Baldor Energy Savings Tool Version 3.0 11/27/2018 Baldor Energy Savings Tool Version 3.0

Baldor Energy Savings Tool Version 3.0 11/27/2018 BE$T - an Overview Baldor Energy Savings Tool Version 3.0 (A software estimating tool for electric motor energy calculations.)

Baldor Energy Savings Tool 11/27/2018 Baldor Energy Savings Tool A software package designed to assist you with Formal energy audits Premium efficient motor upgrades ASD energy savings calculations Motor Management Evaluations Project quotations Quick motor nameplate data reference Includes various calculators for easy reference

BE$T 3.0 - Agenda Saving Energy Program Basics Example problems 11/27/2018 BE$T 3.0 - Agenda Saving Energy Program Basics Example problems

Part I – Saving Energy You save energy by improving the overall efficiency of the driven system. There are many energy wasters within a given system, but one component that should always be checked is the power input side or the electric motor. The BE$T program concentrates on improving the power input of the system. BE$T calculates the estimated energy that can be saved by using Premium Efficient motors and drives where applicable. Payback periods for motor efficiency upgrades are calculated and motor replacement timetables are recommended.

Why is Motor Efficiency Important? - Wasted Energy $ 11/27/2018 Why is Motor Efficiency Important? - Wasted Energy $ 10 Hp motor running at full load Measured Power in - 8,025 Watts Power out = 10 Hp x 746 = 7460 Watts Efficiency = Power Out / Power In Efficiency = 7460 / 8025 Efficiency = .930 or 93.0%

11/27/2018 What is Higher Efficiency Worth? Even a 4.5 point efficiency gain is important. 40 HP Super-E with 94.5% efficiency compared to standard motor with 90% eff. Operating 50 weeks/year

BE$T – Basic Motor Calculations 11/27/2018 BE$T – Basic Motor Calculations Annual Motor Operating Cost To find the annual operating cost of one motor (HP * .746Watt/HP * %ML * Hours * ¢/kWh) / Efficiency To find the annual operating cost difference between two motors (HP * .746Watt/HP * %ML * Hours * ¢/kWh) / {1/(Enew– Eold)} HP = horsepower 0.746 is the number of watts in a horsepower %ML – the percent motor load I.e 75%, 100% etc. ¢/kWh is the cost of one kilowatt hour of electricity Enew– Eold this equation represents the energy the difference between the energy used by the two motors. %ML = percent motor load, Hours = annual operating hours, E = efficiency

11/27/2018 Obtain Even More Energy Savings by Using Drives on Variable Torque Loads Potential Energy Savings Air conditioning 20-25% Compressors 20-25% Central refrigeration 25-35% Blowers and fans 30-35% Feedwater pumps 30-50% When a VFD is added to a variable torque loads you can expect to save approximately 20% to 50% of the energy consumed without the VFD. If the load is constant then adding a VFD would actually add additional energy cost. The only advantage would be greater control of the motor’s speed. Source: Wisconsin Center for Demand-Side Research

Where do Drive Savings Come from? Look between the curves. 11/27/2018 Where do Drive Savings Come from? Look between the curves. Typical variable torque Fan and Pump Curve The savings occur between the curves This generic graph shows a typical motor energy use curve and the curve of the energy used if a VFD was installed. The energy savings is the difference between the two curves. 160.21.1

11/27/2018 Why does this work? Variable Torque Pump and Fan Loads use the Affinity Laws, the required HP is a cubic function of rpm. 100% 75% % LOAD Fan or Pump Load Curve 50% 25% Notice at full load the energy required is the same. At 50% of motor speed the energy required to move a variable torque load is about 20% of the motor load. %Power ~ Speed3 0% 0% 25% 50% 75% 100% % SPEED / % FLOW 110.8.6

In words, using an adjustable speed drive saves energy by? Reducing the speed of a variable torque pump or fan significantly reduces the energy usage of the driving motor. The “why” can be summarized by a set of rules called the affinity rules. Flow produced by the system is proportional to the motor speed. Pressure produced by the system is proportional to the motor speed squared. Horsepower required by the system is proportional to the motor speed cubed.

An Example: A adjustable speed drive (ASD) running a variable torque load at 50% speed needs to deliver only 12.5% of the horsepower required to run it at 100 percent speed.

Not every driven system can benefit from using an Adjustable Speed Drive A constant torque system would not use a drive to save energy, but may use one for convenience. If you have a variable torque system. Look at the typical operating points or load profile of the system throughout the day to see if the system could benefit from a drive. The load profile determines the amount of energy savings that is possible. Does the system require full power all the time? Does the load on the system vary throughout the day? The load profile can be set in the program.

