DT Media Newsletter. April Drive Technologies Division

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1 Complete delivery of mechanical drive for jacking system of the world s largest heavy-lift jack-up vessel Special feature Siemens has recently delivered mechanical drives for a jacking system for a wind turbine installation vessel. The customer is Shipyard Crist SA headquartered in Gdansk, Poland, which is currently building the high performance heavy-lift jack-up vessel Innovation for HGO InfraSea Solutions. As of mid 2012, Innovation will be the largest of its kind and will install heavy foundations and offshore wind turbines in the North Sea at water depths of up to 50 meters. The potential for offshore wind in Europe is estimated at around 100 gigawatts, which equal two-thirds of the power plant capacity currently installed in Germany. At present, only approximately two percent of that potential is being utilized. The time required to transport and install wind turbines is a crucial factor when setting up an offshore wind farm. A new generation of special ships has been developed and consists of a large self-propelled vessel with the capacity to accommodate numerous complete wind turbines or jackets on board. A heavy-lift crane lowers the jackets on the predetermined position and places the equipment precisely and safely on the stable, previously installed, foundation pile or structure. To ensure a safe and precise operation of the crane the ship can be lifted out of the water on four legs. The Siemens delivers the complete mechanical drive for the jacking system of Innovation, which will be the largest heavy-lift jack-up vessel of its kind. Image (computer animation): HGO. 1

2 ship thus offers a stable working platform for installation of jackets or wind turbines. For this jacking system Siemens supplied 96 mechanical drives with heavy-duty Flender planetary gearboxes. Due to their high-quality and durable gearing, the planetary gears are designed for high concentrated loads, thus enabling stability when the boat is lifted in and out of the water. Siemens also supplied the same number of individually VSD operated electric motors in marine version together with watercooled Sinamic S120 frequency converters. Furthermore, the Simatic PCS7 control system will be used for overall automation. Siemens supplied as well four Geafol medium voltage transformers. As single source supplier, Siemens offers VSD controlled complete Rack and Pinion Systems particularly suitable for frequently operated jacking systems on lift boats. This project shows how we developed an integrated system for the customer clearly demonstrating our strengths in optimizing the entire drive train. says Dr. Bernhard Hoffmann, VP of Drive Applications at Siemens Business Unit Mechanical Drives. HGO InfraSea Solutions is a joint venture of HOCHTIEF Solutions and GeoSea, a company of the Belgian DEME Group. HGO InfraSea Solutions develops, constructs, manages and charters special-purpose vessels used to build and maintain offshore wind farms as well as offshore oil and gas facilities. Further information regarding Flender gear units for lift boats: Due to their high-quality and durable gearing, the heavy-duty Flender planetary gearboxes are designed for high concentrated loads, thus enabling stability for heavy-lift jack-up vessels. 2

3 Full speed ahead! Siemens gear technology in the world s largest ferryboat Special feature The need to transport large quantities of goods and high numbers of people remains undiminished. The world s largest ferryboat will start running between the continents of Africa and Europe later this year. Among the factors crucial to the success of such technical achievements are reliable, efficient propulsion solutions, such as the Flender gearboxes used by Siemens. They are not only characterized by their performance capability and efficiency, but also provide safety and comfort for the passengers on board. The largest ferryboat in the world to date will start running later this year between Tunisia and Italy/France. It has a capacity of 3,200 passengers and 1,060 vehicles. Daewoo Shipbuilding & Marine is building the ocean giant in its South Korean shipyard for CoTuNav, the Tunisian state shipping line. Daewoo chose Siemens type Navilus GVLQ 2500 Flender propulsion gearboxes which are designed for both high power and quiet running. The giant ferry is propelled by means of a multi-engine design. Two of the ship s four diesel engines transmit the required power via the Flender gearbox to the corresponding propulsion drive with adjustable propellers. A design with four engines and two propellers provides a good combination of safety and comfort for passenger ships. Selecting one or two-engine mode enables the propulsion drive to be run at different speeds. Each engine can be engaged and disengaged via a multipleplate clutch. This enables the power to be increased so that the ship can reach a top speed of 27.5 knot, which corresponds to about 50 km/h. As well as the efficiency and power of the propulsion system, the flexibility of the service work also plays an important role, after all a giant ferryboat cannot simply be parked on the open sea. The advantages of a multi-engine solution combined with Flender gearboxes pay off here again. The selectable multiple-plate clutch enables one engine to be disengaged at any time it requires service, while the other engine continues to propel the ship. With a width of 7.35 m, a height of 4.92 m and a length of 3.7 m, the giant Flender gearboxes weigh 89 tons, which makes them the largest marine gearboxes ever built in the Siemens Voerde Works. Additional special features of the Siemens gearboxes are the built-on oil supply system and the monitoring system, which allows unsupervised operation. Furthermore, the propeller thrust bearings are integrated into the gearbox, so the gearbox housing has very high torsional rigidity. This means that the teeth mesh perfectly under all conditions, even with rapid load changes during bad weather. 3

