Solutions for every requirement:
Continually achieving higher productivity
pumps
fans
COMPRESSORS
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Pumps, fans, compressors:
For industry, building systems - and your added value
No matter how diverse the requirements may
be - you‘ll always find the optimum product
in our extensive portfolio for pumps, fans and
compressors
Whether in ventilation and refrigeration systems or when pumping liquids:
Take advantage of the value added and new potential for increasing efficiency:
III Higher productivity, higher degree of cost-effectiveness - with a unified, integrated
product portfolio and comprehensive solutions
III Lower operating costs - by minimizing the energy requirement
III Improved plant and system availability - based on the highest product quality,
reliable support from a single source and fast spare parts service
III Complete security for your investment - due to a tailored set of services, including
training courses
III New possibilities for making changes and expanding - using a scalable portfolio
and modular system components
Tailored solutions for the widest
Water and wastewater,
… building systems,
… chemical industry,
range of industry sectors
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Perfectly functioning pumps, fans and compressors are absolutely essential in all of these areas. Without these technologies, it would neither be possible to pump oil from Siberia to
Central Europe nor would climate control systems be conceivable.
No matter how different the requirements and conditions
may be for the various applications, the focus always remains
the same: To implement the pump, fan or compressor application as efficiently as possible. Today, autonomous products would no longer be sufficient. Furthermore, the
prevailing constraints must be taken into account and
optimally utilized. To achieve all of this you require a partner
that can extensively support you in all areas:
III with all of the drive and automation products for pumps,
fans and compressors from a single source
III with competent and extensive support
III with fit-for-the-future customer-specific concepts and
focused engineering support when dimensioning the
drive system
We are this partner.
Advantages for the machinery construction OEM
III High level of cost-effectiveness through an excellent priceperformance ratio
III Products and systems are available worldwide through global
customer support
III Components can be selected in a user-friendly way using a
standard set of tools
III Maximum efficiency and lifetime based on innovative drive
and automation products from a single source
III Products and systems tailored to the application
III Simple and fast installation and commissioning through a set
of standard engineering tools
Pumps | Fans | Compressors
Universal use – a whole range of advantages
They often go unnoticed - however, pumps, fans and compressors are of decisive importance in many areas of our
day-to-day life. Day in and day out we rely on their reliable
function - to ventilate and supply buildings or supply drinking
water and remove wastewater. The same goes for the chemical industry, for example in the production of mineral oils
and plastics - or in the pharmaceutical industry. They also do
important service in energy supply - presently a current issue
around the world.
Advantages for the plant operating company
III Minimized operating costs by implementing energy-saving
concepts
III High degree of cost effectiveness through products and
systems with an outstanding lifetime
III Lower noise levels due to low-noise drive systems
III Full transparency as a result of numerous diagnostic
functions in products and systems that are harmonized and
coordinated with one another
III Maximum security for the future as a result of the long-term
availability of spare parts
Whether machinery construction OEM or plant operating company: Everybody involved profits from our extensive ongoing training programs and the possibility of being able to integrate the widest range of components in the Totally Integrated Automation environment.
… food & beverage,
… pharmaceutical
... textiles and printing machines
… as well as oil & gas
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Pumps - activate efficiency
Requirements placed on pumps:
Pumps are used in many industrial sectors - whether in the chemical,
pharmaceutical, food & beverage industries, textiles, paper, mining, water
and wastewater. Here, they pump or compress the widest range of liquid or
gaseous media. Slow and high-speed pumps must be driven – and reliable,
disturbance-free and quiet operation is always decisive.
It is also important to save energy by using high–efficiency motors and drive
inverters with adapted magnetic flux.
Centrifugal pumps
Oscillating pumps
Rotary pumps
Centrifugal pumps are pumps to
increase the energy using a rotating
impeller.
Reciprocating pumps are used to pump
liquids and gases.
Rotary positive-displacement pumps are
mainly used to transport plastic masses
and dispersions.
III
III
III
III
III
Rotating accelerators
Submersible motor pumps
Side-channel pumps
Non-clogging pumps
Centrifugal pumps
(single or multi-stage)
III Dosing pumps
III Radial piston pumps
III Axial piston pumps
III
III
III
III
Eccentric worm pumps
Gear pumps
Screw pumps
Impeller blade cells
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Fulfill requirements – and how you profit from our products
Requirements placed on pressure boosting units
In a piping system that comprises several pumps and possibly a higher-level control, the pressure boosting unit ensures that a constant pressure is reliably maintained even when the demand fluctuates.
