Download Drives for Water Industry

Innovative technology
for the highest availability
and cost-effectiveness
Drives for Water Industry
Answers for industry.
No compromises when it comes to
supplying water with the highest quality
In the water industry, topmost priority is given to achieving the optimum water quality and an absolutely
reliable supply. At the same time, ever-increasing cost pressure demands water plants with the highest
degree of cost-effectiveness. As a consequence, the technology used must operate reliably, efficiently
and with a high degree of precision.
The demands placed on the drive technology are especially high. Drives play a key role when it comes to
supply reliability and plant efficiency. Pump drives maintain the water pressure at the right level around
the clock, always adapt the pumped quantity to the actual demand and regulate, where required, the
mixing ratio. Further, their energy demand is the most significant element of the overall energy costs.
With this as background, drive converters offer enormous cost-saving potential: The precise and continuous closed-loop speed control ensures that the drive runs at the optimum operating point – and
that energy costs can be significantly reduced.
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First-class solutions for all tasks
Whether small distribution pumps, blower
compressors in water treatment plants or
multi-Megawatt drives in large main pumping stations. As partner to the water industry, Siemens offers a unique and extensive
range of products and systems that addresses all of the sector-specific drive applications encountered in the water industry.
With our solutions we consequentially ensure the highest reliability and efficiency.
We offer individual components as well as
products and systems that are perfectly
harmonized and coordinated with one
another; these are based on proven standards and tailored solutions – from a single
source. Our portfolio includes motors and
drive converters with a power rating of a
few Watts up into the high double-digit
Megawatt range, low-voltage drives as
well as medium-voltage drives.
Perfectly tailored to the
requirements of the sector
Our motors and converters ensure optimum pumping – with the maximum degree of availability and with minimum
operating costs. In fact, these advantages
can be further expanded if our drive components work together as a system. This
is because we develop and manufacture
our motors and drive converters right
next to another, we perfectly harmonize
them and subject them to a grueling test
under real operating conditions in one of
our state-of-the-art system test facilities.
The result: Drive systems that distinguish
themselves as a result of the highest
degree of availability and maximum
efficiency.
Typical applications
In water supply
• Retrieving drinking water
• Transporting water
• Dosing
• Treating drinking water
• Distributing water
• Irrigation systems
In wastewater
• Transporting wastewater
• Transporting sludge
• Aerating and mixing the
activated sludge
• Centrifuges
• Equipment in wastewater handling
such as rakes etc.
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The key to the highest supply availability:
Reliability in continuous use
A water supply must be guaranteed
The complete bandwidth of motors
Rugged with a long service life
around the clock. This is the reason
Our motors set standards when it comes
to reliability and efficiency. Our portfolio
extends from standard motors for pumping stations up to special submersible
pump motors with degree of protection
IP68. We also offer explosion-protected
motors e.g. for the settling process. They
have a flameproof enclosure and on the
pump side they have a rotating axial seal.
Our motors distinguish themselves as a
result of their rugged mechanical design,
long lifetime as well as low maintenance
and reliable operation. Enclosures, bearings, active parts, ventilation and cooling
system are perfectly harmonized with
one another. Innovative insulation systems in conjunction with the VPI technique ensure a high voltage strength
when either connected directly to the
line supply or fed from a drive converter.
These insulation systems also result in
stiff winding overhangs and excellent corona protection for maximum switching
and reversing strength. Our motors play a
decisive role in achieving a higher degree
of plant availability and a more reliable
water supply.
that in many applications the name
of the game is reliable long-term and
continuous use. Put in another way:
Absolute fault-free operation is mandatory – the same goes for the highest
efficiency. This is because the energy
costs are especially important for
motors that continually run.
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Our portfolio includes motors with every
possible conceivable cooling type and degree of protection to comply with almost
any specification – such as pump motors
with locating bearings on the drive side
and integrated PTC thermistors – as well
as high-power torque motors. These gearless permanent-magnet synchronous motors are especially reliable, require little
maintenance but have an extremely high
efficiency. They are especially suitable for
slow-running pumps.
