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Drives for Water Industry - Industria de Siemens

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Innovative technology<br />

<strong>for</strong> the highest availability<br />

and cost-effectiveness<br />

<strong>Drives</strong> <strong>for</strong> <strong>Water</strong> <strong>Industry</strong><br />

Answers <strong>for</strong> industry.


No compromises when it comes to<br />

supplying water with the highest quality<br />

In the water industry, topmost priority is given to achieving the optimum water quality and an absolutely<br />

reliable supply. At the same time, ever-increasing cost pressure <strong>de</strong>mands water plants with the highest<br />

<strong>de</strong>gree of cost-effectiveness. As a consequence, the technology used must operate reliably, efficiently<br />

and with a high <strong>de</strong>gree of precision.<br />

The <strong>de</strong>mands placed on the drive technology are especially high. <strong>Drives</strong> play a key role when it comes to<br />

supply reliability and plant efficiency. Pump drives maintain the water pressure at the right level around<br />

the clock, always adapt the pumped quantity to the actual <strong>de</strong>mand and regulate, where required, the<br />

mixing ratio. Further, their energy <strong>de</strong>mand is the most significant element of the overall energy costs.<br />

With this as background, drive converters offer enormous cost-saving potential: The precise and continuous<br />

closed-loop speed control ensures that the drive runs at the optimum operating point – and<br />

