SINAMICS GL150 medium-voltage converters. Robust and reliable performance for high power and starting applications. siemens.

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1 SINAMICS GL150 medium-voltage converters Robust and reliable performance for high power and starting applications siemens.com/sinamics-gl150

2 Portfolio The reliable and complete range Medium-voltage drives from Siemens SINAMICS PERFECT HARMONY GH180 SINAMICS PERFECT HARMONY GH150 SINAMICS GM150 SINAMICS SM150 SINAMICS SM120 CM SINAMICS GL150 SINAMICS SL kva 10 MVA (air-cooled) MVA (water-cooled) 4 30 MVA (water-cooled) MVA (air-cooled) 0 24 MVA (water-cooled) MVA (air-cooled) MVA (water-cooled) MVA (water-cooled) MVA (air-cooled) 6 85 MVA (water-cooled) (higher power on request) MVA (air-cooled) MVA (water-cooled) Output voltage kv Output voltage kv Output voltage kv Output voltage 3.3 kv (IGCT & IGBT) 4.16 kv (IGBT) Output voltage kv Output voltage kv Output voltage kv Multi-cell voltage source inverter (PH VSI) Multi-cell voltage source inverter (M2C VSI) 3-level NPC voltage source inverter (DFE VSI) 3-level NPC voltage source inverter (AFE VSI) Customizable modular voltage source system (VSI) Load-Commutated inverter (LCI) Cycloconverter (CC) Air- and water-cooled Water-cooled Air- and water-cooled Air- and water-cooled Water-cooled Air- and water-cooled Air- and water-cooled Setting the benchmark Around the globe our SINAMICS drives set the benchmark for quality and reliability. With the most diverse portfolio of drives in the industry, we can better supply the right drive solution every time. Our portfolio features: Voltage classes from 2.3 to 13.8 kv A seamless range of power ratings from 150 kw to up to 85 MW (and even higher on request) All levels of dynamic response and performance Single-motor drives and multi-motor systems Motor speeds from 10 rpm to 15,000 rpm in the Megawatt range The decisive plus when it comes to experience Everywhere it involves the highest degrees of availability, our customers rely on our drives to support their critical applications. Siemens has been offering legendary levels of reliability and performance for over four decades. Our market-leading performance and quality is not by accident it is the result of our commitment to our customers, our focus on innovation and our extensive experience and know-how that started back in 1969 with our first LCI drive. Well-proven foundation Based on well-proven technological concepts, we are continually developing our medium-voltage drives to provide: Increasingly higher reliability for our drives and your operation Improved safety Continuously reducing our drive footprints Constantly lowering the energy and service requirements Reducing maintenance costs Simplifying the handling process thoughout engineering, installation, integration, commissioning Enhancing and simplifying the operator control Always the optimum solution We can offer you the optimum drive for any conceivable medium voltage application that utilizes a drive system. We have the widest range of drive converter technology in the industry, from Load-Commutated Inverters (LCI), using thyristor technology, to Voltage-Source Inverters (VSI) with HV-IGBTs/IGCTs, to our more modular cell-based drive Topologies (with LV IGBTs) that offer greater Voltage / Power scalability and motor friendliness. It is time to stop selecting a drive that requires supplementary equipment in order to meet your application s needs and instead choose the drive that is best designed to meet and exceed your application s performance specifications and goals. 2

