DT Media Newsletter. Sinamics frequency converters used in construction of JadeWeserPort deep-water harbor in Wilhelmshaven, Germany

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1 Sinamics frequency converters used in construction of JadeWeserPort deep-water harbor in Wilhelmshaven, Germany A 100-meter-long suction dredger is being used to construct the JadeWeserPort deep-water harbor in Wilhelmshaven. The speed-controlled drive concept for the underwater suction pump features Sinamics frequency converters from the Siemens Drive Technologies Division. This means the pump drive unit is not only energy-efficient but also grid-friendly, and it simplifies servicing of the entire suction dredger. At the mouth of the river Jade in Wilhelmshaven on the North Sea coast, the JadeWeserPort is emerging as a new deep-water harbor independent of tidal influence. The work will involve flushing huge amounts of earth into the mouth of the Jade. The construction company, Bunte of Papenburg, commissioned the development of the mega dredger Pirat X for this purpose. It is 100 m long, 16 m wide and with a flow rate of up to 12,000 m3/h of water-solid mix, the ship can extract and flush up to 70,000 m3 of sand per day. The suction pipe is equipped during normal operations with a cutting head that breaks up the seabed to a depth of 32 m. The cutting head is driven by a hydraulic motor with a capacity of 1 MW. The suction mechanism has three pumps located behind each other. Underwater pump 1 with a power requirement of approximately 850 kw is driven by an electric motor and is located at the front on the air intake. Its task is to take up the water that has been separated from the sand and to force it through the suction pipe to pump 2. Located at the upper end of the suction pipe and behind it are pumps 2 and 3, each with a 1.8 MW rating. The pumps transport the rinsed sand to its final destination. These are driven directly by diesel motors. The 100-meter-long suction dredger Pirat X is being used in the construction of the JadeWeserPort deep-water harbor. 1

2 Precise and efficient: variable-speed drive system Underwater pump 1 is equipped with a variable-speed drive system. This motor is specially designed for operation under water. A special three-chamber principle in the terminal box prevents the motor from immediately filling with water if a cable bushing should become porous. The motor output is controlled at a rated power of 1 MW via a Sinamics S150 frequency converter from Siemens that features an active infeed module. Furthermore, the active rectifier circuit of the infeed converter is equipped with a clean power filter. The harmonic component is thus reduced to a minimum, preventing any damaging additional temperature rise in the supplying onboard generator. On the motor side, the frequency converter is equipped with a voltage limiter to protect the motor insulation as far as possible. The required energy is provided by a built-in diesel generator. The mechanical rated power of the generator is 949 kw and thus harmonizes with the rated power of the diesel unit. Like the motor, the generator is equipped with PT100 temperature sensors in the windings and bearings, and it has an anti-condensation heater. The semi-sinusoidal load generated by the active infeed module of the frequency converter allows full utilization of the generator despite inverter operation. For this reason, it was possible to select for the Jade-Weser project a 12-cylinder standard diesel unit that was available at short notice. Benefits of speed-controlled drive solutions Thanks to the use of Sinamics S150 speed-controlled frequency converters, the suction pump can adapt quickly and precisely to the fluctuating granule sizes of the gravel and sand. The mechanical components of the entire drive train are also protected thanks to the Thanks to variable-speed drives, energy can be saved in the double-digit percentage range, especially in the case of fluid-flow machines like pumps. soft, stepless starting and stopping in variable-speed operation. The speed, and thus the energy consumption, is constantly and precisely matched to operating requirements. In addition, the drive can be rotated with the converter extremely slowly in the clockwise and anti-clockwise directions. This means that the problem of extremely tight screw connections can be solved through the interaction of a suitable screw fixing device and a fixed, extremely slow rotational speed. A handheld service operator station specially constructed for this purpose is connected with the converter controller via a plug-in connection. This signals to the converter when repair is necessary, so that only extremely slow speeds are implemented. In conclusion, the demanding and unique project involving the huge suction dredger was carried out in a practical and energy-efficient way. 2

