento provide super quiet propulsion

systems for the NOAA FRV40ships 3 and 4. For each project,TWMC works closely with the shipyard,ship designers, and noise consultantsto assure that the propulsion equipmentdesign results in a ship that meets thenoise signature required.

With a vision for growth, TECO iscontinuing to expand its globalresources. “We are a very progressivecompany in the normally un-glamorous,‘low-tech,’ and mature product worldof electric motor manufacturing,”said TWMC National Sales ManagerPat Rogers, reflecting on a recent visitto several TECO plant expansions.

The Wuxi facility, originallydesigned to manufacture formwound medium and high voltagemotors and low voltage adjustablespeed drive products, is two years intooperations and already has expansionsunderway. As projected, the plant hasbeen up-to-speed and fully-loaded forone shift since March, with a plannedsecond shift expansion in the near future.

The new random wound small motorplant expansion, also on the Wuxi property,was built to support motor products up to100 HP. With the final assembly lineinstalled, the first motors shipped in earlyApril. This new plant has an expected

capacity of 400,000 units in one shift in fourmonths, which will gradually be increased.

Another newly expanded TECO plantbuilt next to the TECO Industrial Park inJiang Xi, China will produce mostlymedium and high voltage productsincluding wound rotor and synchronousmotors, induction motors (630mmframes and above), and hydrogenerators.

These two new factories further expandTECO’s manufacturing capabilities formotor and generator products in China

to range from 1 HP to 25,000 HP.“Together these expanded manu-

facturing facilities will enable TECOto amply supply current needs and pro-jected growth for both domestic andinternational markets,” said Paul Chiueh,Director of New Business Development.

Detailed attention is paid to theproducts that are manufactured, clean-liness of the plants, and efficientlycoordinating manpower to operate ator above capacity. A customer fromthe United Kingdom who recently

visited several TECO plants in Asiacommented, “You never see this pace ofmanufacture and attention to detail outof European motor manufacturers.”

“Our customers want their suppliersto be long-term thinkers with plans tosource products and/or componentsfrom the emerging low cost areas of theworld, while maintaining the high qual-ity standards they demand,” saidRogers. “TECO is certainly experienc-ing and living this mission.”

TORQUE REPORT2

Fulfilling a Mission of Growth: TECO Factory Upgrades

Production underway at the small motor plant expansion at TECO’sWuxi facility. Entrance to the Jiang Xi plant expansion (inset).

“Torque Report” is a periodical publication of TECO-Westinghouse Motor Company. Its editorial mission is to inform our readership in the areas of motor application industries, as well as business andworld affairs that have an impact on our mutual concerns. Comments, inquiries, and suggestions should be directed to: Torque Report, TECO-Westinghouse Motor Company, 5100 N. IH-35, Round Rock,TX 78681 USA. Phone: 1-800-451-8798. FAX: 512-244-5512. E-mail: torquereport@tecowestinghouse.com. Website: www.tecowestinghouse.com. Copyright © 2005 TECO-Westinghouse Motor Company.

Flying High: TWMCFlying High: TWMCMotors DrivMotors Drive Airporte AirportCoolCooling Compring CompressorsessorsContinued from page 1

The first twenty-one motors weredesigned, manufactured, tested, andshipped within seven to eleven weeksafter receiving the order in July of 2004.Providing this time-efficient turn-aroundfor the customer was a significant accom-plishment for the project. Another sixmotors were shipped in December of2004. The remaining motors orderedwere sent to the customer in 2005 withthe final two shipping in September.

One of the fastest growing airports inthe world, the Dubai InternationalAirport presently has the annual capacityto handle 22 million passengers. Withthe completion of the expansion, to befinished in 2008, the airport will havethe annual capacity to handle over 70million passengers.

Super Quiet Motor Technology Propels TWMCto Forefront of Marine Applications Continued from page 1

For base load operation, a singlemotor failure can reduce plant outputanywhere from 200 MW to completeshutdown. Combine this risk with the factthat many original power plant motors inthe United States have been in operationand under maintenance for over 25 years.Until recently, spare motors for criticalapplications were only purchased on a“buy when fail” scenario since outagecycles were typically longer and allowedfor service and refurbishment of themotors. For one power plant in themidwest, it took a motor failure incidentand plant shutdown toevaluate their overallplant reliability withemphasis on reducing“down time” to get theplant back up and running.

After the incident, theutility plant evaluated13 critical motors fromvarious OEM’s for theirfour generating facilitieslocated along theMissouri River. The motor applicationsranged from 700 HP coal conveyormotors to 7,000 HP induced draft fanmotors. Since these were existingplants, the motor critical dimensions(shaft height, foundation bolt locations,and shaft dimensions) had to be retrofittedexactly to allow quick interchangeabilityin the event of failure.