Pumps
III A dry running protection function is integrated in the drive inverter - this
means that a sensor can be eliminated
III Pressure surges in piping systems are minimized using soft starting and
stopping
III Low cavitation due to intelligent drive inverters
III Automatic restart after a power failure
III Critical speeds are suppressed
III Pump units can be cascaded for pressure boosting systems
III Energy-saving mode in controlled operation
III Energy-saving potential through:
– high efficiencies of EEF1 and EPAct motors
– the speed can be adapted using drive inverters that can be used to
continuously raise and lower the pressure
Solution: Products for pressure boosting units
For a pressure boosting unit, our products - that are perfectly harmonized
with one another - ensure the necessary drive. In addition to powerful motors
and drive inverters we can also offer you our compact Micro-PLC SIMATIC S7-200.
This PLC allows you to implement tailored automation solutions that can be
quickly and simply supplemented.
Pressure boosting unit
1LA 8 motor
SINAMICS G150/G130
3RW44 SIRIUS soft starter
SIMATIC S7-200
SITRANS pressure transducer
Flender couplings
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Fans - ensure a fresh breeze
Requirements placed on fans:
Fans are used in the widest range of industrial sectors - whether in building
systems, for water and wastewater, chemical, pharmaceutical industries, oil
& gas industries, paper and mining. Fans move atmospheric air. High energy
efficiency and low-noise operation are important parameters. The power
demand of a fan increases to the square of the speed which means that
they have special characteristics that must be taken into account.
Radial fan
Axial fan
The air is drawn-in in parallel to the
drive axis, deflected through 90° by the
rotation of the rotor and then radially
discharged.
The rotor axis runs in parallel to the
airflow.
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Fulfill requirements - and how you profit from our products
Requirements placed on air handling systems
Air handling systems are responsible for distributing and regulating the air in
buildings and industrial plants. They include all of the fans for the air intake
and discharge, heating and cooling equipment, heat exchangers, filters as well
as air de-humidifiers and air humidifiers.
Fans
III Energy-saving potential through:
– high efficiencies of EEF1 and EPAct motors
– the speed can be adapted using drive inverters that allow the pressure
to be continuously raised or lowered
III Automatic restart after a power failure
III Flying restart to connect to a spinning motor
III Critical speeds can be suppressed
III V-belt monitoring function integrated in the drive inverter
Solution: Products for air handling systems
Specifically designed for use with fans and blowers, our optimally harmonized
products secure a perfect room climate. Powerful, high performing motors and
drive inverters interact perfectly with the control systems, switchgear, flow
measuring systems and sensors.
Air handling system
1LG6 motor
MICROMASTER 430
SIMATIC ET 200S motor starter
3RW44 SIRIUS soft starter
LOGO!
SITRANS temperature sensor
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Compressors - increase productivity
Requirements placed on compressors
Compressors are used in a wide variety of applications whether climate
control and refrigeration systems, chemical and pharmaceutical industries,
water and wastewater, general machinery construction, food & beverage
industry, mining and paper. Their task is to pump and compress gases with
pressures that can reach almost any magnitude. In addition to fulfilling
general requirements regarding the efficiency - availability and a high
power density are decisive factors.
Refrigeration compressors
Air compressors
Gas compressors
Refrigeration compressors are used to
compress the cooling medium in refrigeration systems to maintain rooms at
certain temperatures and for refrigerated display cabinets and chilled distribution depots.
Air compressors are used for ventilation systems, pneumatic controls and
transport of solids, liquids and gases,
industrial production facilities, bottle
blowing, air for breathing and medical
applications.
Gas compressors are used in the basic
materials and process industries - e.g.
for air separation plants, blast furnace
blowers and ammonia plants. Furthermore,
they are also required for gas liquefaction
and when pumping gas.
III Scroll compressor
III Reciprocating compressor
III Screw compressor
III
III
III
III
III
III Reciprocating compressor
III Radial compressor
III Axial compressor
Roots blower
Side-channel blower
Rotary compressor
Reciprocating compressor
Screw compressor
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Fulfill requirements - and
how you profit from our products
Requirements placed on chillers
Chillers - comprising a compressor, condenser, relief valve and heat exchanger
- are refrigeration machines that are used in the area of climate control for
buildings. Here, they produce the cold water for the air conditioning systems.
Solution: Products for chillers
Our perfectly harmonized products ensure the necessary low temperatures
when operating chillers. Powerful motors and drive inverters interact
perfectly with the controls, switchgear, flow measuring systems and sensors.
