Drives for Water Industry - Industria de Siemens
Drives for Water Industry - Industria de Siemens
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.