The motor environment was also aconcern. Many of the original motors

were Weather Protected Type I (WPI)and subjected to coal dust, fly ash, andother particles, that caused the motorinternals to get considerably dirtybetween outage cycles. The utility sub-sequently invested in motor enclosureupgrades to either totally enclosed(TEFC) designs or WPII enclosureswith filters. In order to accommodateexisting building structures, enclosuredesigns were modified to clear theobstructions while still maintaining thesame air inlets and air discharge outlets.

Electrically, the performance of themotors was required tobe equivalent or betterthan the existing motorOEM designs. Some ofthe new motors requiredincreased nameplateratings for processconditions or added aservice factor to thedesign, while powerfactor, full load RPM,full load amperage, and

locked rotor amperage values weremaintained. This allowed for use of theexisting starting equipment withoutmajor disturbances.

With staggered deliveries, some of thenew motors have already been installedin planned outages, allowing the exist-ing motors to be refurbished and storedwith the motors not yet installed…ready to reduce downtime for the plantin the event of a failure.

As part ofa replace-ment motorprogram,this spare7000 HP,1 0 P o l emotor isi n s t a l l e dwhile thee x i s t i n gmotor isrefurbished.

In December of 2004, South Carolina Secretary of State Mark Hammond,Director General R.C. Wu from the Taiwan Economic and Cultural Office inAtlanta, and Spartanburg Chamber of Commerce Chairman John Poole visitedthe TECO-Westinghouse Motor Company facility in Spartanburg, SC.

Earlier in May of 2004, Secretary of State Hammond had met with TECO VPGeorge Lien in Taiwan where a visit to Spartanburg was recommended. Pleasedwith the hospitality by VP Lien in Taiwan, the group accepted the invitation totour the Spartanburg facilities.

“We greatly appreciate your investment in Spartanburg County and this finestate,” wrote South Carolina Secretary of State Mark Hammond in a letter ofthanks. “I would also like to compliment [your personnel] on the wonderful andinformative tour of your facilities. The delegation was very impressed andenjoyed their hospitality.”

Hammond Visits TWMC Facilities in SC

Dealers Industrial, a distributor andservice center for TECO variable speeddrives, has grown their business withTECO-Westinghouse Motor Companyexponentially over the last four years.Meeting and exceeding their sales goalseach year, they have been able to takeadvantage of niche markets, as well aspenetrating the industrial market.

Dealers’ growth recently forced themto move into a new 20,000 square footfacility in New Jersey that includes afull motor shop and area to stock TECOFM100 and MA7200 drives in 230Vand 460V up through 40 HP.

On track to have another great yearwith TWMC, Dealers has successfullymarketed all of the TECO drives products,including the new variable torquePA7300 for the HVAC market, and theextended HP range of the constanttorque GA7200 for applications such assand dredging and stone quarries.

JefJeff Brf Brennerenner, co-owner, co-ownerof Dealers Industrial,of Dealers Industrial,

showcases racks ofshowcases racks ofTECO drives prTECO drives productsoducts

in-stock and rin-stock and ready-to-goeady-to-goat the company’at the company’s news newfacility in New Jerseyfacility in New Jersey..

RReplacement Motor Preplacement Motor Progrogram Generam GeneratesatesUtiUtilliitty Plant Ry Plant Releliabiiabilliittyy

DrivDrives Suces Success wicess withthDealers IDealers Industrialndustrial

TORQUE REPORT 3

TORQUE REPORT4

With regard to oil temperaturestability, mineral-based oils areusually superior to lower-pricedmist lubricants. Synthetic oilswork well at high or lowtemperatures, and can befire resistant.

TECO Tech TipTWMC Engineers Earn Highest LevTWMC Engineers Earn Highest Levelelof Vibrof Vibration Analyst Certiation Analyst Certificationsfications

TWMC Engineering ManagerBill Branca and Test EngineerBryan Evans recently earnedCategory IV Vibration Analystcertifications through theVibration Institute. This interna-tionally recognized organizationis dedicated to the exchange anddissemination of practical infor-mation aboutvibration andcondition mon-itoring, ande v a l u a t i n gm a c h i n e r ybehavior andc o n d i t i o n .According tothe Institute,TWMC is thefirst motormanufacturer tohave employ-ees who areCategory IVcertified vibra-tion analysts.

Joining anexclusive groupof less than 100i n d i v i d u a l sw o r l d w i d e ,Branca andEvans both suc-cessfully completed all require-ments and passed examinations toachieve the Category IV level ofthe vibration analyst certificationprogram offered by the Institute.This is the highest level of ISOcertification for vibration ana-lysts, and both Branca and Evanswill be certified for five years.