Compressors
III Energy-saving potential through:
– high efficiencies of EEF1 and EPAct motors
– the speed can be adapted using drive inverters that can continuously
raise or lower the pressure
III Manufacture of customized hermetic or semi-hermetic motors
III Reduced inrush current for increased starting torque using special
winding designs
III Reliable filter monitoring by sensing the differential pressure
III Precise pressure monitoring using control and sensor systems
III The optimum operating point of the compressor can be set using the drive
inverter. A high dynamic response when critical states are encountered is
guaranteed using a high overload capacity
Chiller
1LE1 motor
1PK3
SINAMICS G110
3RW40 SIRIUS soft starter
SIMATIC S7-200
SITRANS pressure transducer
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Flexible use - individual design
Compressors
Pumps/fans
Drive converter
Touch panel
Touch panel
Drive
converter
Contactor
combination
Contactor combination
Pressure sensor
Coupling
Pressure sensor
Pressure sensor
Distributed, conventional
Coupling
Geared motor
Geared motor
Distributed, conventional
1
No matter whether standalone pumps, fans and compressors
are required - or solutions as part of a complete plant or
system: We can provide you with a complete product portfolio to give you a high degree of flexibility regarding your
2
1 Typical compressor situation
2 Fans installed on a roof
pumps, fans and compressors. We can offer you products
that are optimally harmonized with one another - including
our motors, geared motors, drive converters, motor starters,
soft starters, switchgears, transformers and reactors. We also have
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Compressors
distributed
Pumps/fans
central
Touch panel
distributed
SIMCODE pro
Drive
inverter
SIMCODE pro
Drive
inverter
Contactor
combination
Contactor
combination
Drive
inverter
Contactor
combination
Pressure sensor
Coupling
Pressure sensor
Pressure sensor
Distributed on PROFIBUS/PROFINET
Coupling
Pressure sensor
Geared motor
Geared motor
Central on PROFIBUS/PROFINET
1
controls, I/O products, software and devices for communication, operator control and visualization as well as sensors.
No matter whether you prefer central or distributed solutions,
whether you conventionally hard wire the components - or
Coupling
Geared motor
Geared motor
Distributed on PROFIBUS/PROFINET
2
1 Complex plant with compressors connected
in series
2 Plant with pumps connected in series
use fieldbus systems: We also have the optimum products
and systems for your application.
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Totally Integrated Automation
ERP – Enterprise Resource Planning
Ethernet
Totally Integrated
Automation
MES – Manufacturing Execution Systems
SIMATIC IT
Ethernet
PROFINET
Industrial
Ethernet
SIMATIC PCS7
Process Control (DCS)
SIMATIC HMI
Human Machine
Interface
SIMATIC Controllers
Modular/Embedded/
PC-based
SIMATIC
Distributed I/O
SIMATIC
Sensors
Safety Integrated
SIMATIC NET
Industrial
Communication
SIMOTION
Motion Control
System
SINUMERIK
Computer
Numeric Control
SINAMICS/
Drive Systems
Industrial Controls
and Power
Distribution
Industrial Software
for
• Design and
Engineering
• Installation and
Commissioning
• Operation
• Maintenance
• Modernization
and Upgrade
Control
Process
Instrumentation
PROFIBUS
AS-Interface
KNX / EIB
GAMMA instabus
Totally Integrated Automation: The higher-level philosophy for pumps, fans and compressors
With Totally Integrated Automation (TIA) we offer our customers a standard and unique range of products and services for process and factory automation – including of course applications involving pumps, fans and compressors.
All of the sub-steps as well as also the information flow across all product levels - from the field level up to the company supervisory level - can be fully integrated. This means more productive engineering, efficiency and a higher
degree of profitability across all processes.
Because of the consequential integration and unification, Totally Integrated Automation also plays a significant role in
minimizing costs over the complete lifecycle - and reduces the complexity of industrial plants and systems.
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Comprehensive - our portfolio at a glance
Motors
Our motors cover voltages from 230 V
to 13.2 kV, power ratings from 0.06 kW
to 100 MW - and therefore every conceivable pump, fan or compressor application. Our standard motors are extremely
energy-saving and reduce the stressing
on the plant as a result of the increased
efficiency according to CEMEP EFF1 and
EPAct. They are available up to 690 V
for line supply and converter operation.
The pump motors with locating bearing
on the drive side and integrated PTC
thermistors guarantee a high degree of
availability. Depending on the type being
used, compressor motor service factors
of up to 1.25 are possible. Standard fan
and blower concepts can be realized as
a result of the unified, noise-optimized
and separately-ventilated 1 PP series of
motors with power ratings from 0.09 to
200 kW. The bearing design distinguishes
itself as a result of the excellent vibration
characteristics, a long lifetime and low
maintenance costs. An additional cooling
circuit inside the trans-standard motors
ensures a uniform temperature distribution. This reduces the thermal stressing
and increases the operational reliability.