that energy costs can be significantly reduced.<br />

2


First-class solutions <strong>for</strong> all tasks<br />

Whether small distribution pumps, blower<br />

compressors in water treatment plants or<br />

multi-Megawatt drives in large main pumping<br />

stations. As partner to the water industry,<br />

<strong>Siemens</strong> offers a unique and extensive<br />

range of products and systems that addresses<br />

all of the sector-specific drive applications<br />

encountered in the water industry.<br />

With our solutions we consequentially ensure<br />

the highest reliability and efficiency.<br />

We offer individual components as well as<br />

products and systems that are perfectly<br />

harmonized and coordinated with one<br />

another; these are based on proven standards<br />

and tailored solutions – from a single<br />

source. Our portfolio inclu<strong>de</strong>s motors and<br />

drive converters with a power rating of a<br />

few Watts up into the high double-digit<br />

Megawatt range, low-voltage drives as<br />

well as medium-voltage drives.<br />

Perfectly tailored to the<br />

requirements of the sector<br />

Our motors and converters ensure optimum<br />

pumping – with the maximum <strong>de</strong>gree<br />

of availability and with minimum<br />

operating costs. In fact, these advantages<br />

can be further expan<strong>de</strong>d if our drive components<br />

work together as a system. This<br />

is because we <strong>de</strong>velop and manufacture<br />

our motors and drive converters right<br />

next to another, we perfectly harmonize<br />

them and subject them to a grueling test<br />

un<strong>de</strong>r real operating conditions in one of<br />

our state-of-the-art system test facilities.<br />

The result: Drive systems that distinguish<br />

themselves as a result of the highest<br />

<strong>de</strong>gree of availability and maximum<br />

efficiency.<br />

Typical applications<br />

In water supply<br />

• Retrieving drinking water<br />

• Transporting water<br />

• Dosing<br />

• Treating drinking water<br />

• Distributing water<br />

• Irrigation systems<br />

In wastewater<br />

• Transporting wastewater<br />

• Transporting sludge<br />

• Aerating and mixing the<br />

activated sludge<br />

• Centrifuges<br />

• Equipment in wastewater handling<br />

such as rakes etc.<br />

3


The key to the highest supply availability:<br />

Reliability in continuous use<br />

A water supply must be guaranteed<br />

around the clock. This is the reason<br />

that in many applications the name<br />

of the game is reliable long-term and<br />

continuous use. Put in another way:<br />

Absolute fault-free operation is mandatory<br />

– the same goes <strong>for</strong> the highest<br />

efficiency. This is because the energy<br />

costs are especially important <strong>for</strong><br />

motors that continually run.<br />

The complete bandwidth of motors<br />

Our motors set standards when it comes<br />

to reliability and efficiency. Our portfolio<br />

extends from standard motors <strong>for</strong> pumping<br />

stations up to special submersible<br />

pump motors with <strong>de</strong>gree of protection<br />

IP68. We also offer explosion-protected<br />

motors e.g. <strong>for</strong> the settling process. They<br />

have a flameproof enclosure and on the<br />

pump si<strong>de</strong> they have a rotating axial seal.<br />

Our portfolio inclu<strong>de</strong>s motors with every<br />

possible conceivable cooling type and <strong>de</strong>gree<br />

of protection to comply with almost<br />

any specification – such as pump motors<br />

with locating bearings on the drive si<strong>de</strong><br />

and integrated PTC thermistors – as well<br />

as high-power torque motors. These gearless<br />

permanent-magnet synchronous motors<br />

are especially reliable, require little<br />

maintenance but have an extremely high<br />

efficiency. They are especially suitable <strong>for</strong><br />

slow-running pumps.<br />

Rugged with a long service life<br />

Our motors distinguish themselves as a<br />

result of their rugged mechanical <strong>de</strong>sign,<br />

long lifetime as well as low maintenance<br />

and reliable operation. Enclosures, bearings,<br />

active parts, ventilation and cooling<br />

system are perfectly harmonized with<br />

