DT Media Newsletter January 2012

Transcription

1 Integrated efficiency Cost-saving potential is in the complete drive train Drive technology is the key to energy-efficient operation in the industrial environment. This represents a large percentage of the energy costs. The energy-saving potential is thus correspondingly high. According to an analysis conducted by ZVEI this is 10% by using high efficiency motors, 30% by using frequency converters and 60% by optimizing the drive system. Depending on the particular application, an individual combination of various measures results in the maximum effect. When viewing the individual components of the drive system, the efficiency of motors can be significantly increased by using design measures and certain material combinations. Within the range of the Simotics motor family Siemens offers both High Efficiency (IE2) and Premium Efficiency (IE3) motors for various applications. The former group has an efficiency that is up to seven percent higher than conventional motors. While IE2 motors are already stipulated by law in the European Economic area, IE3 motors, too, might become obligatory within the next years. Their efficiency is up to ten percent higher than conventional motors. The maximum system efficiency can be achieved when all of the components of the drive train interact with one another in an optimized fashion. 1

2 When it comes to frequency converters, the closedspeed control is of special significance. It allows the power drawn in partial-load operation to exactly adapt to the actual demand. As a consequence, energy is no longer simply wasted; this allows energy consumption to be slashed by 60 percent, in extreme cases even by 70 percent. Energy recovery, too, is important. The Sinamics G and S converters capable of energy recovery do not require a braking resistor and feed the braking energy back into the line supply where it can be used at another location in the plant or system. As a consequence, energy costs can be slashed by up to 60 percent, for instance in hoisting applications. There are, however, more aspects to integrated efficiency along the drive train. Liquid cooling of motors and frequency converters, for example, is the more efficient alternative because the temperature of the water used for cooling increases and can be used as pre-heated service and process water. Further savings potential can be realized by energy exchange between generating and motoring axes. If some of the axes, at least in specific process phases, operate in the regenerative mode as following drives, the energy that is taken from the process can be recovered and used. This is done by using frequency converters, as is the case for the Sinamics S120 drive family for example. The state of the plant and the drives also play a crucial role when it comes to energy efficiency. Leakage might cause particular drives to be switched on more frequently and for longer periods of time without anyone knowing. Specific maintenance and optimization measures can resolve this issue. In this case, a diagnostics device, as for example the motorstarter M200D, sends a diagnostics status message when a drive is worn or when load levels increase which can be centrally monitored by a higher-level maintenance station. Excessive energy demand and increased costs can thus be prevented. All in all, it is obvious that the maximum possible energy efficiency and cost effectiveness according to stateof-the-art technology can only be achieved by taking a holistic approach. This means taking into account possible interactions and synergies of the individual measures and combining them on an applicationspecific basis. Within the range of the Simotics motor family, Siemens offers motors with a high efficiency. They form the basis of an efficient drive system. 2

3 The main thread through automation Totally Integrated Automation, or "TIA" for short, is the holistic view of automation. The benefits that it brings are clearly demonstrated in the construction of thread handling machines. As the thread must run through such machines accurately, so must all the automation components perfectly interact with each other. The safety technology also blends into the TIA concept which runs like the main thread through the plant. Threads made of polyester, fiberglass or polyamide frequently form the basis for rugged tires, tubes and seals. To achieve the required stability of the threads, they must be pretreated individually. The Mehler Engineering + Service GmbH (MES) in Fulda/Germany specializes in planning and constructing thread handling machines required for this purpose. A thread handling system was recently delivered that comprised tensioning mechanisms, immersion system and redirecting rollers to ensure even tension. The servo motors required for this purpose were driven via Sinamics S120 frequency converters from Siemens. and high degree of supply system compatibility can be achieved. In addition to the purely technical aspects, operation of the equipment is noticeably user friendly. This applies, in particular, to the easy programming and parameterization of the frequency converters which can be implemented using the "Sizer" and "Starter" programs included in the scope of supply. Starter is used by the MES planning engineers at the control level, because the settings can be saved and archived with the program. Regardless of whether the threads had to run through at a variable or constant production speed, the modular construction of the S120 converter comprising Power Module and Control Unit made it easy to combine individual drive performance values for power and control. It can be used to control synchronous and induction motors as well as torque and linear motors. Thanks to the regenerative feedback capability of the converters via so-called Line Modules, a constant DC-link voltage Solutions from the modular system, such as the pre-assembled load feeders shown here, are used for the direct drives in the thread handling machines. 3

4 The advantages of the system concept of TIA are also clear in the safety technology. The drives of thread handling machines, for example, must always rotate slowly when the new threads are being drawn in on setting up. The safety function SLS (Safely Limited Speed) is particularly useful here which, in addition to other safety functions, is integrated into the Sinamics S120 converter. On top of this, the Simatic S7-300 controller ensures fail-safe communication on the Profinet connection using the Profisafe protocol. It is also important to remember that the thread handling machines contain a number of additional drives, such as fans and pumps, that are started directly. Load feeders comprising Sirius contactors and Sirius circuit breakers of the new generation are implemented for this purpose for switching and protection. Thanks to innovative link modules, the units can be combined quickly, reliably and without the normal wiring costs. It is demonstrated here, once again, that the advantages of Totally Integrated Automation with its modern, perfectly interacting solutions pay off and it acts as the main thread running through the automation. MES equips its thread handling machines with Sinamics S120 frequency converters from Siemens. The concept of Totally Integrated Automation enables the devices to be programmed and parameterized extremely easily. 4