3 LCI drives For large synchronous motors SINAMICS GL150 LCI drives Robust technology at a reasonable price The SINAMICS GL150 drive is the cost-effective solution for large synchronous motors using LCI (Load-Commutated Inverter) technology. There is no upper limit for the power rating and the technology is extremely rugged and reliable. By using thyristors, the number of components has been reduced to an absolute minimum. Its simple and compact design makes the SINAMICS GL150 extremely reliable and with very little maintenance required. Suitable for soft starting or continuous duty operation SINAMICS GL150 is designed for single-motor drives for applications with either square-law or constant load characteristics, as starting converter for soft starting or as continuous duty drive converter for variable-speed processes. Inherent regenerative capability Its circuitry means that it is suitable for 4-quadrant operation without any additional costs i. e. it can be used for driving and braking in both directions of rotation. Maximum efficiency: Up to 50% lower energy requirement For pumps, fans and compressors with square-law load characteristic, the SINAMICS GL150 fully utilizes an important feature of variable-speed drive technology the energy efficiency: It reduces the energy consumption by up to 50%. Innovation in low power range The converter power section of the air-cooled SINAMICS GL150 has been upgraded to provide an optimized solution in the lower power range to meet current market requirements. With new options and compact design, the new converter power section is tailored to the starting applications and perfectly suited for retrofit business. SINAMICS GL150 at a glance Air-cooled up to 19.4 MW Water-cooled up to 85 MW without parallel connection (higher power available on request) Perfect for synchronous motors Compact design with highest power density per m 3 Simple plant integrations Easy-to-use operator control and monitoring Extremely reliable Low-maintenance design Seamless integration into higher-level automation systems Offers other key features such as arc-fault-tested design and control redundancy 3

4 Applications For large high-power synchronous motors and starting converter applications The SINAMICS GL150 drive is optimally suited for numerous directly driven applications. The SINAMICS GL150 is also frequently used as a starting converter for large synchronous motors. The recent innovations with the aircooled drive also expand the capabilities and increase the feasibility of the drives. Motors and generators to support lower power applications in directly driven or starting applications. GL150 supports large synchronous motor applications such as: Large high-speed compressors and pumps Main marine drives, booster drives, shaft generators Boiler feed pumps Starting blast furnaces Wire rod mills Starting generators in pumped-storage power plant SINAMICS GL150 drives serve some of the most demanding applications all around the world in industries such as: Marine Power generation Oil and gas Metals 4

5 Features & Benefits Stress-free operation in a compact, space-saving design Fuseless operation In the SINAMICS GL150, we have completely eliminated fuses in the power electronics. We are able to do this because thyristors are dimensioned to ensure they can handle over-current situations. In addition to the thyristor components, over-currents are also detected on both the line side and the motor side, and are limited by the transformer on the line side. No stress on the motor and line supply The motor voltage is generated from a separately excited synchronous motor and not by the drive. This principle means that there are no voltage gradients (dv/dt) that stress the motor. The motor insulation only has to be designed for the supply voltage and increased insulation is not required as protective measure against steep voltage edges and peaks. On the motor side, the SINAMICS GL150 is available in a 12-pulse configuration to reduce the harmonics and on the line side in a 24-pulse configuration. This fulfills even the most stringent specifications regarding harmonics. Even more compact By reducing the number of components, over the years, the drive units have become increasingly more compact. This is complemented by the modular drive converter concept. The patented LCI design is extremely compact and space-saving. The circuit configuration means significantly smaller DC links can be used. Negatively coupled reactors are 40% smaller than non-coupled devices. High efficiency The LCI concept also increases the efficiency in other important areas: The drive efficiency is extremely high (99%) as a result of the low switching losses and the low-loss thyristor technology. As a result, this reduces the demands placed on the cooling system and also the space required for the installation. Features Compared to VSI drives, most cost-competitive solution for large power ratings Rugged thyristor devices provide highest power at lowest parts count Patented DC reactor is an important differentiating feature Regenerative capability is inherent to the design Optional control redundancy Arc-fault-tested design Integration in SINAMICS control platform Mature and proven LCI topology Over 40 years of experience Large installed base Customer benefits Widely accepted solution for marine applications, starting applications and general-purpose applications above 30 MVA Highest power density results in a compact design Highly reliable Very high efficiency Highly compact design Fault-tolerant Regeneration without additional cost Robust against line supply failures For higher availability requirements Maximum safety Simplifies plant integrations, installation and operation Competitive drive solution Reassurance of proven reliability and continued support 5