The highest efficiencies can be achieved
with our broad portfolio of reliable Siemens/Flender geared motors. Their use
is especially effective at low speeds from
0.1 to 1000 rpm as well as when high
torques are required. The reason for this
is not only that they are equipped with
energy-saving motors, efficiency Class
EFF2 or EFF1, but also because they offer
a wide selection of application functions.
Their modular design as well as various
types of construction and mounting
versions ensure the highest degree of
flexibility - and they can be optimally
combined with SINAMICS drive converters and SIRIUS motor starters. We can
offer you extensive application know
how to simplify your engineering and
installation.
Flender couplings set quality standards.
Whether as standard coupling from a
wide modular portfolio or as special
coupling adapted to the particular
application - our engineers select the
optimum solution for your particular
application. In the torque range from
15 - 1.500.000 Nm, our standard
range of couplings fulfills ATEX95 and
API 610/671 requirements as well as the
requirements of various Classification
Societies such as DNV or GL. References
throughout the world confirm our
competence as global partner. We are
always close to our customers worldwide
due to our service and supply network
and our professional support.
Geared motors
Couplings
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Drive inverters
Motor starters
Our communications-capable SIRIUS
motor starters are the right choice when
it comes to controlling, protecting and
starting motors. Direct, reversing and
soft starters cover the complete range
- from a high number of switching operations for pump applications without
pressure reservoir up to soft starting of
large fans. Whether centrally installed
in the control cabinet or directly in the
field - our motor starters have optional
We can offer you drive inverters for every requirement to address future-orientated drive
concepts - with simple prompted commissioning using standard tools. For instance
MICROMASTER 420, 440 and for pump drives
with the energy-saving mode of the 430 version. SINAMICS G110 drive converters are especially suitable for basic applications in the lower
power range. SINAMICS G120 drive converters
are admirably suited for fan and blower systems up into the medium power range. They
have a modular design comprising Control Unit
and Power Module and are also available as versions that are capable of regenerative feedback
into the line supply.
SINAMICS G130 chassis units and SINAMICS
G150 cabinet units are tailored to single-motor
drives with a high power rating that do not require regenerative feedback into the line supply
- for example, for pumps, fans and compressors
from 75 to 1500 kW. SINAMICS SM and GM
continues the G150 range from 0,8 MW to
25 MW in the medium voltage range. Further,
with ROBICON Perfect Harmony we also offer
transformer, power section and closed-loop
control in a compact unit - up to 100 MW.
SIMATIC ET 200S FC is fully integrated in the
SIMATIC control environment as distributed
drive for more complex plants and systems.
integrated intelligent monitoring functions including preventive maintenance
as well as Safety Integrated functionality. From simple contactor/circuit-breaker
combinations through pre-wired load
feeders and encapsulated compact starters up to motor starters for the distributed SIMATIC ET 200S and ET 200pro
I/O - all our motor starters are especially
space-saving and can be quickly mounted.
Soft starters
Low-voltage soft starters are used
wherever the particular application
requires soft starting and/or stopping –
i.e. when the motor cannot start with its
full power. For instance our SIRIUS 3RW
soft starters are the ideal solution for
heating blowers, to prevent belt slip or
in washing systems to avoid water pres-
sure surges (water hammer). Further,
they prevent unpleasant secondary
effects such as subjecting the machine
to high mechanical loads or causing
voltage dips in the line supply.
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SIMOCODE pro is the flexible, modular
motor management system for lowvoltage constant-speed motors. It is
preferably used to protect and control
pumps, fans and compressors. It can be
simply and directly connected to higherlevel automation systems via the
PROFIBUS DP interface. From a functional perspective it addresses all of the
requirements between the motor feeder
and automation system. It combines all
of the necessary protection, monitoring
and control functions for every motor
feeder in just one compact system. The
range of functions extends from simple current, voltage and power sensing
through detection of the direction of
rotation or drive belt slip or breakage.
Other functions include monitoring the
pump for dry running operation, filter
dirt and monitoring the flow or filling
level. Furthermore, the system can be
flexibly expanded by digital ground fault
and temperature modules.
Whether compact time relays or reliable
monitoring relays, especially low profile
interface relays, plug-in relays, lownoise power relays or interface converter
- SIRIUS relays have everything for your
motor feeder. As a result of the display,
freely selectable limit values and many
parameterization possibilities, our relays
ensure optimum line supply, load and
application-related setpoint monitoring
and higher plant and system availability.
The user-friendly range of relays offers a
multitude of diagnostic and monitoring
functions and can be used for the widest
range of applications: To monitor the
line supply of permanently installed and
transportable equipment - such as HVAC
compressors, refrigerated containers,
cranes or compressors on construction
sites. They can also be used to monitor
loads connected to the motor - for instance to detect when the pump is running under no-load conditions.
