ARC WHITE PAPER
By ARC Advisory Group
APRIL 2013
Integrated Drive Systems
What Is an Integrated Drive System? .......................................... 3
The Siemens Integrated Drive Systems ....................................... 6
Siemens Legacy as an Electrical Equipment Supplier ...................... 9
Business Issues Faced in Absence of an Integrated Drive
System Offering ..................................................................... 12
Mining Industry Benefits of Integrated Drive Systems .................. 15
Oil & Gas Industry Benefits of Integrated Drive Systems .............. 17
Cement Industry Benefits of Integrated Drive Systems ................ 18
Last Word ............................................................................. 21
VISION, EXPERIENCE, ANSWERS FOR INDUSTRY
ARC White Paper • April 2013
VSD
Motor: 6000HP, 1800RPM, 6kV, TEWAC
Gear:
Rated speed 1785/6761 RPM
Coupling
Base Plate
Integrated Drive Systems
Single purchase order for entire drive system; streamlined processes
Coordinated delivery times across multiple products
Custom service contracts and extended warranty options
Technologically innovative products and processes from a single source
Matched engineered components
Time to market, development and implementation efficiency
Highly flexible, complete process and customer-oriented solutions
Optimized design efficiencies
Engineered systems built from a comprehensive range of components
Systems responsibility
Streamlined Business Process Benefits of
Integrated Drive Systems for EPCs, OEMs and End Users
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ARC White Paper • April 2013
What Is an Integrated Drive System?
Drive train is a term widely used
referring to a combination of
electric drive, motor, gearbox,
and coupling which transfers
electrical energy to a rotating
part of machinery. This paper
will focus on drive trains in the
mining, cement, and oil and gas
markets.
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ARC White Paper • April 2013
Drive Trains Are Engineered Solutions Often Posing
Huge Challenges
Reducing Risk and Cost of a Drive Train Implementation
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ARC White Paper • April 2013
Siemens Integrated Drive System Components
Maximize ability to customize
products/solutions to meet my specs
(operational effectiveness)
Optimized components designed to work
together (operational effectiveness)
Maximize speed of implementation
(simplification of the process)
Minimize installation downtime (efficiency)
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ARC White Paper • April 2013
The Siemens Integrated Drive Systems
Integrated Drive System
Team Approach
Expert Consultation
Pre-tested
Installation
Maintenance
Customization
Purchase Order Process Streamlined
Optimal Design Configuration
Warranty administration
Single point of contact
Logistics management
Operation and Engineering Center (OEC)
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ARC White Paper • April 2013
Operations and Engineering Center Support of
Integrated Drive System Project
Project Management
Adjustable Frequency Drives
(low voltage, medium voltage, DC)
SIMOTIC Motors (AC Induction, DC)
Gearbox Units
Mechanical Couplings
Siemens Integrated Drive Systems Offering
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ARC White Paper • April 2013
Siemens Provides Critical Technical
Overview Necessary for IDS
Evaluating direct online vs. VSD starting for
energy efficiency, cost, and performance
Optimizing economic, efficiency, and reliability for specific application
Provide comprehensive diagnostic tools for
entire drive train
Optimization with ‘what if’ scenario
Modeling analysis
Thermal analysis of a system
Torsional analysis
Resonance points
Load dynamic analysis
Appropriate method of cooling gear units to
prevent overheating
Flexibility requirement in coupling to avoid
vibration
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Value Derived from a Global Base of
Proven Products
ARC White Paper • April 2013
Siemens Legacy as an Electrical
Equipment Supplier
Electric Drives
Technology
Product Family
Max
Power
Range
Low Voltage AC Drives
SINAMICS S120, S150, G130, G150,
G180
4.5 MW
Medium Voltage AC Drives
SINAMICS GM150, SM150, GL150,
SL150 GH180
85 MW
DC Drives
SINAMICS DCM
2.5MW
Siemens’ Variable Speed Drive Portfolio
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ARC White Paper • April 2013