one another. Innovative insulation systems<br />

in conjunction with the VPI technique<br />

ensure a high voltage strength<br />

when either connected directly to the<br />

line supply or fed from a drive converter.<br />

These insulation systems also result in<br />

stiff winding overhangs and excellent corona<br />

protection <strong>for</strong> maximum switching<br />

and reversing strength. Our motors play a<br />

<strong>de</strong>cisive role in achieving a higher <strong>de</strong>gree<br />

of plant availability and a more reliable<br />

water supply.<br />

Additional advantages:<br />

• High mechanical strength and<br />

thermal endurance<br />

• Extremely long lifetime and<br />

low-maintenance bearings<br />

4


• The vibration quality surpasses<br />

stringent IEC and NEMA standards<br />

• Innovative cooling systems <strong>for</strong> uni<strong>for</strong>m<br />

cooling and minimizing the thermal load<br />

• Enclosure that is resistant to shocks<br />

and vibration and with a high<br />

vibrational stiffness<br />

• Corrosion protection <strong>for</strong> humid and<br />

aggressive environments<br />

Highest power in the smallest space<br />

Our motors are unbeatable when it comes<br />

to envelope dimensions and weight at<br />

any power rating. This means that they<br />

require significantly less space and can be<br />

simply integrated into a complete plant.<br />

Further, they are also extremely quiet –<br />

additional noise-reducing measures are<br />

not required.<br />

Significantly lower maintenance costs<br />

As a result of their service-friendly <strong>de</strong>sign,<br />

our motors distinguish themselves due to<br />

the extremely long maintenance intervals.<br />

Further, the high efficiencies improve the<br />

energy consumption there<strong>for</strong>e reducing<br />

operating costs. We offer energy-saving<br />

motors in the “High Efficiency” version <strong>for</strong><br />

the range up to 200 kW – that is especially<br />

efficiency-sensitive. Up to 90 kW, these<br />

motors are <strong>de</strong>signated as efficiency class<br />

EFF1. When compared to conventional<br />

motors, they have losses up to 40% less –<br />

which often means that they have a payback<br />

time of just a few months.<br />

Energy-saving motors<br />

The best example <strong>for</strong> cost-saving, efficiency<br />

and environmental friendliness:<br />

Our energy-saving motors that require<br />

less energy <strong>for</strong> the same power output.<br />

In fact, this can even be proven with the<br />

appropriate calculations using SinaSave®.<br />

This is a software tool that we <strong>de</strong>veloped,<br />

which allows you to calculate the payback<br />

time of your investment.<br />

The advantages – an overview:<br />

• Complete product range according to<br />

EU/CEMEP, EPAct and NEMA<br />

• Simple motor selection using an efficiency<br />

classification system (EFF1/EFF2)<br />

• 1LE1, 1LA9 and 1LG6 motors fulfill both<br />

EFF1 as well also EPAct efficiencies<br />

• Lower operating costs as a result of the<br />

high EFF1 efficiency<br />

• High motor and lubricant lifetime<br />

thanks to the lower motor temperature<br />

<strong>for</strong> EFF1, EPAct and NEMA motors<br />

• CO 2 reduction in operation reduces the<br />

environmental impact<br />

Geared motors: Concentrated power,<br />

compact <strong>de</strong>sign<br />

Our MOTOX series of geared motors have<br />

output torques up to 20,000 Nm and higher<br />

rated gear unit torques than conventional<br />

geared motors but with the same envelope<br />

dimensions. All gear unit types are available<br />

in the power range from 0.09 kW to 200 kW –<br />

from helical through offset shaft, helical<br />

bevel and helical worm up to worm geared<br />

motors.<br />

They are admirably suited <strong>for</strong> applications<br />

such as longitudinal and rotary scrapers,<br />

rakes, mixers or spiral conveyers.<br />

5


A farsighted investment:<br />

Drive converters <strong>for</strong><br />

variable-speed operation<br />

Flow rates can be controlled far more precisely and faster with variable-speed drive<br />

systems than when using mechanical control concepts – and can be adapted to the<br />

actual <strong>de</strong>mand. The advantage: A significantly higher <strong>de</strong>gree of reliability and quality<br />