6 Reliability Reliability and efficiency at the highest level SINAMICS GL150 air-cooled compact and innovative design Air-cooled version of SINAMICS GL150 power section for high power rating Perfect for high-speed synchronous motors with the highest ratings SINAMICS GL150 is admirably suited for directly driven high-speed compressors and pumps. SIMOVERT S from Siemens the predecessor of the SINAMICS GL150 controls the speed of the highest-rated high-speed compressor drive ever built. Frequently, SINAMICS GL150 is used as a starting converter to softly start large synchronous motors for instance, for blast furnace blowers. In this case, a SINAMICS GL150 brings the multi-megawatt motors up to the line synchronous speed and then transfers them over to the line supply. Over four decades of reliability LCI drives The simple and rugged concept of LCIs from Siemens has been ensuring maximum availability with a high degree of cost-effectiveness for three decades now. The combination of extremely rugged thyristor technology in a fuseless design, combined with an intelligent response to external disturbances, makes these drive units extremely reliable requiring little maintenance. The LCI concept is based on a combination of synchronous motor and simple thyristor bridges on the line and motor sides. The two thyristor bridges are force-commutated and no forced commutation circuitry is required. This makes the power electronics extremely simple and rugged. Higher motor voltages can be achieved by using a high number of thyristors with a high blocking capability in a series circuit. The series thyristor circuits for the highest power ratings can be optionally configured corresponding to an n+1 redundant design. This further increases the availability. One of the advantages of the patented arrangement of the DC link reactors is the insensitivity to a single ground fault. The power unit as well as the closed-loop control can be redundantly configured as an option to achieve the highest availability. Liquid-cooled version of the SINAMICS GL150 power unit 6

7 Redundancy Leading-edge technology that is easy to handle Technology based on the latest drive generation Four decades but always representing state-of-the-art technology: SINAMICS GL150 is the latest generation of our LCI drives. It remains an ultra-modern drive unit due to digitalization of its operation via: Full digital control, including transvector control State-of-the-art software tools for commissioning PROFIBUS interface Fully digital, including transvector control, state-of-the-art software tools for commissioning and PROFIBUS interface. The last item specifically allows for these drive units to be seamlessly integrated into Totally Integrated Automation the higher-level automation environment of Siemens as well as additional analog and digital interfaces. The thyristor modules are optoelectronically gated and the thyristors are individually monitored. Benefits of redundancy concept Increased MTBF rates Improved fault tolerance Higher serviceability Reduced potential breakdown time The new redundant control system option is fully automatic. It is a further development of proven and extremely reliable concept for marine applications, such as cruise liners where the SINAMICS GL150 serves as the main propulsion drive. Functioning in case of failure: In case of any software faults or breakdown of control components in the active system, the stand-by system immediately takes over control of the drive. In case of almost all conceivable faults and critical warnings in the control system, the complete converter remains available with 100% of its power and performance after switching over. Due to the high-performance SINAMICS software and control hardware, the transition happens automatically and needs less than 100 ms. As a result, there is no critical loss of speed or torque. The switching-over procedure has practically no effect on the application process. If there are any failures (power supply, error in the CPU cyclic operation, software faults, etc.) in the stand-by system, it will have no influence on the motor current or the voltage. 7

8 Innovation Improved air-cooled for applications from 1.4 MW to 9 MW SINAMICS GL150 air-cooled innovation The upgraded power part completes the low end of power range of the SINAMICS GL150 family portfolio as single drive for applications with a quadratic, constant load characteristic. The new line-up consists of: 6/6 pulse drives up to 5 MW 12/12 pulse drives up to 9 MW Typical applications for air-cooled converters in this power range are: Starting converter for large synchronous motors and gas-turbine sets Starting converter for pumps and fans The new design is characterized by: The use of proven and reliable SINAMICS GL150 components Compact dimensions Reduction of parts Compact design of the DC-link reactor thanks to forced cooling (weight reduction) Optimized busbars that permit the integration of the internal disconnector option (avoiding the need for an additional cabinet) Stable cabinet covers without doors in the mid-voltage section (arc-fault- and earthquake-tested design) Accessibility of the low-voltage section, even during operation A special line-side fuses retrofit option integrated in the design Line-side internal synchronization voltage sensing (only for starting converters) 8