We can offer you everything for an efficient and integrated power distribution
system based on Totally Integrated Power. This includes SIVACON switchgear
and busbar distribution systems, SENTRON
circuit-breakers and load disconnectors
as well as the matching software package.
Our communications-capable circuit-
breakers, the SIMATIC Power Control
power management software and the
state-of-the-art SIMOCODE pro motor
management system are integrated
into Totally Integrated Automation - our
unified basis to implement customized
automation solutions.
Products
Motor management system
Relays
Power distribution
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Transformers, fans, reactors, filters and power supplies
SIRIUS transformers ensure the right
voltage for every situation. Whether in
industrial or production machines, marine, plant or control panel building - our
single or three-phase transformers <
16kVA according to EN 61558 combine
all of the properties and features of safety, isolating, control and line transformers. The complete series of types
have been certified for use in the US and
in Canada. Further, our single and threephase SIRIUS power transformers < 16
kVA can be used worldwide. Not only
this, with our SIRIUS power supplies we
can offer a complete range of products
that have been internationally certified.
SIDAC reactors and filters - either in a
standard or customized version - smooth
current and suppress noise signals with
supreme confidence. And our SIVENT
fans reliably ensure that electrical machines and systems are cooled, are used
to cool power transformers in power
stations and are also used in washing,
automobile washing and dust removal
technologies as well as in industrial furnace, shipbuilding and rail vehicle construction.
Controls, I/O, software
SIMATIC controllers stand for the highest degree of flexibility and scalability
- with standard or fault tolerant controllers, compact devices, distributed or
PC-based automation solutions. SIMATIC
Technology is available in different
mechanical formats to cost-effectively
address your technological tasks such
as counting, measuring, cam control,
closed-loop control and motion control:
From loadable software blocks through
technology controllers up to control systems. In order to guarantee the safety of
man and machine, the SIMATIC Safety
Integrated fail-safe system is embedded
in the standard automation.
Further, with SIMATIC Software we
can offer you a universal configuring
and programming environment for
SIMATIC controllers, including operator
control and visualization systems.
SIMATIC fully supports your engineering
workflow with the STEP7 basis package
and numerous engineering tools.
The modular family of SIMATIC ET 200
remote I/O permits distributed solutions
to be configured - e.g. also for pumps,
fans and compressors: Compact or
modular, with digital I/O interfaces or
complete distributed systems with drive
technology - either in the control cabinet
or directly installed in rugged industrial
environments.
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Connections can be very simply configured within the scope of Totally Integrated Automation - also via different
networks and all systems.
In order to transition from PROFIBUS to
Ethernet or vice versa, only the communications processor has to be replaced
- without having to make any changes or
modifications to the user program and
without incurring any additional engineering costs. SIMATIC NET offers solu-
tions for every requirement for open and
integrated industrial communication:
III PROFIBUS - the recognized standard
for the field area
III PROFINET - the international Ethernet
standard for real time communications
down to the field level
Products
Communication
Operator control and visualization
SIMATIC HMI offers a finely graduated
range of products for operating devices
and visualization software for machinerelated operator control and monitoring
up to scalable SCADA system for the
widest range of requirements in process
visualization.
Pressure Transducers
SITRANS P, series Z are compact single-range measuring devices for gauge
and absolute pressure measurement.
SITRANS P ZD is a configurable pressure
transducer with a display. It is available
with either radial or axial connection to
the process. Both series are suitable for
measuring pressure and absolute pressure of gases, liquids and steam. They dis-
tinguish themselves with the high
long-time stability, low deviation from
the characteristic, wide measuring
ranges as well as with stainless steel
or ceramic membrane and with solid
stainless steel connections and casing.
On the other hand, SITRANS T opens
up the complete range of temperature
transducers and sensors.
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Our portfolio in the field:
Tailored products for manufacturers of pumps,
fans and compressors
Enhanced functionality for pump manufacturers
Challenge
An international pump manufacturer wanted to have a
better integration of the motor in the pump. In this case
the task was to design the pump cover so that it simultaneously acted as motor flange – allowing the overall length
of the unit to be significantly reduced. Additional requirements included the possibility of using the widest range of
media and mounting an inverter integrated in the motor.
Solution
A special bearing plate and a special shaft to hold the
impeller were used for the pump geometry. Further, a seal
was inserted between the pump and motor space in a
special bearing end plate. The pump can be used for
pumping different media as a special coating is applied to
the aluminum and grey cast iron bearing endshields. The
inverter was able to be integrated in the motor by using a
specially designed adapter on the motor terminal box.