4 Energy-efficient ship propulsion systems from Siemens Special feature For more than one hundred and thirty years, Siemens has been specializing in the planning, manufacture and assembly of electrical equipment for all types of merchant and naval vessels, as well as submarines. This covers turnkey projects and conversions throughout a ship s life cycle. The Siemens Marine & Shipbuilding Division offers shipyards and shipping lines solutions which sustainably increase the environmental compatibility and commercial efficiency of the entire shipping operation. Exhaust gas heat conversion on board ship to supply the on-board power network and to boost the propulsion with hybrid drives (Waste Heat Recovery System WHRS) Fuel consumption is one of the major cost items in ship operation. Highly efficient propulsion solutions and intelligent energy management are crucial to remaining competitive in the long term. At the same time, technologies that are more environmentally compatible are required to meet the ever stricter worldwide environmental protection regulations. The Waste Heat Recovery System (WHRS) helps to meet both of these demands optimally. Clean, efficient, flexible The WHRS uses exhaust gases from the diesel propulsion engine to produce additional electrical power from the ship s fuel in a clean and efficient manner. The system offers decisive competitive advantages by cutting energy costs by up to 12 percent, reducing CO2 and NOX emissions, and significantly lowering maintenance costs. The user also gains more flexibility in the ship design. Smaller fuel tanks give greater scope in the design of the ship s lines and its interior, and the main propulsion system can have a lower rated power. Reliable, internationally available standard components and well-established spare parts logistics make maintenance easier and ensure maximum safeguarding against failure. Diagram of the WHRS from Siemens 4

5 Versatile, powerful, safe In two-stroke direct propulsion systems, the WHRS uses hot exhaust gases to generate superheated steam, which drives a two-stage steam turbine. An exhaust gas turbine can be fed with excess exhaust gas that is not needed for turbocharging. Together with the steam turbine, it drives the electricity generator (waste heat conversion principle), which generally supplies the entire on-board power network. Surplus electric power can be used to boost the propulsion system by means of an electric drive that acts directly on the propeller shaft. At a low machine load, the waste heat recovery system can be run in parallel with a diesel generator set. Parallel operation with a shaft generator, also known as power take-off operation, is easily implemented, because this electric machine is in any case installed to feed in excess energy. This is a slow-running electric machine mounted directly on the propeller shaft without gears, which can work both as a generator and as a motor. All the functionalities of the WHRS are controlled by a power management system that ensures optimal use of the available energy, and automatically adjusts the shaft generator operation to match respective requirements. This utilizes reserve power, reduces the wear on the main propulsion system, and increases the reliability of the onboard power supply. Optimization of ship operation with the EcoMain communication platform The many on-board technical installations and systems supply informative data about their status, performance and efficiency. The EcoMain communications platform helps to utilize the commercial potential of the ship by optimizing its operation. Through a wide range of on-board interfaces, EcoMain collects data from as many technical systems as possible, prepares it in a standardized format, and makes it available on a common data platform. Energy consumption, emissions, bunkering with liquids, maintenance schedules, document and knowledge management and a great deal more can be evaluated and subsequently optimized. The greatest potential for improvement lies in energy consumption, environmental compatibility and maintenance intervals. Targeted decision support for green fleet management The system assists the ship management by providing specific information for optimization: Lower-level modules below EcoMain, such as the power management system, help in the making of decisions to improve the performance of a ship or an entire fleet. As a result, EcoMain enables significant cost savings to be made with green fleet management, which safeguard the investment and the future of the fleet. These are crucial competitive advantages. Kay Tigges, the expert for Green Ship technology at Siemens and the Siemens Inventor of the Year 2009, commented: Efficiency and environmental sustainability are not opposites in the shipping industry; on the contrary, together they form a competitive factor. 5