Additional advantages:
• High mechanical strength and
thermal endurance
• Extremely long lifetime and
low-maintenance bearings
• The vibration quality surpasses
stringent IEC and NEMA standards
• Innovative cooling systems for uniform
cooling and minimizing the thermal load
• Enclosure that is resistant to shocks
and vibration and with a high
vibrational stiffness
• Corrosion protection for humid and
aggressive environments
operating costs. We offer energy-saving
motors in the “High Efficiency” version for
the range up to 200 kW – that is especially
efficiency-sensitive. Up to 90 kW, these
motors are designated as efficiency class
EFF1. When compared to conventional
motors, they have losses up to 40% less –
which often means that they have a payback time of just a few months.
• 1LE1, 1LA9 and 1LG6 motors fulfill both
EFF1 as well also EPAct efficiencies
• Lower operating costs as a result of the
high EFF1 efficiency
• High motor and lubricant lifetime
thanks to the lower motor temperature
for EFF1, EPAct and NEMA motors
• CO2 reduction in operation reduces the
environmental impact
Highest power in the smallest space
Energy-saving motors
Geared motors: Concentrated power,
compact design
Our motors are unbeatable when it comes
to envelope dimensions and weight at
any power rating. This means that they
require significantly less space and can be
simply integrated into a complete plant.
Further, they are also extremely quiet –
additional noise-reducing measures are
not required.
The best example for cost-saving, efficiency and environmental friendliness:
Our energy-saving motors that require
less energy for the same power output.
In fact, this can even be proven with the
appropriate calculations using SinaSave®.
This is a software tool that we developed,
which allows you to calculate the payback time of your investment.
Significantly lower maintenance costs
As a result of their service-friendly design,
our motors distinguish themselves due to
the extremely long maintenance intervals.
Further, the high efficiencies improve the
energy consumption therefore reducing
The advantages – an overview:
• Complete product range according to
EU/CEMEP, EPAct and NEMA
• Simple motor selection using an efficiency classification system (EFF1/EFF2)
Our MOTOX series of geared motors have
output torques up to 20,000 Nm and higher
rated gear unit torques than conventional
geared motors but with the same envelope
dimensions. All gear unit types are available
in the power range from 0.09 kW to 200 kW –
from helical through offset shaft, helical
bevel and helical worm up to worm geared
motors.
They are admirably suited for applications
such as longitudinal and rotary scrapers,
rakes, mixers or spiral conveyers.
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A farsighted investment:
Drive converters for
variable-speed operation
Flow rates can be controlled far more precisely and faster with variable-speed drive
systems than when using mechanical control concepts – and can be adapted to the
actual demand. The advantage: A significantly higher degree of reliability and quality for water and wastewater systems. Further, variable-speed operation opens up
enormous cost-saving potential. This is the reason that a drive converter often has
a payback time of just a few months.
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The clever alternative to fixed speeds
For conventional control techniques, the
motors always run with the speed required
for the maximum flow rate. Excessive flow
rates are mechanically “throttled” – which
means that energy is simply thermally dissipated. Contrary to this, state-of-the-art drive
systems with drive converters precisely adapt
the speed – and therefore the energy drawn –
to the actually required flow rate. The motor
therefore only draws the actually required
power. Power factor and efficiency remain
almost constant. This avoids over-dimensioning the motor and the energy requirement
is significantly reduced. The cost-savings are
especially high for positive displacement
machines – such as pumps or blower compressors and depending on the plant characteristic, can be up to 50%, even up to 70%
in extreme cases .
Low-stress operation reduces
maintenance costs
The starting characteristics of a variable-speed
drive also have a positive impact: Only the rated current is drawn, which means that current
peaks – that typically occur when starting –
are eliminated along with the associated high
torque surges. The soft starting and stopping
reduces the stress on the complete mechanical drive transmission line. Further, operating
conditions that can damage the machine or
system – such as cavitation, the inclusion of
gas, compression surges and vibration – can
be eliminated. By slightly adapting the motor
speed, cavitation bubbles that damage the
pump impeller blades can be eliminated and
continuous streams of gas being pumped
along with the medium are avoided. Not only
this – ultrasonic compression surges typical
for compressors are also eliminated. Suppressing certain pump speeds also avoids undesirable vibration and oscillation. Additional advantages include: Mechanical control elements
are eliminated, the power factor is improved
and the process control optimized when
compared to mechanical control techniques.
The complete range of drive converters
We supply the ideal drive converter for every
application and every motor. As a result of
their modular design and wide range of available components and options these drive units
can be optimally adapted to the specific application requirements and be combined to form
perfectly harmonized, reliable and highly-efficient systems. The drive units are designed so
that their energy-saving potential can be especially effectively utilized. With their rugged
closed-loop vector control that does not require an encoder they are specifically tailored
to drive tasks without regenerative feedback
into the line supply – this makes them ideal for
applications in the water industry.