“We wanted to be the first motormanufacturer to have engineerscertified at the highest level pos-sible,” said TWMC EngineeringManager Bill Branca.

The Vibration Institute’s pro-gram consists of an annualNational Technical TrainingSymposium, short courses, and an

internationally recognized certifi-cation program for assessing indi-vidual levels of expertise inmachinery vibrations. CategoryIV Vibration Analyst requirementsare governed by an industry-basedboard, and are based on ISO18436:2, Condition Monitoringand Diagnostics of Machines -

Requirementsfor Training andCertification ofPersonnel - Part2: Vibrat ionC o n d i t i o nMonitoring andDiagnostics.

The knowledgethat is obtainedfrom certifica-tion trainingencompasses anunderstandingof vibrationissues in awide-variety ofdriven equip-ment includingpumps andcompressors, aswell as motors.Branca andEvans’ achieve-ments are a sig-

nificant benefit to TWMC and itscustomers, as highly certifiedanalysts are able to better under-stand the impact of vibration onTWMC motors and customerproducts, and can assist in theassessment of vibration issuesthat may occur in testing.

This past June, Branca pre-sented a seminar on electricmotor vibration at the VibrationInstitute's annual symposium,which was held in Richmond,Virginia (USA).

“We hope to continue to takea more active role with theVibration Institute in the future,”said Branca.

“Passport to Europe” -TWMC Products ObtainCE Mark, ATEX Certification

Test Engineer Bryan Evans performs abump test on a motor during final testing.Evans and Engineering Manager BillBranca recently earned Category IVVibration Analyst certifications.

In March of 2005, TWMC took the first steps insecuring entry of its products into the Central andEastern European market. Through the experience ofdesigning, manufacturing, and shipping motors thatwere CE marked and ATEX certified for a customerorder, TWMC has laid the foundation for obtaining a“passport” into the Central and Eastern Europemarketplace, gathering a wealth of knowledgethrough this process.

The European Union (EU) grew to 25 memberstates on May 1, 2004. With a population of 450 millionand a GDP of $12 trillion, the EU now accounts foralmost 20 percent of world trade. This expansionpresents an unparalleled opportunity for companiesdoing business, or wanting to do business, in the EU,as it is the largest single market in the world.

The CE mark is placed as a declaration on certainproducts that the item meets all the requirements ofrelevant EU directives. The mark is mandatory forselling products to and within over 29 Europeancountries. Proof that the item or product meets therelevant requirements must be documented for theuse of a CE mark on a product to be permitted. Over50 percent of all products from the United States thatare exported to Europe require the CE marking.

For goods that have applications for potentiallyexplosive atmospheres, compliance with theAtmospheres Explosibles (ATEX) directive ensuresthe removal of obstacles and difficulties related tothe free movement of these goods within the EU.ATEX certified products are marked with an ATEXcertification logo.

Based on TWMC’s certification experience, thecompany has gained the knowledge required tounderstand and develop guidelines for effective entryinto the market for non-sparking, increased safety,and pressurized motor designs.

K.J . Elect r icrecently joinedforces with TECO-W e s t i n g h o u s eMotor Companyand entered into a“Moto r Repa i rAlliance Agreement.”

The purpose ofthe agreement is toextend the TECO-Westinghouse presence in theupstate New York and NewEngland marketing areas, and togive K.J. Electric a greater rangefor motor repair. The agreementwas designed for companies thathave an established reputationamong their customers for reliable,high quality motor repair services.K.J. Electr ic and TECO-Westinghouse’s new relationshipwill allow for additional high qual-ity service for all of their customers.

Under the new agreement, thecompanies will be jointly target-

ing industries including utilities,metals, and paper industries, allwhich typically have populationsof larger horsepower motors. Thisalliance will extend the engineer-ing, testing, rewind, re-design,and stator core replacement capa-bilities in the region.

A full service, independentindustrial distributor of electricmotors, controls, drives, andpower transmission products, K.J.Electric also specializes in motorrepair, manufacturing, and indus-trial control panel fabrication.

“You Betcha!” is a popular phrase inNorth Dakota, and is a favorite sayingof Randy and Pam Hahn, owners of MidPlains Distributing Inc. Headquarteredin Fargo, this is their story of joining theTECO-Westinghouse team, and theirdrive and commitment to growing theTECO-Westinghouse business.

In 2002, Mid Plains began purchas-ing explosion proof and single-phasemotors from TECO-Westinghouse, sell-

ing a significant amount of TECO-Westinghouse products from 2002-2003. After determining a need for anew primary motor supplier at thebeginning of 2004, they immediatelyturned to TECO-Westinghouse as theirfirst choice for a new motor line.