<strong>for</strong> water and wastewater systems. Further, variable-speed operation opens up<br />

enormous cost-saving potential. This is the reason that a drive converter often has<br />

a payback time of just a few months.<br />

6


The clever alternative to fixed speeds<br />

For conventional control techniques, the<br />

motors always run with the speed required<br />

<strong>for</strong> the maximum flow rate. Excessive flow<br />

rates are mechanically “throttled” – which<br />

means that energy is simply thermally dissipated.<br />

Contrary to this, state-of-the-art drive<br />

systems with drive converters precisely adapt<br />

the speed – and there<strong>for</strong>e the energy drawn –<br />

to the actually required flow rate. The motor<br />

there<strong>for</strong>e only draws the actually required<br />

power. Power factor and efficiency remain<br />

almost constant. This avoids over-dimensioning<br />

the motor and the energy requirement<br />

is significantly reduced. The cost-savings are<br />

especially high <strong>for</strong> positive displacement<br />

machines – such as pumps or blower compressors<br />

and <strong>de</strong>pending on the plant characteristic,<br />

can be up to 50%, even up to 70%<br />

in extreme cases .<br />

Low-stress operation reduces<br />

maintenance costs<br />

The starting characteristics of a variable-speed<br />

drive also have a positive impact: Only the rated<br />

current is drawn, which means that current<br />

peaks – that typically occur when starting –<br />

are eliminated along with the associated high<br />

torque surges. The soft starting and stopping<br />

reduces the stress on the complete mechanical<br />

drive transmission line. Further, operating<br />

conditions that can damage the machine or<br />

system – such as cavitation, the inclusion of<br />

gas, compression surges and vibration – can<br />

be eliminated. By slightly adapting the motor<br />

speed, cavitation bubbles that damage the<br />

pump impeller bla<strong>de</strong>s can be eliminated and<br />

continuous streams of gas being pumped<br />

along with the medium are avoi<strong>de</strong>d. Not only<br />

this – ultrasonic compression surges typical<br />

<strong>for</strong> compressors are also eliminated. Suppressing<br />

certain pump speeds also avoids un<strong>de</strong>sirable<br />

vibration and oscillation. Additional advantages<br />

inclu<strong>de</strong>: Mechanical control elements<br />

are eliminated, the power factor is improved<br />

and the process control optimized when<br />

compared to mechanical control techniques.<br />

The complete range of drive converters<br />

We supply the i<strong>de</strong>al drive converter <strong>for</strong> every<br />

application and every motor. As a result of<br />

their modular <strong>de</strong>sign and wi<strong>de</strong> range of available<br />

components and options these drive units<br />

can be optimally adapted to the specific application<br />

requirements and be combined to <strong>for</strong>m<br />

perfectly harmonized, reliable and highly-efficient<br />

systems. The drive units are <strong>de</strong>signed so<br />

that their energy-saving potential can be especially<br />

effectively utilized. With their rugged<br />

closed-loop vector control that does not require<br />

an enco<strong>de</strong>r they are specifically tailored<br />

to drive tasks without regenerative feedback<br />

into the line supply – this makes them i<strong>de</strong>al <strong>for</strong><br />

applications in the water industry.<br />

7


SINAMICS: The unified and<br />

integrated drive family<br />

With SINAMICS, <strong>Siemens</strong> is offering an innovative family of drives that sets<br />

standards in every perspective. In addition to a standard and simple operator<br />

control philosophy, the members of the SINAMICS family all use the SIZER<br />

engineering tool <strong>for</strong> selecting and dimensioning as well as STARTER <strong>for</strong> commissioning<br />

and diagnostics. The following drive units are precisely pre<strong>de</strong>stined<br />

<strong>for</strong> the water industry: SINAMICS G120, G130, G150, GM150 and GL150. And<br />