Electric Motors
Technology
Product
Family
Max
Power Range
General
Purpose AC
SIMOTICS GP
200 HP
Severe Duty AC
SIMOTICS SD
1,650 HP
Trans-standard for harsh conditions
SIMOTICS TN
1,650 HP
Definite
Purpose AC
SIMOTICS DP
1,650 HP
Explosion
Protected AC
SIMOTICS XP
1,350 HP
DC Motors
SIMOTICS DC
2,150 HP
Large Custom Motors & Generators
Multiple Product Families
100,000 HP
High HP
Engineered
Motors
2,950-136,000 HP
Geared Motors
SIMOGEAR
260 HP
The Siemens Global Motor Portfolio
Note: Engineered solutions available in higher power rating
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ARC White Paper • April 2013
Flender Acquisition Complements the Core Business
Helical / Bevel Helical Gear Units
Vertical Gear Units
Planetary Gear Units
Geared Motors
The Siemens Flender Brand
Mechanical Drive Types
Mechanical Drives and Coupling
Flexible
Highly Flexible
Hydrodynamic
Torsionally Rigid
Types of Coupling
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ARC White Paper • April 2013
Business Issues Faced in Absence of an
Integrated Drive System Offering
High Power Drive Trains Are Custom Engineered
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ARC White Paper • April 2013
Unifying Order Management across the Drive Train
Opportunities to Optimize the Design
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ARC White Paper • April 2013
Integration Challenges Faced
Service and Repair
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ARC White Paper • April 2013
Mining Industry Benefits of Integrated
Drive Systems
Revenue and Capital Expenditure Index of the
Mining and Metals Industry;
Source: ARC CapEX Index
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ARC White Paper • April 2013
Conveyors
Gearless Conveyors
Horizontal mills
Vertical mills
Crushers
Grinding rollers
Water/slurry pumps
Draglines
Mining trucks
Mining Shovels
Mining Industry
Applications
Combustible
Corrosive
High temperature
High degree of condensation
High elevation
IDS Designed for Mining
Industry Environment
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ARC White Paper • April 2013
Oil & Gas Industry Benefits of
Integrated Drive Systems
Offshore/Onshore Drilling and
Production
Gas/Liquid Pipeline
LNG
Gas Storage
Refining
Petrochemicals
Oil & Gas Industry Applications
Examples
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ARC White Paper • April 2013
Cement Industry Benefits of Integrated
Drive Systems
Industry
Energy Cost
Variable Cost
1995
2010
Automotive
2%
5%
Cement & Glass
9%
21%
Chemical & Petrochemicals
5%
11%
Food & Beverage
2%
5%
Mining & Metals
22%
50%
Oil & Gas
6%
14%
Pharmaceutical
4%
9%
Pulp & Paper
4%
9%
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ARC White Paper • April 2013
Crushers
Roller presses
Vertical mills
Tube mills
Rotary kilns
Separators
Bucket elevators
Conveyor belt
Fans
Cement Industry
Applications
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ARC White Paper • April 2013
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ARC White Paper • April 2013
Last Word
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ARC White Paper • April 2013
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ARC White Paper • April 2013
Analysts: Himanshu Shah, Salvatore Spada
Acronym Reference: For a complete list of industry acronyms, please refer
to www.arcweb.com/research/pages/industry-terms-and-abbreviations.aspx
AC
Alternating Current
ASD
Adjustable Speed Drive
MV
Medium Voltage
DC
Direct Current
MW
Mega Watt
MMDC Main Motor and Drive Contractor
EMPP Electrical Motor and Two
Planetary Gears
OEC
Operations & Engineering Center
OEM
Original Equipment
EPC
Engineering, Procurement and
Construction
PLM
HP
Horse Power
ROI
Return on Investment
RPM
Revolutions per Minute
HVAC Heating, Ventilation, Air
IDS
Manufacturer
Product Lifecycle Management
Conditioning
SITRAIN Training for Industry
Integrated Drive System
TCO
Total Cost of Ownership
LC-I Load Commutated Inverter
VFD
Variable Frequency Drive
LNG
VSD
Variable Speed Drive
Liquid Natural Gas
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All information in this report is proprietary to and copyrighted by ARC. No part
of it may be reproduced without prior permission from ARC. This research has
been sponsored in part by Siemens. However, the opinions expressed by ARC
in this paper are based on ARC's independent analysis.
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