9 Innovation 9

10 Soft starting Getting everything up and running just right Circuit-breaker Converter transformer Line-side thyristor converter Starting converter control DC link with reactors Motor-side thyristor converter Synchronizing control Step-up transformer Bypass circuit-breaker Block diagram of a starting converter in this case, for two synchronous motors High-voltage synchronous motor Excitation equipment SINAMICS GL150 as starting converter for soft and reliable starting When used as starting converter, SINAMICS GL150 can bring a maximum of four multi-megawatt motors up to the synchronous line supply frequency and then transfer them over to the line supply. The transfer is bumpless which reduces the stress on the line supply and the complete mechanical transmission line. The consequence less wear and a longer equipment lifetime. Using SINAMICS GL150, even blast furnace blowers with power ratings above 50 MW can be started from standstill and transferred over to the line supply within one to two minutes. With this starting technique, the rotor is not thermally stressed as the motor is already operated in sync with the supply voltage starting from zero speed. This is quite a different situation than when using either a reactor or auto-transformer start. The rate of successful starts lies above 99% and is therefore significantly higher than when using conventional starting techniques. This represents a decisive step in achieving higher availability and better cost-effectiveness with blast furnace systems. 10

11 Commissioning From installation to operation in no time Medium-voltage drives the simple way Not only is the technological concept of the SINAMICS GL150 simple and rugged. Installation, integration into the plant and operator control are also simple and straightforward. All of the closed-loop control functions, the power supply, the signal adaptation elements and the terminals for external signals are accommodated in a system cabinet thus eliminating several integration steps. Simple integration into the plant Integration into the plant is simplified as a result of the low envelope dimensions of the unit regardless of power rating and its high degree of flexibility when it comes to the configuration. In addition to that, all of the open-loop control and power electronics, the excitation supply, the incoming switchgear and all of the auxiliaries can be installed in special prefabricated containers. This reduces construction and installation costs. Lastly, the drive system arrives on site already tested, which can significantly reduce your project and commissioning times. Commissioning made easy STARTER is the standard commissioning tool for all drives belonging to the SINAMICS family. Without requiring any special system know-how, the commissioning engineer can configure even the most complex systems in a short time thanks to the simple, menu-prompted operator interface. Functions can be checked and parameters optimized using integrated test routines. Trace functions graphically show signal characteristics therefore simplifying drive optimization and diagnostics. 11

12 Compatible motors Best prerequisites for maximum security against failure Synchronous motors and drives from Siemens Siemens synchronous motors at a glance Power ratings Voltages Shaft heights Speed No. of poles 2 8 Degree of protection Explosion protection Cooling Bearings MW and more kv 710 1,250 mm up to 6,300 rpm IP55 Ex p, Ex n Air-to-air heat exchanger Air-to-water heat exchanger Sleeve bearings, active magnetic bearings Unbeatable range of drive products Siemens is globally the No. 1 for medium-voltage drives and for high-voltage motors. The range of units covers all conceivable medium- and high-voltage applications in all major process industries, and across all voltage classes and power ratings. Confidence-building experience For many decades now, Siemens has been one of the leading suppliers of LCI drives that have ratings extending up into the high double-digit megawatt range. They have been running in combination with our HV motors for years in some instances for decades around the world, driving compressors, pumps, blowers, extruders, kneaders and crushers with some of the highest power ratings. SIMOTICS HV high-voltage motors The extensive portfolio of SIMOTICS HV high-voltage motors has the solution that precisely fits each and every high-voltage industrial application. They set themselves apart as a result of their outstanding reliability and performance, as well as the range of motors, with power ratings up to 100 MW and voltage classes up to 13.2 kv. 65-MW compressor motor running at 3,600 rpm for the first completely electric gas liquefaction system in the world in Hammerfest / Norway Soon to be winging its way to site: A 24-MW motor for the West-to-East Pipeline in China One of the two 21-MW motors for the main drive of a cruise ship 12