<strong>for</strong> especially stringent requirements on the line supply quality, the S series<br />

with SINAMICS S150 or S120.<br />

8<br />

Simple to operate<br />

Whether low voltage or medium voltage:<br />

All of the SINAMICS cabinet units are<br />

equipped with the user-friendly AOP 30<br />

operator panel that displays simple operator<br />

control and commissioning functions<br />

in plain text. This means that no additional<br />

manuals are required when commissioning<br />

the drives. Drive parameters such<br />

as current, actual speed and speed set<br />

point are displayed in operation using<br />

bar-type displays.<br />

Numerous interfaces and highest availability<br />

SINAMICS drives are equipped with<br />

numerous interfaces:<br />

PROFIBUS, PROFINET and various analog<br />

and digital inputs and outputs. This ensures<br />

that the drive units can be easily<br />

integrated into higher-level automation<br />

systems. All SINAMICS drive units distinguish<br />

themselves as a result of their highest<br />

<strong>de</strong>gree of availability. Their simple,<br />

clearly structured <strong>de</strong>sign makes them<br />

rugged and reliable. When service is required,<br />

modules can be replaced with just<br />

a few manual operations – special tools<br />

are not required. Further, intelligent<br />

maintenance functions can be integrated,<br />

e.g. in the medium-voltage


SINAMICS GM150 drive converters that<br />

automatically issue a signal if maintenance<br />

is required. Service and maintenance<br />

work can always be optimally<br />

planned. This means that unpredictable<br />

and sud<strong>de</strong>n pump failures are a thing of<br />

the past – which also goes <strong>for</strong> the resulting<br />

supply bottlenecks.<br />

Space-saving and quiet<br />

Our drive converter cabinets have a footprint<br />

that is up to 70% less than conventional<br />

units thanks to their exceptional<br />

compactness. This means that electrical<br />

rooms can be dimensioned significantly<br />

smaller – which has a positive impact on<br />

the costs. Integration into existing plants<br />

and systems is also simplified. Our drive<br />

converters are the first choice when it<br />

comes to low noise: Only 69 db(A) at full<br />

load – even <strong>for</strong> cabinet units with power<br />

ratings of several 100 kW, additional<br />

noise-reducing measures are simply not<br />

required.<br />

First choice <strong>for</strong> pump drives<br />

• Rounding-off times avoid overpressure<br />

conditions and water hammer there<strong>for</strong>e<br />

reducing the level of stress on the<br />

hydraulic and mechanical systems<br />

• To ensure safe, reliable operation,<br />

mechanical resonance frequencies are<br />

skipped, locked rotors are <strong>de</strong>tected and<br />

loads monitored<br />

• The efficiency is optimized <strong>for</strong> no-load<br />

operation; the flux set point of the control<br />

is adapted <strong>de</strong>pending on the load. Un<strong>de</strong>r<br />

no-load conditions, this reduces the rated<br />

motor flux by up to 50% and saves the<br />

corresponding amount of energy<br />

• Operation can be monitored online<br />

It is being increasingly specified that<br />

pumps must also be disconnected from<br />

the line supply in a controlled fashion if<br />

the flow rate is to be reduced. This is<br />

mainly done to avoid oscillations in the<br />

hydraulic system.<br />

Bypass function: Using this function integrated<br />

in the drive converter, a pump motor<br />

can be connected to the line supply –<br />

either when a specific speed is reached<br />

or using a separate command with a contactor.<br />

There are two versions of this bypass<br />

circuit: Without (cold synchronization)<br />

or where the motor is synchronized<br />

to the line supply (hot synchronization).<br />

This means that the drive converter can<br />

be used as starting and stopping converter<br />

and staging functionality can be more<br />

simply implemented. The staging function<br />

permits a drive converter to be used to<br />

feed several motors and pumps – the perfect<br />

solution especially when it comes to<br />

pumping large quantities of water. A typical<br />

example of such an application: The<br />

drive converter starts the first pump and<br />

monitors its speed. As the rate of flow<br />

increases this pump drive is synchronized<br />

and connected to the line supply. The<br />

same drive converter is then used to start<br />

a second pump – that is then used to precisely<br />

control the flow rate. This means<br />

that pumps are not directly connected<br />

to the line supply (direct start) there<strong>for</strong>e<br />

avoiding un<strong>de</strong>sirable high starting currents.<br />

With this constellation, theoretically,<br />

an unlimited number of pumps can be<br />

monitored using just one drive converter.<br />

Flying restart function: This function is<br />

used to connect a drive converter to a motor<br />

that is still running. If the drive converter<br />

was to be powered up without this<br />

function, then the motor would not be<br />

able to establish its flux. This could cause<br />

the drive system to trip due to an overcurrent<br />

condition. The flying restart function<br />

first <strong>de</strong>termines the motor speed.<br />

Technology controller: The technology<br />

controller integrated as standard controls<br />

process quantities such as pressure,<br />

quantity, temperature, level.<br />

9


Customized SINAMICS functions<br />

Specific pump functions<br />

A whole raft of functions – that have<br />

been specifically <strong>de</strong>signed <strong>for</strong> pumps –<br />

can be implemented using a software<br />

macro. This simplifies the operator control<br />

and parameterization of the drive<br />

converter. The pumps functions are<br />

already pre configured.<br />

EnergySaving: If the motor is not required<br />

it can be completely shut down using this<br />

function. This is done automatically if the<br />

system <strong>de</strong>viation of the technology controller<br />

lies below a <strong>de</strong>fined limit value <strong>for</strong> a<br />

time that can be parameterized.<br />

EnhancedEnergySaving: This function<br />

can be used to extend the time <strong>for</strong> which<br />

the drive converter is powered down as a<br />

result of the EnergySaving function – in<br />

or<strong>de</strong>r to save more energy and to avoid<br />

unnecessarily starting and stopping the<br />

pumps. And an additional spin-off – the<br />

pipes are also purged.<br />