In their own words, “This decisionwas due to the excellent service and thequality of the products we had receivedduring the previous two years.”

From that time on, the Hahns tooktheir motor home on the road. Part oftheir focus was to reach and serviceremote, rural areas throughout the mid-west with TECO-Westinghouse elec-tric motors, while also distributingproducts to larger clients. During theremainder of 2004, Mid-Plains success-fully increased their business 750%.With their success they bought a newmotor home and turned it into a rollingbillboard for TECO-Westinghouse.

Taking the vehicle out for approxi-mately two-thirds of the year, the 38-foot motor home has become theHahn’s traveling sales room where theyconduct “on-site” seminars for cus-tomers right at the customer plants andfacilities. According to Randy, the cou-ple logs about 25,000 to 30,000 miles ayear selling motors.

This year Mid-Plains is looking todouble their sales numbers.

TORQUE REPORT 5

Repair Partners ProgramKicks Off With K.J. ElectricTWMC Debuts 7200GS

Sensorless Vector VFDThe TWMC Controls and Systems Group recently

announced the arrival of their newest product, theModel 7200GS Sensorless Vector VFD. The evolu-tionary design combines the best of the time-tested,high quality GA7200 V/HZ VFD with the latestsensorless vector control technology.

Product features of the 7200GS include a smallerpackage size, built in DC link choke, and communi-cations protocols. Sensorless vector technologyanswers the needs previously provided only by DC

drives. The 7200GS offershigh starting torque, precise

speed control without anencoder, and fast response- all hallmarks of sensor-less vector technology.These features are neededfor optimal performance inapplications such as plas-tic extruders, wood chip-pers, crushers, mixers, andoverloaded conveyors.

Ranging from 25 HP to450 HP, the 7200GS madeits debut in June 2005.

On a ROn a Rololl: Mid-Plains Bl: Mid-Plains Brings Motor Showrrings Motor Showroom to Customersoom to Customers

The Hahns of Mid-Plains Distributing in front of their 38-ft.sales room on wheels. They log 25,000 to 30,000 miles a year selling TWMC motors.

TTORQUEORQUE RREPORTEPORTOOCTOBERCTOBER 20052005

5100 N. IH-35Round Rock, TX 78681

1-800-451-8798

If you are interested in receiving futureissues of TTORQUEORQUE RREPORTEPORT, please visit

www.tecowestinghouse.com/torquereport.htmor send an e-mail to

torquereport@tecowestinghouse.com.

Continuing a legacy of support for U.S. Navy submarine operations that haslasted over a century, TWMC successfully completed factory acceptance tests andthe delivery of an advanced mission-specific motor/generator (MG) test set to

Portsmouth Naval Shipyard in July.The objective of the project was toprovide substantial enhancements intesting capabilities to directly supportPortsmouth Naval Shipyard’s (PNSY)key national defense mission.

As the oldest naval shipyard contin-uously operated by the United Statesgovernment, PNSY continues to playan instrumental role in U.S Navy histo-ry. In 1690 the first naval warship in

North America was constructed at what is now PNSY. During WWII, PNSY launchedover 70 new submarines, with four launches occurring in a single day. In the years tofollow, PNSY played a large part in U.S. Navy submarine design and development.

Portsmouth Naval Shipyard and Westinghouse enter the Atomic age together.In 1959 the USS Nautilus, the first nuclear powered vessel, entered PNSY for the

initial successful overhaul and refueling of its Westinghouse S1W nuclear reactor.Today, forty-six years later, America’s frontline defensive fleet of Los Angeles classattack submarines return to PNSY for mod-ernization, overhauling, and re-fueling.

PNSY and TWMC engineers beganworking together in late 2003 focusing onthe range of intricate technical require-ments of this project. Once all critical performance characteristics were selected,TWMC design engineers went “full speed ahead” to solve the many complex calcu-lations this new MG set would require.

The PNSY MG set, comprised of a high performance 1500+ HP, AC synchro-nous motor coupled to a state-of-the-art, ultra-high current, multi-voltage DC gen-erator, provides greater performance than previous systems supplied.

Full Throttle: Historic U.S. Naval ShipyardTakes Delivery of AC/DC MG Test Set

With load testing completed, the U.S. Navy’s newAC/DC MG Set is prepared for shipment.

To our TWMC families,friends, and customers

that have been affected bythe recent hurricanes:

We wish you comfort and peaceduring this difficult time,

and are working to re-buildour communities together.Our heartfelt thoughts andprayers go out to you.

Submarine bearthed at Portsmouth NavalShipyard on the Piscataqua River.