13 Compatible motors The system partner on the motor side more than just reliable Together with SINAMICS GL150, Siemens synchronous motors form a perfectly Integrated Drive System: Whether for high-speed compressors with the highest power rating for transporting or liquefying gas, or large extruders and water pumps or for main ships drives, these rugged synchronous motors are the foundation for maximum reliability. The enclosure, bearings, active parts, ventilation and cooling system are perfectly harmonized with one another. The materials, components and production techniques utilized have been carefully selected with this objective in mind. The Micalastic insulating system that Siemens uses for all our high-power high-voltage motors has proven itself over many years of operation in applications all around the world. An important component is the VPI insulation technique (Vacuum Pressure Impregnation) which allows the motor to be connected directly to the line supply and MV drive. The insulation has a high switching and reversing strength as a result of the high winding overhang stiffness and excellent corona shielding. All of this together with the extremely high mechanical strength and thermal endurance ensure an extremely long winding lifetime. The bearings also have extremely long lifetimes and require hardly any maintenance. Motors with integrated safety Siemens synchronous motors are equipped as standard with bearing and winding monitoring devices to cope with even the most extreme situations. It goes without saying that all of the synchronous motors are available in explosion-protected versions: With pressurized enclosure Ex p for gas explosion protection, Zone 1. For high-speed synchronous motors, we also offer oil-lubricated sleeve bearings or active magnetic bearings. When using magnetic bearings, an extremely wide speed control range can be implemented for instance, 600 6,300 rpm at 23 MW when fed from a SINAMICS GL MW motor running at 5,040 rpm for a compressor station of a gas pipeline from Great Britain to Belgium 23-MW motor running at 6,300 rpm to pump gas south of Groningen / The Netherlands 42-MW motor for the blast furnace blower in the Anshan steelworks, China 13

14 SINAMICS GL150 Technical data Specifications Power connection Line supply voltage Air cooling: up to 5.4 kv +/ 10% Water cooling: up to 12 kv +/ 10% Frequency: 50/60 Hz +/ 3% Line supply power factor: approx at rated speed and load Either from the top or bottom Motor connection Motor voltage Air cooling: up to 4.8 kv Water cooling: up to 11 kv Either from the top or bottom Auxiliary power supply Air-cooled: 1 AC 230 V ± 10%, 50/60 Hz ± 3% 3 AC 400 V ± 10%, 50/60 Hz ± 3% Water-cooled: 1 AC 230 V ± 10%, 50/60 Hz ± 3% Line-side rectifier LCI (Load-Commutated Inverter), thyristor rectifier in a B6C-circuit, 6-pulse, 12-pulse or 24-pulse, regenerative feedback into the line supply Motor-side inverter LCI (Load-Commutated Inverter), thyristor inverter in a B6C-circuit, 6-pulse or 12-pulse Efficiency > 99.0% at rated speed and load Cooling Air cooling with top-mounted cabinet fan Water cooling using heat exchanger with redundant pumps as standard Degrees of protection Air cooling: IP20 (higher degree of protection on request) Water cooling: IP41 (higher degree of protection on request) Ambient conditions Temperature: C ( F), up to 45 C (113 F) with power derating Installation altitude: 1,000 m above sea level: 100% load capability > 1,000 m to 3,000 m above sea level: Current derating > 2,000 m to 3,000 m above sea level: Additional voltage derating Humidity: < 85% (condensation not permissible) Safety functions (this is only a selection of those available) Short-circuit and ground fault monitoring Overcurrent, overvoltage and undervoltage monitoring Line supply voltage failure monitoring Overtemperature monitoring (drive converter and motor) Overspeed protection, anti-stall protection (motor) Cooling circuit monitoring Self-diagnostics of the control and power unit Closed-loop control Vector control with and without speed encoder Separately excited synchronous motors can be connected (excitation equipment is available separately) Operation as starting converter Operation as continuous duty drive Speed accuracy: ± 0.1% without encoder, ± 0.01% with encoder Torque accuracy: +/ 3% Field-weakening operation Starting converter: 1:8 Continuous duty drive: 1:1.5 Maximum output frequency: 125 Hz Standards IEC, EN, CE DIN EN / VDE 0160 T103 (IEC ) DIN EN / VDE 0160 T104 (IEC ) DIN EN / VDE 0160 T105 (IEC ) DIN EN / VDE 0558 T11 (IEC ) DIN EN / VDE 0160 (IEC 62103) DIN EN / VDE 0113 T11 (IEC ) Standard features Flying restart Automatic restart Operating hours counter for fans and circuit-breaker Maintenance functions STARTER software for user-friendly commissioning and diagnostics with a PC Control I/O Analog inputs: 2/4 Analog outputs: 0/4 Digital inputs: 6/6 Digital outputs: 4/16. Others through optional expansion modules Speed encoder Communications: PROFIBUS-DP or PROFINET (other on request) Selection of additional options Increased degree of protection Suitable for marine duty Teleservice module Anti-condensation heating Additional I/O modules Output transformer (starting converter) Bypass control for up to 4 motors (starting converter) Demagnetizing equipment for the output transformer (starting converter) Redundant configurations (control and/or semiconductor redundancy) Grounding breaker at the input and output Circuit-breaker at the converter output Various versions of the heat exchanger 14