MaintenanceCleaning: A constant flow<br />

rate means that suspen<strong>de</strong>d particles in the<br />

liquids being pumped can be <strong>de</strong>posited<br />

over time. This can reduce the effective<br />

pipe diameter or even block the pumps.<br />

The MaintenanceCleaning function is used<br />

to briefly increase the pump speed to<br />

counteract this sediment build-up.<br />

WallDepositsPrevention: If tank levels<br />

are kept constant over a longer period<br />

of time in wastewater treatment systems<br />

<strong>de</strong>posits occur at the edge of the tank. To<br />

avoid these <strong>de</strong>posits, the WallDeposits-<br />

Prevention function always varies the set<br />

point <strong>for</strong> the technology controller so that<br />

the tank level is permanently raised and<br />

lowered.<br />

10


Additional SINAMICS functionalities<br />

<strong>for</strong> the water industry<br />

MICROMASTER low-voltage converters<br />

The MICROMASTER family of drive converters<br />

addresses drive applications in the<br />

power range from 0.12 kW to 250 kW<br />

and distinguishes itself as a result of the<br />

extremely easy handling – from installation<br />

& mounting through commissioning<br />

up to operation. These drive units are<br />

suitable <strong>for</strong> pump drives up to 250 kW<br />

and can control up to three motors. They<br />

are equipped with an integrated dry running<br />

protection <strong>for</strong> pump drives – as well<br />

as additional features <strong>for</strong> specific applications<br />

that can be implemented using<br />

freely assignable function blocks.<br />

Medium-voltage drive converter:<br />

ROBICON Perfect Harmony<br />

ROBICON Perfect Harmony rounds off our<br />

drive portfolio in the medium-voltage level.<br />

It is the undisputed No. 1 worldwi<strong>de</strong><br />

in medium-voltage drive converters regarding<br />

both market share as well as installed<br />

power. With this drive unit, lowvoltage<br />

cells are connected in series so<br />

that a medium-voltage drive converter is<br />

created that can be extremely precisely<br />

scaled – over a wi<strong>de</strong> voltage and power<br />

range. Presently, this drive unit is consi<strong>de</strong>red<br />

to be the most compact mediumvoltage<br />

drive converter in the market:<br />

Trans<strong>for</strong>mer, power unit and control are<br />

combined in one unit. The complete<br />

system can be commissioned in a plug<br />

& play fashion without requiring any<br />

assembly work on-site.<br />

The extremely high voltage quality avoids<br />

losses due to harmonics, reduces the level<br />

of stress both on the line supply and<br />

the motor and also fulfills the most stringent<br />

regulations relating to harmonics.<br />

The proven core topology ensures the<br />

highest <strong>de</strong>gree of compactness, voltage<br />

quality and availability. The innovative<br />

cell-bypass concept in conjunction with<br />

the process-tolerant ProToPS® protective<br />

system guarantees the highest <strong>de</strong>gree of<br />

reliability. This is because even if a cell<br />

fails, the drive still remains operational as<br />

the <strong>de</strong>fective cell is simply bypassed. If a<br />

fault <strong>de</strong>velops, instead of simply powering<br />

down the drive, ProToPS® provi<strong>de</strong>s a<br />

graduated system of alarms. This means<br />

that operating companies have more<br />

time to appropriately respond and take<br />

suitable countermeasures.<br />

11


Best-practice<br />

water supply examples<br />

Ba<strong>de</strong>n-Württemberg state water supply<br />

Task<br />

The Ba<strong>de</strong>n-Württemberg state water supply<br />

was to be mo<strong>de</strong>rnized – with the objective<br />

to increase flexibility and efficiently use the<br />

groundwater reservoirs. This involves one of<br />

the largest long-distance water supply utilities<br />

in Germany: More than three million<br />

people are supplied with drinking water<br />

through an extensive network of pipes<br />

770 km long. This is <strong>for</strong> an area that in addition<br />

to Stuttgart also inclu<strong>de</strong>s Aalen, Esslingen,<br />

Göppingen, Ludwigsburg, Schwäbisch<br />

Gmünd and Ulm.<br />

Solution<br />

The groundwater reservoirs were equipped<br />

with variable-speed low-voltage drive systems<br />

<strong>for</strong> the pumps. The extremely precise<br />

and flexible drive concept always guarantees<br />

the correct mixing ratio – and there<strong>for</strong>e the<br />

optimum drinking water quality. It also ensures<br />

the maximum availability and reliability<br />

of the water supply. The variable-speed<br />

operation simultaneously saves energy and<br />

reduces the level of stress on the system.<br />

Schwetzinger Hardt waterworks<br />

Task<br />

A higher <strong>de</strong>gree of safety, reliability and<br />

cost-effectiveness. This is what the City of<br />

Mannheim expected when it came to mo<strong>de</strong>rnizing<br />

their water supply. This was to be<br />

done based on innovative operating control<br />

methods with process visualization and remote<br />

access.<br />

Solution<br />

The drinking water pumping stations were<br />

equipped with variable-speed low-voltage<br />

drive systems – <strong>for</strong> precise, reliable energysaving<br />

operation that also reduced the<br />

stress on the system. The drive system is<br />

integrated in a SIMATIC WinCC-based supervisory<br />

control system. This means that it<br />

can be operated and monitored from everywhere<br />

– also via remote access.<br />

Products used:<br />

• N-compact low-voltage motors<br />

• SINAMICS G150 drive converters<br />

Products used:<br />

• 1LG6 low-voltage motors<br />

• SINAMICS G150 drive converters<br />

12


Madrid water supply<br />

Task<br />

The Spanish capital wanted to guarantee a<br />

safe, reliable and cost-effective water supply<br />

<strong>for</strong> approximately one million people living in<br />

the southern part of the city. This represents<br />

approximately 250 liters per day <strong>for</strong> each person<br />

– also during the dry summer period.<br />

Solution<br />

The main drinking water pumping stations<br />

were equipped with variable-speed, medium-voltage<br />

drive systems in or<strong>de</strong>r to secure<br />

precise and flexible usage of the water reserves.<br />

The existing motors were only partially<br />

replaced. Those in a good condition<br />

were upgra<strong>de</strong>d <strong>for</strong> variable-speed operation.<br />