5 Constantly good conditions with artificial snow production The snow conditions are a major factor in the success of a ski season. The right technology is essential for those whose job it is to make winter sports an unforgettable experience whatever the weather. Schmitten AG at Zell am See in Austria is well aware of this, and has proved once again with its latest artificial snow project that the white stuff does not necessarily have to fall from the sky. With the energy-efficient drive technology for the snowmaking machines, extending the season will be even more lucrative. In the Schmittenhöhe ski area in Zell am See, 100 percent of the pistes can be covered with artificial snow. The best conditions for snowmaking are found at temperatures between -5 and -10 degrees Centigrade. Climate change has resulted in fewer cold days, so winter sports operators must constantly invest in the performance of their snowmaking machines. The latest Schmitten AG expansion stage was commissioned towards the end of 2010 and comprises three plant expansions and new constructions. Pumping systems equipped with efficient drive technology from Siemens form the central core. Simotics three-phase induction motors, that are characterized by high availability and a long service life, are used to drive the massive high-pressure water pumps for producing the artificial snow. Up to 375 kw, the upper limit of applicability of the new international efficiency standard, motors are also available off-the-shelf in the high energy efficiency class IE3 which was a decisive factor in acceptance of the drive solution. This was due to the operator's insistence on energy-saving systems, and as a result they are already endorsing these electric motors. In Zell am See, Schmitten AG ensures that the snow on the pistes is of a constantly high quality using 298 snow guns and 86 propeller systems. 5

6 The Sinamics G150 frequency converters used also have a positive effect on the energy balance. In comparison to plants with valve control of the water supply, which are still common in many other winter sports areas, electronic pressure and speed control saves a considerable amount of energy and also reduces the wear in the pumping stations. The devices are supplied in the form of "turnkey" cabinets and, thanks to their high control accuracy, they enable precisely synchronized operation of the water pumps. The more frequency converters there are in the network, however, the more harmonics there are that require compensation. Schmitten AG has chosen suitable line filters to enable it to comply with the THD (Total Harmonic Distortion) values prescribed by the energy supplier. Their matching and integration in the drive solution has just become easier. Since 2010, Sinamics converters have been available with the option L01, the so-called line harmonics filter. This complete unit is called Sinamics G150 Clean Power and contains the compensation filter as a fully integrated cabinet unit connected between the control section and power section of the converter. Finally, the safety technology also plays an important part. To produce fine granular snow, the water must shoot through the gun nozzles at high pressure, which means that the pumps have to generate a pressure of up to 100 bar due to the difference in altitude between the station and the mountain peak. If a fault occurs in the equipment unit, rapid shutdown is essential to prevent damage. It is easy to implement the shutdown of individual machines without loss of the complete pumping system, thanks to the fail-safe shutdown feature that is available as an option in Sinamics G150. This enhances the availability of the snowmaking machines and secures artificial snow production at Zell am See for the future. Simotics three-phase induction motors from Siemens provide a reliable drive system in the new high-pressure pumping stations on the Plettsau peak. 6

7 Siemens uses Sinamics SL150 cycloconverters for first time in an ore mill for copper producer Quadra FNX Quadra FNX Mining Ltd., a Canadian mining company, commissioned Siemens to modernize the drive in a SAG mill at its Robinson open-cast copper mine in Nevada, USA. This was the first time that an ore mill had been equipped with a Sinamics SL150 cycloconverter. The modernization concept developed by Siemens allowed for most of the existing electrical equipment to be retained, thus reducing downtimes during conversion to a minimum. A new diagnostics system is ensuring an immediate increase in operational reliability and availability of the plant. The Sinamics SL150 cycloconverters in operation at the Robinson mine since the fall of 2011 are the first to be used in an ore mine. Two air-cooled inverters circulate the air in a closed circuit inside the container module (e-house). This prevents ingress of dust particles or copper powder from the ambient air into the frequency converter. The standardized solution concept for modernizing ore mills means that it is not necessary to replace the motor or transformers. The software is based on the standard Simine Mill GD for gearless mill drives and was adapted for Robinson, where operation is via a twin-pinion drive. A Sinamics DCM inverter handles the excitation unit. The Sinamics SL150 cycloconverter was pre-assembled in a container module (e-house) and installed in parallel with existing components. This made it possible to install all the internal cabling and perform all the internal testing procedures prior to shutdown of the plant. Downtime during conversion could therefore be limited to only three days. Siemens' scope of supply also included new protection devices, a new diagnostics system, as well as operating data acquisition systems and a remote service feature. These provide maintenance personnel with an immediate, up-to-date overview of the relevant plant parameters and allow them to avoid or quickly remedy unscheduled shutdowns. In addition to hardware and software engineering and adaptation of the automation equipment, Siemens was also responsible for installation supervision and commissioning. Siemens Industry Inc. was closely involved in project handling. Quadra FNX Mining Ltd. was created in May 2010 by the merger of Quadra and FNX Mining and is one of North America's leading copper producers. The company runs a number of ore mines in Chile, Canada and the USA, as well as development projects in Chile and Greenland. The Robinson open-cast copper and gold mine in Nevada was bought by Quadra from BHP Billiton in Further information about solutions for the mining industry can be found at The installation of the new container module (e-house) in parallel with the existing components helped to reduce downtimes of the ore mill to a minimum. 7

8 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: Footage DT Newsletter January 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