15 Rated output current Output voltage Shaft output No. of pulses, line side A V kw hp No. of pulses, motor side Article No. 1 Configuration GL150 air-cooled innovation 2 1, / 1.3 2,800 3, SL3850-2UL1 - A0 I 1, / ,900 5, SL3850-2UL1 - A0 I 1, / 2.3 3,900 5, SL3850-2UM1 - A0 I 1, / 2.3 4,800 6, SL3850-2UM1 - A0 I 2 x 1,340 2 x 2.5 / 2.3 9,000 12, SL3850-8UM1 - A0 J GL150 air-cooled 1,700 2,600 6, , / SL3850-3UN1 - A0 A 1,500 4,600 9, , / SL3850-3UP2 - A0 B 2 x 1,700 2 x 2,600 12, , / SL3850-5UN2 - A0 B 2 x 1,500 2 x 4,600 19, , / SL3850-5UP3 - A0 C GL150 liquid-cooled 2 x 2,400 2 x 2,400 16, , / SL3855-5UM4-0 D 2 x 2,350 2 x 4,800 32, , / SL3855-5UP5-0 E 2 x 2,350 2 x 7,200 48, , SL3855-5US6-0 F 2 x 2,350 2 x 9,600 64, , / SL3855-5UU7-0 G 2 x 2,350 2 x 11,000 74, , SL3855-5UW7-0 H 1 Please contact your sales partner to complete the configuration 2 Available in new innovative air-cooled configuration 3 Values are referred to the data of a typical synchronous motor 4 Please inquire, modified frame size Configuration Width Height Depth Weight Dimensions (air-cooled innovation) mm inch mm inch mm inch kg I/I 2, , , ,000 J 3, , , ,000 Dimensions (power unit) A 2, , , ,300 B 3, , , ,600 C 6, , , ,700 D 4, , , ,400 E 5, , , ,000 F 7, , , ,000 G 9, , , ,000 H 9, , , ,000 Dimensions (drive control ) 1, ,

16 There s Find out more: to it siemens.com/sinamics-gl150 Discover the advantages of the SINAMICS GL150 Scan the QR code below and learn about how the SINAMICS GL150 improves performance and reliability for high power and starting applications. The advantages of SINAMICS GL150 at a glance Subject to change without prior notice Article No.: PDLD-B Dispo GuB/... WS Printed in Germany Siemens AG 2015 The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners. Follow us on: twitter.com/siemensindustry youtube.com/siemens Siemens AG Process Industries and Drives Large Drives P.O. Box NUERNBERG GERMANY