The flow rate can now be quickly and precisely<br />

adapted to the actual water <strong>de</strong>mand<br />

using the motor speed. Further, variablespeed<br />

operation reduces the level of stress<br />

on the mechanical system of the complete<br />

pumping station – and when compared to<br />

conventional control concepts – now allows<br />

double-digit energy savings to be realized.<br />

Products used:<br />

• H-compact PLUS high-voltage motors<br />

• Liquid-cooled SINAMICS GM150<br />

medium-voltage drive converters<br />

Jakarta water supply<br />

Task<br />

The pumping stations were to be retrofitted<br />

in or<strong>de</strong>r to secure reliable and cost-effective<br />

water supply <strong>for</strong> the ever-growing metropolis<br />

of Jakarta with its population of millions.<br />

The existing motors, switchgear technology<br />

and cabling were to be kept.<br />

Solution<br />

With the mo<strong>de</strong>rnization, the existing technology<br />

was kept in operation (motors, cabling,<br />

switchgear and instrumentation).<br />

However, low-voltage and medium-voltage<br />

drive converters were integrated into the<br />

existing system. Further, additional components<br />

from <strong>Siemens</strong> ensure safe and absolutely<br />

reliable operation. These components<br />

inclu<strong>de</strong> an incoming contactor, main control<br />

switch with fuses to protect the semiconductors<br />

as well as a line reactor to limit<br />

harmonics.<br />

Products used:<br />

• SINAMICS G150 drive converter<br />

• Medium-voltage drive converter<br />

(previous SINAMICS GM150 series)<br />

13


Best-practice water<br />

treatment examples<br />

Basel water treatment<br />

Task<br />

The energy usage was to be further reduced<br />

<strong>for</strong> one of the largest wastewater treatment<br />

plants in Switzerland located close to Basel.<br />

The existing motors were to be replaced by<br />

motors with especially high efficiencies.<br />

Solution<br />

450 kW high-efficiency low-voltage motors<br />

are now used to drive large Archime<strong>de</strong>s<br />

screw-type pumps that are used to transport<br />

the incoming wastewater into the treatment<br />

system located approximately 10 meters<br />

higher. Thanks to their special bearings they<br />

can handle the high cantilever <strong>for</strong>ces. In the<br />

especially efficiency-sensitive power range<br />

below 200 kW, energy-saving motors with<br />

the highest efficiency Class EFF1 are used –<br />

especially there where the wastewater is<br />

transported into the biological stage of the<br />

settling plant after mechanical precleaning.<br />

From here, the water flows just by gravity<br />

into the postsettling basins. The activated<br />

sludge comprising bacteria and microbes<br />

settles out. Part of the sludge is returned to<br />

the biological stage using so-called return<br />

sludge pumps. Energy-saving motors are<br />

also used here. Calculations have shown<br />

that the payback time of the energy-saving<br />

motors is a maximum of three years.<br />

Products used:<br />

• N-compact low-voltage motors<br />

• 1LA9, 1LE1 and 1LG6 EFF1<br />

energy-saving motors<br />

14


Overview of motors <strong>for</strong> the<br />

water industry<br />

Low-voltage motors<br />

Induction<br />

Aluminum frame<br />

Low-voltage motors<br />

Induction<br />

Gray cast-iron<br />

frame<br />

Low-voltage motors<br />

Synchronous<br />

High-Torque<br />

gearless<br />

High-voltage motors<br />

Induction<br />

High-voltage motors<br />

Synchronous<br />

Power range<br />

in kW<br />

Power range<br />

in kW<br />

Voltage classes<br />

in V<br />

0.06 – 45 0.75 – 4,000 Up to 2,150 200 – 30,000 5,000 – 100,000<br />

230 – 690 230 – 690 400, 460, 690 2,000 – 13,200 6,000 – 13,200<br />

Voltage classes<br />

in V<br />

Cooling type<br />

Shaft heights<br />

in mm<br />

56M – 225M 100L – 630 400, 450, 500 315 – 1,250 710 – 1,250<br />

Pole No. 2 – 8 2 – 8 16 2 – 16 2 – 8<br />

Degree of<br />

protection<br />

Speed in rpm 750 – 6,000 750 – 6,000 Up to 800 Up to 15,000 Up to 6,300<br />

Degree of protection IP55, IP56, IP65 IP55, IP56, IP65 IP55 IP23, IP55 IP55<br />

Cooling concept Rib-cooled Rib-cooled<br />

Air/air heat<br />

exchanger;<br />

Air/water heat<br />

exchanger;<br />

Open-circuit aircooled<br />

Rib-cooled,<br />

water-jacket cooling<br />

Rib-cooled<br />

Air/air heat<br />

exchanger;<br />

Air/water heat<br />

exchanger;<br />

Open-circuit aircooled<br />

Air/air heat<br />

exchanger;<br />

Air/water heat<br />

exchanger;<br />

Open-circuit aircooled<br />

Motors<br />

Converter-si<strong>de</strong><br />

system partner<br />

SINAMICS G120<br />

MICROMASTER<br />

SINAMICS G120<br />

MICROMASTER<br />

SINAMICS G130<br />

SINAMICS G150<br />

SINAMICS S150<br />

SINAMICS G130<br />

SINAMICS G150<br />

SINAMICS S150<br />

SINAMICS S120<br />

ROBICON Perfect<br />

Harmony<br />

SINAMICS GM150<br />

ROBICON<br />

Perfect Harmony<br />

SINAMICS GM150<br />

SINAMICS GL150<br />

16


Overview of drive converters<br />

<strong>for</strong> the water industry<br />

SINAMICS G120 SINAMICS G130 SINAMICS G150 SINAMICS GM150 SINAMICS GL150 MICROMASTER ROBICON Perfect<br />

Harmony<br />

0.37 – 90 75 – 1,500 75 – 1,500 600 – 27,000 6,000 – 120,000 0.12 – 250 150 – 120,000<br />

