Dodge vertical gearmotors Dodge MPT Gearmotors for pumping

Dodge vertical gearmotors Dodge MPT Gearmotors for pumping applications © ABB | Slide

Dodge Gearing Since 1949 – Large reducers in tough applications © ABB 9/5/2021 | Slide 2

What is the Dodge vertical gearmotor? © ABB 9/5/2021 | Slide 3 § Integral combination of planetary gearing and high HP, low pole count induction motors § Innovative solution to provide cost effective alternative for low speed, high HP, vertical pumping applications § Sold as an integrated solution. Gearing and motor are not sold separately. § Product line covers specific range – 6 sizes § Final selection is specific to each individual application § Value proposition varies for each application

Where to consider Dodge vertical gearmotors? § Vertical applications § Low impeller speed – 100 RPM to 500 RPM § © ABB 9/5/2021 | Slide 4 4: 1 to 10: 1 ratios § High KW – 750 KW to 22, 000 KW § High torque: 62, 000 Nm to 790, 000 Nm § Where total cost of ownership is important

Example vertical pumping applications § © ABB 9/5/2021 | Slide 5 Flood Control (750 KW – 5, 500 KW)

Example vertical pumping applications Power plant recirculating water (750 KW – 7, 500 KW) © ABB 9/5/2021 | Slide 6

Example vertical pumping applications § © ABB 9/5/2021 | Slide 7 Waste water pumping (750 KW – 5, 500 KW)

Example vertical pumping applications § © ABB 9/5/2021 | Slide 8 Irrigation (750 KW – 14, 000 KW)

Example vertical pumping applications § © ABB 9/5/2021 | Slide 9 Desalinization (2, 000 KW – 5, 000 KW)

Typical vertical pump technology • Utilize low speed, high pole count, induction or synchronous motors • Typical impeller speeds of 100 – 500 RPM • Motor speed is determined by discrete # poles © ABB 9/5/2021 | Slide 10

Dodge vertical gearmotor alternative Typical Systems Vertical gearmotor Option Large high pole, low speed, synchronous motors Low pole induction motors and single reduction reducers Lower cost, high efficiency, high power factor solution, providing the exact speed required in a smaller package. © ABB 9/5/2021 | Slide 11

Vertical gearmotor advantages Utilization of standard 4, 6, and 8 pole motors Alternative to high pole count vertical motors Low pole count induction motors are less expensive than high pole synchronous or induction motors. § § © ABB 9/5/2021 | Slide 12 Typical savings of 10% to 45% depending on application. § Higher efficiency and power § Can select exact ratio required for desired output speed § Smaller and lighter – reduces support structure and facility cost § Thrust loading can be easily accommodated in reducer § Simplified maintenance and better availability § Single source and complete drive package § Can be designed with clutches for self contained soft start

Vertical gearmotor advantages Alternative to horizontal motors and right angle reducers © ABB 9/5/2021 | Slide 13 § Eliminates alignment issues between motor and reducer § Can be smaller and lighter – reduced support structure and facility cost § Higher efficiency planetary gearing vs helical and bevel gearing § Single source and complete drive package § Can be designed with clutches for self contained soft start

Vertical gearmotor – planetary gearing Design: § © ABB 9/5/2021 | Slide 14 Planetary gearing arrangement § Divides power into three paths, reducing load on individual gears § High power density § High efficiency (99%) § Double Helical type gearing for lower noise and vibration § Gear ratios selected to optimize pump speed for efficient operation

o t ha W the t as h lity uti v pro Kw / kva Useful work © ABB 9/5/2021 | Slide 15 ide Non-work producing power reqd to start and magnetize load The Importance of Power Factor § Power Factor (PF) is the ratio of real power performing useful work to the apparent power required by the equipment. § High pole count induction motors have a lower PF than low pole count induction motors - more KVA must to be delivered to the motor to supply the real power needed. § Because a utility must deliver more amperage to a customer with a low PF system, the utility will normally charge a higher rate per KW-hr if the customer has a low PF.

Vertical gearmotor advantages Select exact output speed required © ABB 9/5/2021 Motor Pole Count RPM @ 60 Hz RPM @ 50 Hz 14 514 429 16 450 375 18 400 333 20 360 300 22 327 273 24 300 250 26 277 231 28 257 214 30 240 200 32 225 188 34 212 176 36 200 167 38 189 158 40 180 150 | Slide 16 • The base speed of a motor is set by the frequency and discrete number of poles. • Use of gearing allows more flexibility in designing the exact output speed required.

Effect of impeller speed on operating point § © ABB 9/5/2021 | Slide 17 Allows for gear ratio selection that provides output speed needed to obtain Best Efficiency Point (BEP) and maximize pump performance

Reliability and maintenance effect of BEP Centrifugal pumps are designed to operate at or near the design rated conditions of head and flow (BEP). © ABB 9/5/2021 | Slide 18 § Pump operation at excess capacity (flow > BEP) and lower head create bearing and shaft seal problems. § Pump operation at reduced capacity (flow < BEP) and higher head result in accelerated deterioration and ultimately failure of the pump.