Advantages
III Significantly shorter length, therefore the coupling and
coupling cover were able to be eliminated
III Compact unit in conjunction with the required
electronics
III Significant energy saving by simply adapting the
operating point using the inverter integrated in the
motor
III The number of spare parts was significantly reduced as
a result of a lower number of components
International
pump manufacturer
Motors for refrigeration compressors for chiller manufacturers
Challenge
A globally active chiller manufacturer wanted a new motor
series that could operate perfectly in a cooling medium
(refrigerant) for semi-hermetic refrigeration compressors
that are used to cool technical processes, climate control
systems and foodstuffs. A winding that is resistant to
refrigerants (e.g. Freon) using a special impregnation, high
production precision, intensive cooling and low residual
humidity were specified. Further it was necessary to
completely fulfill the specifications when starting the
compressor.
Solution
A separate production line guaranteed that the increased
production requirements could be reliably fulfilled. Special
resins secure the required immunity to refrigerants.
Further, a special packaging ensured that the residual
humidity is kept to a minimum. The newly developed
starting winding permits a higher starting torque with
reduced starting current. And extensively optimized motor
cross-section opened up additional advantages.
Advantages
III Long lifetime using reliable, UL-certified products
based on tested components
III Worldwide availability of the necessary parts and
components and competent support from a single
source
III Reduced starting (inrush) current with increased
starting torque using a special winding design
Leading
chiller manufacturer
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Variable-speed pump drives for the state water utility in Baden-Wuerttemberg
Challenge
The state water utility of Baden-Wuerttemberg (LW) is one
of the largest long distance water supply utilities in Germany. More than three million people are supplied with drinking water through a long distance network of pipes extending over 770 km. The ground water capture locations
must be flexibly operated to maintain a high quality of the
drinking water supply. This means that every water capture
location must be able to precisely supply the water quantity
that is required for the correct mixing ratio and therefore
the optimum drinking water quality.
Solution
In order to be able to flexibly and efficiently manage its
ground water capture locations the water utility company
uses variable-speed pump drives. Reliable SINAMICS G150
drive converters that are simple to handle control the pump
speed. These drive converters are integrated into the central supervisory control system through existing SIMATIC S5
controls.
Advantages
III More precise closed-loop flow control and shorter
response times less mechanical control concepts
III Significantly less energy is required
III Operation that reduces stress on the mechanical
equipment - operator-friendly concept with a clear,
transparent structure
III More space in the control room by using a more
compact design
III The pump system is controlled via the central control
room by seamlessly integrating it into the existing
automation environment
References
Solutions for pumps
State water utility,
Baden-Wuerttemberg
Sophisticated filter for the Mongstad refinery
Challenge
Liquid propane gas is stored in the Mongstad refinery located on the west coast of Norway. From there it is pumped
into tanker ships. The variable-speed pumps operate completely immersed in the propane gas – which places high
demands on the drive converters being used. Not only do
they have to be extremely reliable, but they also have to be
perfectly harmonized with the special motors integrated in
the pump – and they must provide an especially clean sinusoidal output voltage.
Solution
The drive converter cabinet was equipped with an IHV
(Integrated High Voltage) filter to ensure disturbance-free
operation of the 6 kV special motors immersed in the
propane gas caverns. These filters generate an almost
sinusoidal 6 kV output voltage - without current and voltage spikes - from the pulsed 2.3 kV output voltage of the
voltage source DC link converter.
ws_pumpen_luefter_GB.indd 19
Advantages
III High availability through safe and reliable operation of
the special submersed motor
III Compact design as a step-up transformer and maintenance-intensive mechanical reactors are eliminated
III Pressure surges are avoided and energy is saved as a
result of the variable-speed operation
Mongstad refinery
24.11.2006 14:59:49 Uhr
Even more successful case studies:
Solutions for fans
Challenge
The Anshan steel plant is the third largest in China. In order
to keep its blast furnaces running each blower must move
huge quantities of air – and more precisely 460,000 m2/h.
As it is generally the case for blast furnaces, the blowers
are only started every four to eight weeks after the blast
furnace has been inspected. When starting, the huge drive
must be carefully ramped-up in a controlled fashion in order to avoid dangerous electrical or mechanical load peaks.
Solution
The blast furnace blowers are equipped with rugged 42 MW
synchronous motors and medium-voltage drive converters.
Using these starting converters, the motor can be started
from standstill in between one and two minutes and then
connected to the line supply. The transition is bumpless – and
the starting converter ensures that the start is especially safe
and reliable. If a start attempt is unsuccessful - for example
due to a brief voltage dip while starting - then a new start
attempt can be immediately made without incurring any
damage.