380 – 480<br />

660 – 690<br />

380 – 690 380 – 690 2,300 – 7,200 1,800 – 12,000 380 – 500 2,300 – 13,800<br />

Cooling using an<br />

external fan,<br />

convection cooling<br />

Integrated fan Integrated fan Air- and<br />

liquid-cooled<br />

Air- and<br />

liquid-cooled<br />

Cooling using<br />

an external fan<br />

Air- and<br />

liquid-cooled<br />

IP20 IP00, IP20 IP20, IP21, IP23,<br />

IP54<br />

Air-cooled IP22,<br />

optional IP42,<br />

liquid-cooled IP43,<br />

optional IP54<br />

Air-cooled IP20,<br />

optional IP41,<br />

liquid-cooled IP41,<br />

optional IP54<br />

IP20<br />

IP31, IP42, IP54<br />

Low-voltage<br />

induction motors<br />

in aluminum or<br />

gray cast iron<br />

Low-voltage<br />

induction motors<br />

in gray cast iron<br />

Low-voltage<br />

induction motors<br />

in gray cast iron<br />

High-voltage<br />

induction and<br />

synchronous motors<br />

High-voltage<br />

synchronous motors<br />

Low-voltage<br />

induction motors<br />

in aluminum or<br />

gray cast iron<br />

High-voltage<br />

induction and<br />

synchronous motors<br />

17


Würzburg water treatment plant<br />

Task<br />

In or<strong>de</strong>r to ensure optimum biological cleaning<br />

the amount of oxygen injected must<br />

be continually adapted to the actual amount<br />

of prevailing dirt and pollution. The City of<br />

Würzburg wanted to achieve a higher <strong>de</strong>gree<br />

of precision in this operation and at<br />

the same time reduce the operating costs.<br />

Solution<br />

The existing fixed-speed drives were replaced<br />

by SINAMICS G150-based variablespeed<br />

systems to achieve a precise and<br />

energy-saving operation that also reduces<br />

the stress on the mechanical system. The<br />

drive converters were integrated into the<br />

existing supervisory control system of the<br />

water treatment plant.<br />

The supervisory control system continually<br />

<strong>de</strong>termines the actual oxygen <strong>de</strong>mand by<br />

measuring the oxygen and ammonium concentration<br />

in the activation basins and appropriately<br />

adjusting the speed of the turbocompressor<br />

drive. This means that the amount of<br />

oxygen injected is significantly more precisely<br />

dosed than be<strong>for</strong>e the mo<strong>de</strong>rnization.<br />

Products used:<br />

• SINAMICS G150 drive converter<br />

15


<strong>Siemens</strong> AG<br />

<strong>Industry</strong> Sector<br />

Large <strong>Drives</strong><br />

P. O. Box 47 43<br />

90025 NÜRNBERG<br />

GERMANY<br />

www.siemens.com/drives<br />

Subject to change without prior notice<br />

Or<strong>de</strong>r No.: E20001-A270-P500-X-7600<br />

Dispo 21503<br />

21/12387 MK.LD.XX.LDAL.52.8.04 WS 04083.<br />

Printed in Germany<br />

© <strong>Siemens</strong> AG 2008<br />

The in<strong>for</strong>mation provi<strong>de</strong>d in this brochure contains<br />

merely general <strong>de</strong>scriptions or characteristics of per<strong>for</strong>mance<br />

which in actual case of use do not always<br />

apply as <strong>de</strong>scribed or which may change as a result of<br />

further <strong>de</strong>velopment of the products. An obligation to<br />

provi<strong>de</strong> the respective characteristics shall only exist if<br />

expressly agreed in the terms of contract.<br />

All product <strong>de</strong>signations may be tra<strong>de</strong>marks or product<br />

names of <strong>Siemens</strong> AG or supplier companies whose use<br />

by third parties <strong>for</strong> their own purposes could violate the<br />

rights of the owners.

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