Dodge vertical gearmotor product line Product Range § 6 standard sizes § Torques range: § § Standard reduction ratios from 4: 1 to 10: 1 § § 60 k. N-m to 790 k. N-m Exact ratios designed for specific application Output speeds from ~ 100 to 500 RPM Test Stand © ABB 9/5/2021 | Slide 19

Vertical gearmotor product range © ABB 9/5/2021 | Slide 20 § Product line is sized by torque rating § HP depends on output speed with general range of § 750 KW to 22, 000 KW at 100 RPM to 500 RPM

Hydroviscous Clutch provides added benefits Controlled Start Transmission (CST) – Vertical gearmotor Functionality § § § © ABB 9/5/2021 | Slide 21 Clutch functions as a mechanical soft start § Eliminate need and costs for VFD or starting system by manually opening/closing valves. § Clutch is engaged slowly to accelerate the load at desired rate § Less surging and less vibration. Prevents water hammer. Motor starts unloaded § Utilize breakdown torque of motor. Special motor torque curves are not required. § Easier on the power grid than starting the motors under load. § Multiple starts are possible by disengaging clutch and leaving motor operating. Clutch acts as torque limiter to prevent overload damage

CST operation 2. The planet gears rotate the free-floating ring gear. 3. The output shaft is integral to the planet carrier and does not turn. 1. As the motor reaches full speed, the sun gear rotates the planet gears. 4. Hydraulic system applies pressure to the annular piston 5. The stationary and rotating plates of the clutch pack are compressed together on their free floating splines 6. This results in application of torque to the ring gear 8. Ring gear speed reaches zero, the output shaft speed will be at one hundred percent of normal operating speed © ABB 9/5/2021 | Slide 22 7. The planet carrier/output shaft increases rotational speed while the planet gears rotate about the ring

CST operation 1 - Sun Gear 2 - Planet Gear 3 - Planet Carrier / Output Shaft 4 - Ring Gear / Brake Ring 5 - Clutch Pack © ABB 9/5/2021 | Slide 23

CST – Max available starting torque w/ standard motor torque curve Breakdown torque Pull up torque © ABB 9/5/2021 | Slide 24

Centrifugal pump high starting torque example Standard across the line start Actual application example § Customer request was for 3, 750 KW @ 900 rpm motor (pump speed 127 RPM) § Pump load curve was provided by the pump manufacturer § “Standard” LAC motor design would start the pump with this load at 80% voltage § © ABB 9/5/2021 | Slide 25 Load curve remains below motor pull-up torque

Centrifugal pump high starting torque example Actual load curve was different than estimated § Required torque to continue accelerating pump exceeds motor capability at 460 rpm © ABB 9/5/2021 | Slide 26 Curve has 2 distinct portions: § Priming § Pumping § Much higher torque is required at lower, priming, speeds. § “Standard” 3750 KW motor electrical design will not start this load

Centrifugal pump high starting torque example Motor design with high pull-up torque is required Higher torque requirement at lower speeds required a special custom motor design. § Double cage § Custom rotor bar Disadvantages of required motor design © ABB 9/5/2021 | Slide 27 § Expensive and long lead time § Across the line starting has significant inrush (even at reduced voltage) generating significant heat losses in the motor § Additional heat results in limited number of motor starts per hour

Centrifugal pump high starting torque example Benefits if CST clutch were used for starting If VGM with CST clutch was used § Motor starts unloaded and reaches design speed § As clutch engages, the torque backs up the curve § Full breakdown torque is available to accelerate the pump § Motor can provide multiple starts § © ABB 9/5/2021 | Slide 28 § Less heat generated with unloaded starts § Pump can be stopped and started using clutch, without stopping motor Standard, less expensive motor can be used

PCCP project - NOLA Total system capacity …. 17 Vertical Gearmotors 41, 100 cubic meters per minute Over 55 billion liters per day © ABB 9/5/2021 | Slide 29 § Flood control project for the City of New Orleans – US Army Corps of Engineers § Gearmotors supplied: § 10 x 3, 750 KW Gearmotors – Size 5 § 7 x 1, 900 KW Gearmotors – Size 3

NOLA – PCCP project – London Ave Canal © ABB 9/5/2021 | Slide 30

PCCP project – 1800 cfs suction intake © ABB 9/5/2021 | Slide 31

PCCP project – 1800 cfs impeller © ABB | Slide 32

PCCP project – 900 cfs pump bowl © ABB 9/5/2021 | Slide 33

PCCP project – pump bowls at staging site © ABB 9/5/2021 | Slide 34

Summary Benefits versus high pole vertical motors © ABB 9/5/2021 | Slide 35 § Lower capital cost – Typically 10 % to 45% vs low speed motors. § Higher efficiency using low pole induction motors § Better power factor than high pole induction motors § Smaller physical size reduces facility requirements § Less weight reduces freight, handling and support structure costs § Optimized pump speeds through gear ratios for system efficiency. Not limited to speeds defined by number of motor poles § Simplified maintenance and better motor availability using standard 4 -6 -8 pole motors § Thrust can be accommodated by the gearbox simplifying motor design. Lower system cost

Summary Added benefits of VGM with CST clutches Minimize intake and piping damage § › © ABB 9/5/2021 | Slide 36 (controlled start reduces water hammer) § Reduce total cost of ownership § Reduce vibration with controlled start § Improve uptime, availability, and reliability § Enable start up of high torque pump with standard motor § Motor starts are unloaded – easy on power grid § Allow for multiple pump starts

Evaluation of applications VGM Value Proposition Capital Cost Trend Induction Motor Alternative Synchronous Motor Alternative § Vertical pumping applications § High power ratings - KW § 750 KW to 22, 000 KW § Low pump impeller speeds § 100 RPM to 500 RPM § Consider thrust loads § Can be accommodated by VGM § adds to value proposition Number of Poles 40 12 © ABB 9/5/2021 | Slide 37