Load Profile - Excellent ASD Candidate 11/27/2018 Load Profile - Excellent ASD Candidate

Load Profile - Poor ASD Candidate 11/27/2018 Load Profile - Poor ASD Candidate

Load Profile - Average ASD Candidate 11/27/2018 Load Profile - Average ASD Candidate

Part II Program Basics & Many New Features 11/27/2018 Part II Program Basics & Many New Features

BE$T – Main Screen Single Motor View 11/27/2018 BE$T – Main Screen Single Motor View Select single motor view here. Inputs Preferences/Views Alternatives

BE$T – Multiple Motors View 11/27/2018 BE$T – Multiple Motors View Toggle Buttons Multiple motor buttons

1st Set the Preferences & Global Settings 11/27/2018 Global Settings

Explore the Menu – Projects dropdown 11/27/2018 Explore the Menu – Projects dropdown Menu Bar

11/27/2018 Explore the Tools Menu

11/27/2018 Explore the Help Menu

11/27/2018 Most entry fields use Dropdown Boxes to select the appropriate data. Enclosure example below. Dropdown Choices

11/27/2018 If you don’t know the existing motor’s efficiency use the built in Efficiencies table. Average efficiencies used by permission from Motor Master. Click in the Efficiency Box, this data pops up.

BE$T – Built in Repair Costs 11/27/2018 BE$T – Built in Repair Costs Average repair costs used by permission from Motor Master. Great New Feature – Rewind Cost Click in the replacement net/repair box to insert this cost

Help Button are available to explain data fields 11/27/2018 Help Button are available to explain data fields Don’t forget to use the help button if you get stuck and need an answer. Help Buttons

11/27/2018 Once the data is filled in for a motor click on the “Instant Calculation Button” to get the calculations

Instant Calculation Results 11/27/2018 Energy Used Payback Selected Motors Search Aid

Look at the Payback Months! You want “fast” Paybacks 11/27/2018 Look at the Payback Months! You want “fast” Paybacks What is Payback? The Time it Takes to Recoup the Extra Cost of a Premium Efficiency Motor by Reduced Energy Consumption ((Baldor Motor Cost – Replace/Repair Cost – Rebates) / Annual Energy Savings) * 12 Much Simpler to Determine Than Present Value Analysis (used in some energy software)

Click on the Blue catalog number to see the Motor’s Data 11/27/2018 Click on the Blue catalog number to see the Motor’s Data Nameplate data is available for all of the motors in the BE$T database. For additional nameplate information please refer to Baldor’s website at www.baldor.com .

You can choose a motors from the Potential Match List 11/27/2018 You can choose a motors from the Potential Match List BE$T sorts motors by highest efficiency then lowest List Price. You can now choose to override this basic rule and select your own motor. This list shows you all of the motors that the program could have chosen to match your requirements. The program will select the one with the highest efficiency and the least cost.

Click to calculate the cost of the entire project. 11/27/2018 For multiple motors projects selecting the “Project Cost Button” combines all motors in a project. Click to calculate the cost of the entire project.

Project Cost Analysis Results 11/27/2018 Project Cost Analysis Results The program calculates the saving of each motor in your project and displays it on the screen. Most people, if they prefer to keep the results will transfer the data to an Excel table for additional processing. Summarized Project Data Raw Data Custom Report Standard Reports

Excel Export showing Raw Data – can be imported as a new project 11/27/2018 Excel Export showing Raw Data – can be imported as a new project

Excel Export Custom Report Template, can add a customer logo 11/27/2018 Excel Export Custom Report Template, can add a customer logo

Standard Reporting of Project Summary 11/27/2018 Standard Reporting of Project Summary Click for printed reports

Standard Report Details 11/27/2018 Standard Report Details

Standard Summary Report 11/27/2018 Standard Summary Report

How add a drive to a motor? Click the ASD Checkbox 11/27/2018 How add a drive to a motor? Click the ASD Checkbox Click if Motor has an ASD

Lastly click the OK button 11/27/2018 Fill in the ASD Data Application Edit Load Profile Add ASD costs The profile shown is typical for a variable torque load. The graph is showing that this motor is running at a certain load factor for a percentage of the time. Change the load profile to match your motor or get an estimate using the generic load profile. The following slides illustrate load profiles and to evaluate if a load profile will be a good candidate for an ASD. Existing ASD? Lastly click the OK button

11/27/2018 To see the ASD graph, 1st click on Instant Cost Calculation button on the input screen then the ASD Graph Button Click Here to See Graph

11/27/2018 The ASD Graphs and data for each motors has been transferred to an Excel Spreadsheet This is two of the six graphs shown on the spreadsheet. The data tables are also shown for each graph.