References
Powerful starting converter for the Anshan steel plant in China
Advantages
III Less wear and longer lifetime of the components
III With over 99% a significantly higher quota of
successful starts
III Harmonized, almost maintenance-free motor-drive
converter system
III Maximum plant availability
Anshan steel plant
Fresh air blower and induction blower for a biomass heating station in Illmenau
Challenge
A biomass heating station generates environmentallyfriendly power and heat from old wood for Illmenau located in the forest of Thuringia, Germany.
For the combustion process in the biomass boiler, fresh air
must be fed in using fans and the smoke that is generated
during the combustion process must be drawn-out using
induction blowers.
Solution
In order to be able to precisely control the combustion
process with short response times but at the same time
keeping operating costs low, the fresh air fan and the induction blower are equipped with variable-speed drive
systems. MICROMASTER 440 drive converters control the
speed of the fresh air fans that have smaller power ratings.
SINAMICS G150 frequency converters are used for the induction blowers. The drive systems are coupled to the higherlevel automation system through a SIMATIC S7-400. The
SIMATIC WinCC process visualization system ensures the
required level of transparency for the complete plant.
Advantages
III More precise control of the air feed and discharge
when compared to mechanical control concepts
III Significantly lower energy consumption
III Operation with low stress on the plant - simple
commissioning and handling
III More space in the control room through a more
compact design
III Optimum process visualization and operator control
functionality via the central control room as the new
system is seamlessly integrated into the existing
automation environment
Biomass
heating station
20
ws_pumpen_luefter_GB.indd 20
24.11.2006 9:52:54 Uhr
Downhole drilling with compressed air at the St. Gotthard
Challenge
The new trans-Alpine railway tunnel (also known as NEAT in
German) – but better known as the Gotthard tunnel - represents one of the most ambitious traffic projects in Switzerland. Miners using compressed air are working hundreds of
meters below the Alps at the Sedrun construction site - from
a geological perspective, a real challenge. In order to effectively support the tunnel construction, downhole drilling is
used.
Solution
Kaeser screw compressors and a 3000 liter compressed air
tank installed on the carriages of the tunnel railway have
been installed for downhole drilling. Siemens motors are
the core of the main compressor drive. The SIGMA Control
and all of the switchgear and communication components
also come from the extensive Siemens portfolio.
Advantages
III Especially effective drilling through a geologically
challenging zone
III Completely reliable in a working environment that tends
to be dirty and dusty
III Particles in the air that are drawn-in can be better processed when compared to fast running systems as a
result of the slow running operation and the generously
dimensioned reservoir of cooling and lubricating liquid
III No transmission losses due to the maintenance-free
1:1 direct drive
III Optimum compressor technology - based on products
and systems that are completely harmonized and
coordinated with one another
References
Solutions for compressors
St Gotthard
Railway Tunnel
Variable-speed compressors for the filter manufacturer Hengst
Challenge
This manufacturer of oil and fuel filters commissioned the
plant in 2000 with two production lines and an aluminum
casting plant. Previously, it was supplied from a common
compressed air station with two oil injected type GA screw
compressors. The number of machines in the casting plant
has been increased therefore increasing the air requirement. A solution is required in order to expand the system
to generate the appropriate amount of compressed air and
to reduce the no-load component.
Solution
The solution comprises a GA 50 VSD (Variable Speed Drive)
screw compressor. The compressor with variable-speed
drive is the ideal buffer that can adapt extremely quickly to
the fluctuating air requirement and due to its wide control
range of between 17 and 100% no-load periods are eliminated. It only supplies the amount of compressed air that
is actually required at any point in time. This successful
concept was also used at the main Hengst plant in Münster,
ws_pumpen_luefter_GB.indd 21
Germany. A VSD compressor was also introduced there as
peak load machine.
Advantages
III High energy saving - additional energy-saving potential
is possible by reducing the pressure in the compressed
air network
III Minimum no-load operation using closed-loop speed
control of the machine to cover peak loads
III Optimum configuration for a power-saving compressed
air supply with screw compressors.
Filter manufacturer
Hengst
24.11.2006 9:52:59 Uhr
Reduce costs, increase efficiency energy-optimized drive systems
The right strategy is crucial: For a drive system these are
electric motors and drive converters. Here, continuous
operation of the motor is of significance – energy-saving
motors with increased efficiency save valuable kilowatt
hours. However, also the drive converters provide additional
cost savings by being able to select the optimum operating
point.
The type of driven load is important when considering variable-speed drives. Electronic closed-loop speed control
instead of mechanical throttles - this means that the energy
consumption of fan, pump and compressor drives can be
reduced by up to 50%. This is where optimized machines for
pumps, fans and compressors come into their own.