6 Siemens obtains certification for condition monitoring of wind energy plants Siemens has once again been certified by Germanischer Lloyd (GL) as an inspection agency for condition monitoring systems for wind energy plants. For the second time, the Field Remote Service department has received certification confirming that the diagnostic competence of its inspection engineers, remote monitoring processes and quality management all meet the requirements of Germanischer Lloyd. Condition monitoring systems (CMS) are used for the vibration-based status monitoring of drive trains. As drive systems, particularly in wind energy plants, must offer maximum availability at all times, the work on prescribing corresponding monitoring systems started at a very early stage in this industry. When the need arises, it is essential to have competent and prompt support available. This can be provided to an increasing extent by the use of modern, high-performance communication media via remote service. agencies is, in turn, a prerequisite for the certification of wind energy plants and therefore of their operation as well. In the course of the assessment, the GL inspectors first examined the Siemens condition monitoring system and the corresponding inspection agency theoretically, and then in practice on site. The certification focused on structures, processes and documentation. This very extensive inspection ensures a sound organizational structure as the basis for high-quality monitoring. Inspection points include training courses and events for the service personnel as well as detailed job specifications in the service area. In order to anticipate possible failures in wind energy plants before they develop and thereby avoid the costly consequences, the Field Remote Service department in the Siemens Industry Sector offers comprehensive diagnostics and status monitoring of wind energy plants by remote access. Utilization of the Siplus CMS4000 condition monitoring system facilitates the status-oriented maintenance of entire wind farms. The inspection agency was re-certified in February of this year following in-depth examination by Germanischer Lloyd Industrial Services GmbH. The associated condition monitoring system had already been certified prior to this. The certification by Germanischer Lloyd attests to the long-term expertise of Siemens in the use of condition monitoring systems, as well as the qualification of its service personnel active in this area. This not only benefits the wind farm operators, but in particular the manufacturers of wind energy plants. This is because certification of CMS and the corresponding inspection 6

7 Fast and efficient punching Twice the number of strokes, half the power consumption A drive-based motion control system and servo motors at the major axes are the pace-setting features of innovative automatic punching machines made in France. The fully electric machines work almost twice as fast as comparable hydraulic pendants while consuming only half the energy. Thanks to sheet metal feed from the coil and userfriendly programming, they are also extremely flexible to use. The French company Dimeco Alipresse, a member of the worldwide acting Dimeco-Group, develops and manufactures individualized coil-feeding systems, machines and accessories for sheet metal fabrication. Flexible automatic systems for punching, forming and assembly have become another core element of their product range, including the first fully electric, coil-loaded punching machine, the Linapunch MC-E. It unifies productivity and energy efficiency and is equipped with advanced control and drive technology developed by Siemens. The rows of hydraulic stamps which were characteristic of Dimeco punching machines for many years are no longer a feature of the new Linapunch MC-E. They have been replaced by two Siemens Simotics 1FK7 servo motors operating in synchronism which control the stroke movement (Z axis) using simple toggle lever kinematics and a central slide plate. The top and bottom dead centers of the toggle lever system are freely programmable, i.e. they are individually adaptable to the relevant punching task. As a result, optimized power ratios with short cycle times are available for any application. In total 13 electric controlled axes require fast and precise mutual coordination. This task is performed by the Dimeco control system Simostar, a combination of the drivebased motion control system Simotion D and a networkcabaple Simatic MP377 Multi Panel from Siemens. The latter acts as interface between the control system and the machine operator and enables set up, operation and observation of all functions of the punching machine, while a full overview of the process is given. The motion controller, in turn, is stipulated during observing the travel and hence for preventing collisions. The core of the motion controller, i.e. the Simotion D435 control module, is an integral component of the Sinamics S120 modular drive system in booksize format. This solution reduces the number of interfaces and cabling required and the overall size of the installation. Punching programs can be loaded via the network or from a USB stick, but can also be written, edited and transferred to the control system at the touch of a button while the machine is running. This capability is particularly significant with respect to contract punching which demands flexibility in processing very small batch sizes while continually changing between batch products. In times of continual rising energy prises efficiency plays a central role in addition to productivity and flexiblity. The Dimeco-example shows, that servo-drive technology is also efficient in the energy point of view: The Linapunch consumes 50% less energy than a comparable hydraulic machine while it doubles the number of strokes. Simotics servo motors at all axes and a motion controller simotion D435 from Siemens enable for the Linapunch MC-E from Dimeco Alipresse high productivity, flexiblity and energy efficiency. 7