Direct entry on the desktop Import an Excel file 11/27/2018 How Do you input Data? Two Methods Direct entry on the desktop Import an Excel file

11/27/2018 To Import data, go to the Projects Menu at the top of the screen and select “Import a Project” then choose a new or existing scenario.

The “Help with Importing” Button Shows an Importing Template Example 11/27/2018 The “Help with Importing” Button Shows an Importing Template Example

11/27/2018 How do I setup the Motor Management Options? These options are found on the global settings menu. Several rules of thumb are employed to establish a formal policy for the repair and replacement of existing motors. These are the: Repair/Replace HP breakpoint Repair/New Price Ratio Payback Months Policies are best established before a failure. Being prepared for and knowing what to do is a critical part of a Motor Management Plan.

Motor Management - Repair/Rewind Breakpoint 11/27/2018 Motor Management - Repair/Rewind Breakpoint

Motor Management - Payback Months 11/27/2018 Motor Management - Payback Months

Motor Management - Rewind/New Cost Ratio 11/27/2018 Motor Management - Rewind/New Cost Ratio

New Features in BE$T 3.0 - Gear and Affinity Law Calculators 11/27/2018 New Features in BE$T 3.0 - Gear and Affinity Law Calculators

New Feature in BE$T 3.0 – Add Custom Motor In multiple motor view click the “add custom motor” button Fill-in the data for motor and click “add motor”

New Feature in BE$T 3.0 – Use Net Pricing by Multiplier 1) Select “view/change project multiplier settings 3) Select Net or List Pricing 2) Add the selling multipliers

New Feature in BE$T 3.0 – Add Custom Customer Logo 1) On Tools menu – Select “Import Custom Logo” 2) Locate and Import Logo

New Feature in BE$T 3.0 – Add Custom Customer Logo 1) Logo is positioned on workspace and Excel Custom Report 2) Reposition logo as needed Logo files can be JPG, BMP, GIF, WMF

Part III Example Problems - Now a real world example. 11/27/2018 Part III Example Problems - Now a real world example. Lets look at a 5 motor project and determine: The Baldor replacement motors The potential energy saved The estimated payback months The Motor Management Plan decisions

Follow these steps create a new project. 11/27/2018 Follow these steps create a new project. Enter the new project name and save it Set the preferences and global settings Enter the data Run the project calculations Review the data Go back and tweak, possibly add a VFD Present report to customer

Create the new project name and save it 11/27/2018 Create the new project name and save it Click on the new projects menu button then select new projects.

Type in project name and press enter to save it. 11/27/2018 Name your new project Type in project name and press enter to save it.

Set the preferences and global values 11/27/2018 Set the preferences and global values 1st - Click on multiple motors. 2nd – Click on global settings button

Set preferences and global values 11/27/2018 Set preferences and global values Enter values for: Select Currency Electric Rate (cents/kWh) HZ & HP Select Efficiency tables Enter Default Motor Load Add Motor Management set points

Select the multiple motor view if not already selected 11/27/2018 Select the multiple motor view if not already selected Click Multiple Motor View

11/27/2018 Enter the data Quantity & Name Here Enter Data Here

Click here to enter next item 11/27/2018 Click here to enter next item New item button

Complete entering the following items 11/27/2018 Complete entering the following items Qty = 3 1 6 10 2

Run the project calculations 11/27/2018 Run the project calculations Click here

11/27/2018 Review Data Note that: 4 of 5 motor processed completely, no premium efficient motor for small ½ hp zone blowers. All of the motors have low payback periods. According to the Motor Management Plan – motors should be replaced with Baldor motors now and/or at failure.

11/27/2018 Review Data Click reports button

11/27/2018 Review Data - Summary Click reports button

11/27/2018 Review Data - Detailed

What happens if we add a ASD to the Chiller Pump? 11/27/2018 What happens if we add a ASD to the Chiller Pump? 2nd - Click on the ASD checkbox 1st - High light the chiller pump motor

Complete application information for the Chiller Pump? 11/27/2018 Complete application information for the Chiller Pump? 1) Select pump and control mechanism 2) Enter ASD costs Adjust load profile if necessary 3) Click OK

What happened? Recalculate 11/27/2018 What happened? Recalculate Payback months drop by 78% Standard E saving improve by $14,359 Super E saving improve by $14,051 A great deal for the customer

Sincerely, Baldor Electric Company 11/27/2018 Thank you for viewing this PowerPoint presentation of the BE$T Energy Saving Tool version 3.0 For additional BE$T program information contact your local Baldor sales representative or contact us via email at bestsupport@baldor.com. Sincerely, Baldor Electric Company