Any additional capital investment costs are already paidback within just a few months. The operating costs are permanently reduced - which means that your plant or system
additionally saves money over the complete lifecycle. However, not only do you profit, but also the environment: This
is because a drive system that is optimized to have a low
energy consumption helps to sustainably reduce CO2
emission.
Additional cost savings can be achieved by dimensioning
the drive system in-line with the requirements. This applies
both for new plants and systems as well as the optimization
and modernization of existing ones.
Simply calculate the cost-saving potential - SinaSave gives you an overview
Our SinaSave® software tool can show you just how quickly an investment in an IEC, NEMA energy-saving motor or a
drive inverter can be paid back. Based on the main parameters of your plant or system the program calculates the energy saving for a specific application. The payback time for the motor and drive converter is calculated from the monthly
total saving and the procurement costs. This payback time is often just a few months.
You can get more details under www.siemens.com/sinasave.
Energy consumption
Energy saving
in EURO
110%
100%
90%
Mechanical
flow control
80%
Energy saving of
219 EUR p.a. for 8760 h
for 0.10 EUR/KWh
60%
Pack back time of the assumed
additional motor costs of 75 EUR
for a 5.5 kW EFF1 energy saving
motor for 0.1 EUR/kWh: 3000 h
Energy saving
50%
40%
30%
20%
Energy consumption
when using drive
10%
inverter controls
0%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Energy saving in EURO
70%
100%
Flow rate
22
ws_pumpen_luefter_GB.indd 22
Operating hours
24.11.2006 9:53:07 Uhr
Whether for pumps, fans or compressors: We can offer you tailored solutions for
each and every application. However, not only can we offer drive and automation technology – we also have the optimum products and systems for many other
areas and sectors. In fact, for every application where you wish to move even
more. We would be more than willing to personally help you identify your own
individual potential.
Spectrum
The optimum solution for each and every application
Whether you need your drive sent to you just-in-time or you require delivery, assembly,
commissioning or maintenance, our experts are always there to serve you. All over
the world, directly on site – and in over 130 countries. You benefit from shorter
delivery times. Because of our optimized logistics and production processes, each and
every component reaches you as quickly as possible.
Service
Anytime, anywhere –
service without borders
You can even place your orders over the Internet.
At www.siemens.com/automation/mall, you can find a clear overview of all our
products. And with EDIFACT, you can complete the entire ordering process online.
But we are also glad to provide the personal assistance you need. If you want support
from a service specialist, or want to order spare parts, or just have a question, through
our hotline you’ll obtain optimum consulting services.
Helpline Service & Support:
http://support.automation.siemens.com
Technical support:
0180 5050222
http://automation.siemens.com/partner
List of sales partners
0180 5050111
23
ws_pumpen_luefter_GB.indd 23
24.11.2006 14:58:52 Uhr
PUBLICIS
www.siemens.com/pumps
www.siemens.com/fans
www.siemens.com/compressors
III Motors
www.siemens.com/motors
III Geared motors
www.siemens.com/gearedmotors
III Couplings
www.flender.com
III Inverters
www.siemens.com/sinamics
www.siemens.com/micromaster
III Motor starters
www.siemens.com/sirius-motorstarter
III Soft starters
www.siemens.com/sirius-starting
III Motor management system
www.siemens.com/simocode
III Relays
www.siemens.com/relays
III Low-voltage power distribution
www.siemens.com/sivacon
www.siemens.com/sentron
III Transformers, fans, reactors,
filters and power supplies
www.siemens.com/mdexx
III Controls, I/O, software
www.siemens.com/simatic
www.siemens.com/microset
III Communications
www.siemens.com/PROFIBUS
www.siemens.com/PROFINET
III Operator control and visualization
www.siemens.com/hmi
III Sensors
www.siemens.com/sitrans
III Totally Integrated Automation
www.siemens.com/tia
III Energy saving
www.siemens.com/energysaving
Siemens AG
Automation and Drives
www.siemens.com/drives
ws_pumpen_luefter_GB.indd 24
Subject to change without prior notice 11/06 | Order No. E80001-A270-P210-X-7600 | Dispostelle 21505 | 2100C9949 MK.SD.PL.XXXX.52.7.01 WS 11065.0 | Printed in Germany | © Siemens AG 2006
One click away from comprehensive information
The information provided in this brochure contains merely general descriptions
or characteristics of performance which in case of actual use do not always
apply as described or which may change as a result of further development of
the products. An obligation to provide the respective characteristics shall only
exist if expressly agreed in the terms of contract.
All product designations may be trademarks or product names of Siemens AG
or supplier companies whose use by third parties for their own purposes could
violate the rights of the owners.
24.11.2006 10:35:23 Uhr