8 Energy-efficient motors for a wide range of applications The call for industrial drives to be designed with the environment in mind is getting ever louder. This is also shown by the Green Automation Initiative launched by the VDMA (German Engineering Federation), which system manufacturers, in particular, are following to an ever greater extent. Siemens is broadening the base of its series of energy-efficient electric motors with the addition of versions in a gray cast-iron housing. IE2 and IE3 motors up to 200 kw are available for the manufacturing and processing industries. They can also be used under severe environmental conditions, and are even suitable for export to Canada, Mexico and the USA. Millions of motors are working throughout the world every day in the manufacturing and processing industries, where they are often in continuous operation. However, not least the stricter general conditions imposed by current legislation are causing changes in the electric motor industry. Since June 15, 2011, motor manufacturers in the European Economic Area can only market induction motors which fulfill the requirements of efficiency class IE2. Similar strict conditions also apply in countries such as Brazil and even stricter ones in the USA. A broad base of efficient drives Siemens has already been supplying the 1LE1 induction motors within its Simotics general purpose motor range for a number of years. They are highly energy-efficient motors in an aluminum housing. Further versions have been added to the series which substantially widen its range of applications. With the addition of the Simotics Severe Duty motors in cast-iron housing to the 1LE1 series in efficiency classes IE2 and IE3, Siemens covers the entire spectrum of industrial applications between 0.75 kw and 200 kw. Great importance was placed on The energy-saving Simotics Severe Duty Motors in the 1LE1 family have a gray cast-iron housing, which enables them to be used in severe environments, such as those encountered in the process industry. 8

9 a fully compatible frame size in the development of these versions, which are designed for use under severe conditions. This means that existing designs do not need to be modified, which saves machine and system manufacturers not only time but also the risk of making unnecessary errors. Safe in all respects The energy-saving motors in a gray cast-iron housing are available in a Basic Line for standard applications and in a Performance Line for very severe environmental conditions, such as are frequently encountered in the chemical and process industries. This is where the PTC motor protection, which is integrated as standard, is beneficial from the economic and ecological points of view. It monitors the temperature of the windings to detect thermal stress arising from the effects of unexpected process or mechanical faults at an early stage. This prevents motors being irreparably damaged by overload. The T-Drains drainage system has also proven itself in practice. A motor can be drained by simply turning the cover. Modular system approach for greater flexibility Just like the aluminum versions of the 1LE1 generation, the gray cast-iron motors also follow a standardized, practically oriented series concept. For example, the mounting feet, which are a standard part of the cast housing, are also available in a convertible, screw-on version. The modular system approach to the built-on components also enables the cast-iron motors to be equipped as required with additional pulse encoders, brakes and external fans. The obliquely divided terminal box, which can be turned in 90 degree steps, has also proved to be very useful for installing the motors, as it allows the cable to the terminal board to be laid according to the space available. The very wide range of applications for the motor versions is also demonstrated by the addition of a number of important standard-compliant details to the technical specifications. These allow machine and system manufacturers to fulfill export orders to the USA, Mexico and Canada just as easily as deliveries within the European Economic Area. Energy-saving statistics Operation accounts for about 90 percent of the lifecycle costs of an electric motor. When one considers that an IE3 is up to ten percent more efficient than an IE1, it can be seen that the investment in energy-saving motors will pay off in a correspondingly short time. The Siemens energy-saving calculator shows how quickly this can actually be achieved at The savings potential of specific applications - such as pumps, fans and compressors - can be precisely calculated at with the Sinasave calculation tool. 9

10 The Industry Sector and in brief The Siemens Industry Sector (Erlangen, Germany) is the world s leading supplier of innovative and environmentally friendly products and solutions for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the Sector enhances its customers productivity, efficiency, and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Divisions Industry Automation, Drive Technologies and Customer Services as well as the Business Unit Metals Technologies. For more information, visit The Siemens (Nuremberg, Germany) is the world s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the Division fulfills the key requirements of its customers for productivity, energy efficiency, and reliability. For more information, visit Download the latest version here: Download the pictures of this newsletter: Media Contact: Siemens Industry Sector Drive Technologies Julia Kauppert Phone +49 (0) julia.kauppert@siemens.com Siemens Industry Sector Drive Technologies Franz-Ferdinand Friese Phone +49 (0) franz.friese@siemens.com