3 Efficient irrigation energy-saving drive system for pumping stations The irrigation of agricultural areas in southern countries has to be as effective and sustainable as possible. The energy efficiency of the pump drives is crucial to achieving cost efficiency. This is the reason why variable-speed drive systems with Sinamics frequency converters from Siemens are used in the irrigation areas of Alentejo in southern Portugal. The Brinches Laje pumping station is designed for 3m2/s flow rates and irrigates 12,000 hectares of land using energyefficient drive systems. The Alqueva reservoir in Alentejo in the south of Portugal is the largest artificial lake in Europe and is used to irrigate more than 110,000 hectares of land. EDIA (Empresa de Desenvolvimento e Infra-Estruturas do Alqueva) is responsible for operating the reservoir, and decided in favor of variable-speed, and thus energy-saving, drive systems from Siemens for the Brinches Laje pumping station that irrigates 12,000 hectares of land. Energy wastage is an important topic for fluid-flow machines such as pumps because their power consumption increases exponentially with their speed. For this reason, EDIA s most important requirement for the drive system was the need to constantly adapt the flow rate of the pump to match current water demand without wasting energy in the process. Siemens was able to meet this requirement by deploying ten low-voltage motors of the N-compact series in combination with Sinamics G150 frequency converters. As well as their compact design, the N-compact lowvoltage motors are characterized by their high efficiency, helping to minimize the energy requirements of the pumping station. However, using the Sinamics G150 frequency converters has an even greater impact on the energy balance. The frequency converters constantly adjust the speed of the motor precisely to the required flow rate, and only draw as much energy as required. This reduces energy requirements by a doubledigit percentage figure. The flow rate can also be set considerably more precisely, and with shorter response times than is the case with throttles or valves. Soft starting and stopping reduces the stress on the mechanical system of the complete drive train, and increases its service life. However, the coordinated drive systems are not isolated solutions, but part of an integrated overall concept. This is why, in addition to the drive systems for Brinches Laje, Siemens also provided programmable controllers, local and remote monitoring systems, and low-voltage switchgear. The entire drive and automation landscape is precisely tailored to the requirements of EDIA and its irrigation project. 3

4 Siemens presents new central drive for tube mills Siemens Drive Technologies Division presents a new central drive for tube mills. Besides its low weight and customer-orientated design, the HCPP 751R stands out with a high level of power density. In addition, the output flange redesign and the shift from forced to splash lubrication has meant a significant reduction in the new central drive s manufacturing costs. A tube mill is one of the largest machines employed in the basic materials industry and is used to grind minerals, ores, coal or cement clinker, and can be driven with either a central or a lateral drive. Central drives particularly have proven themselves in demanding applications where high mill throughput is required. At a total weight of 41.7 t, the new gear unit is far lighter than its predecessor. While Siemens has offered a complete portfolio for lateral drives for some time now, the new central drive completes the tube mill product portfolio. The new foot-mounted gear units for 3,800 kw milling applications have one helical and two planetary gear stages. The output flange is directly connected to the mill via a customer-provided coupling, which enables high torque transmission from the gear unit. Furthermore, the large number of planet gears results in low specific tooth mesh loads and the integrated housing feet enable optimal force flow. The new output flange design and the shift from forced to splash lubrication has enabled a significant reduction in manufacturing costs for the HCPP 751R. The new gear unit is also lighter than its predecessor. Immediately following the central drive s further development, Siemens received an order from one of the largest Chinese cement plant manufacturers. 4

5 Bones made of titanium: CNC technology from Siemens ensures ultimate precision Stringent legal requirements apply to the production of medical implants. From the product design to materials and on through the production process, the prosthesis manufacturer must document and validate the full chain of production. CNC-controlled, high-tech machines enable manufacture of the required high-quality products under constantly high cost pressure. The number of synthetic bone implants is increasing. In Germany, for example, more than 200,000 total hip endoprostheses are implanted annually. This figure cannot conceal the fact that each individual implant must satisfy most stringent requirements. No matter whether the implant is custom-made, or a series product, the production process must be stable and safe at each and every step. So it makes good sense to adopt a reliable technology that helps the manufacturer to satisfy these requirements. Synthetic bones made of titanium are primarily manufactured in cutting processes. Implantcast in Buxtehude/ Germany runs its production of acetabular hip cups on lathes from Siemens. The wide, high-performance functional range of the CNC system is equally suitable SINUMERIK 840D sl with user interface Sinumerik Operate: The two-channel representation creates transparency when programming and setting-up even the most complex parts. The new complex Cephtar SC acetabular hip cups are attached to the bone by means of a thread. for complex individual components and for large quantities. Its fast data processing capability is optimal for series production. The same machine can also be used for the development of new products. For this purpose, Siemens offers an integrated process chain from CAD/ CAM, through data transmission, on to the Sinumerik CNC system for fast and traceable incorporation of changes. Despite its advanced functions, the Siemens control system enables economic and effective production, even for small batch sizes. The intuitive Sinumerik Operate user interface plays a decisive role here with self-explanatory icons on all levels that are easy to configure as favorites. Numerous intelligent functions defined for processing the workpiece are easy and fast to program. A program simulation mode displays the entire cutting process in 3-D to avoid the risk of programming errors and potential related damage to the machine. Medical implants permit no compromise in quality and precision whatsoever. The Sinumerik MDynamics technology package ensures the required surface quality and produces best milling results even at high speeds and on demanding material like titanium. The end of the process chain is not reached until each part has passed a comprehensive quality check. Sensors inspect the accuracy of the contour and the surface finish, and scrutinize the surface for even slightest damage. Implants from implantcast do not reach goods dispatch, and ultimately the patient, until these hurdles have been taken. 5

6 The Industry Sector and Drive Technologies Division 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 Drive Technologies Division (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 Franz-Ferdinand Friese Phone +49 (0) franz.friese@siemens.com