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SINAMICS: The unified and
integrated drive family
With SINAMICS, Siemens is offering an innovative family of drives that sets
standards in every perspective. In addition to a standard and simple operator
control philosophy, the members of the SINAMICS family all use the SIZER
Simple to operate
Whether low voltage or medium voltage:
All of the SINAMICS cabinet units are
equipped with the user-friendly AOP 30
operator panel that displays simple operator control and commissioning functions
in plain text. This means that no additional manuals are required when commissioning the drives. Drive parameters such
as current, actual speed and speed set
point are displayed in operation using
bar-type displays.
engineering tool for selecting and dimensioning as well as STARTER for commissioning and diagnostics. The following drive units are precisely predestined
for the water industry: SINAMICS G120, G130, G150, GM150 and GL150. And
for especially stringent requirements on the line supply quality, the S series
with SINAMICS S150 or S120.
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Numerous interfaces and highest availability
SINAMICS drives are equipped with
numerous interfaces:
PROFIBUS, PROFINET and various analog
and digital inputs and outputs. This ensures that the drive units can be easily
integrated into higher-level automation
systems. All SINAMICS drive units distinguish themselves as a result of their highest degree of availability. Their simple,
clearly structured design makes them
rugged and reliable. When service is required, modules can be replaced with just
a few manual operations – special tools
are not required. Further, intelligent
maintenance functions can be integrated,
e.g. in the medium-voltage
SINAMICS GM150 drive converters that
automatically issue a signal if maintenance is required. Service and maintenance work can always be optimally
planned. This means that unpredictable
and sudden pump failures are a thing of
the past – which also goes for the resulting supply bottlenecks.
Space-saving and quiet
Our drive converter cabinets have a footprint that is up to 70% less than conventional units thanks to their exceptional
compactness. This means that electrical
rooms can be dimensioned significantly
smaller – which has a positive impact on
the costs. Integration into existing plants
and systems is also simplified. Our drive
converters are the first choice when it
comes to low noise: Only 69 db(A) at full
load – even for cabinet units with power
ratings of several 100 kW, additional
noise-reducing measures are simply not
required.
First choice for pump drives
• Rounding-off times avoid overpressure
conditions and water hammer therefore reducing the level of stress on the
hydraulic and mechanical systems
• To ensure safe, reliable operation,
mechanical resonance frequencies are
skipped, locked rotors are detected and
loads monitored
• The efficiency is optimized for no-load
operation; the flux set point of the control
is adapted depending on the load. Under
no-load conditions, this reduces the rated
motor flux by up to 50% and saves the
corresponding amount of energy
• Operation can be monitored online
It is being increasingly specified that
pumps must also be disconnected from
the line supply in a controlled fashion if
the flow rate is to be reduced. This is
mainly done to avoid oscillations in the
hydraulic system.
feed several motors and pumps – the perfect solution especially when it comes to
pumping large quantities of water. A typical example of such an application: The
drive converter starts the first pump and
monitors its speed. As the rate of flow
increases this pump drive is synchronized
and connected to the line supply. The
same drive converter is then used to start
a second pump – that is then used to precisely control the flow rate. This means
that pumps are not directly connected
to the line supply (direct start) therefore
avoiding undesirable high starting currents. With this constellation, theoretically, an unlimited number of pumps can be
monitored using just one drive converter.
Bypass function: Using this function integrated in the drive converter, a pump motor can be connected to the line supply –
either when a specific speed is reached
or using a separate command with a contactor. There are two versions of this bypass circuit: Without (cold synchronization) or where the motor is synchronized
to the line supply (hot synchronization).
This means that the drive converter can
be used as starting and stopping converter and staging functionality can be more
simply implemented. The staging function
permits a drive converter to be used to
Flying restart function: This function is
used to connect a drive converter to a motor that is still running. If the drive converter was to be powered up without this
function, then the motor would not be
able to establish its flux. This could cause
the drive system to trip due to an overcurrent condition. The flying restart function
first determines the motor speed.
Technology controller: The technology
controller integrated as standard controls
process quantities such as pressure,
quantity, temperature, level.
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Customized SINAMICS functions
Specific pump functions
A whole raft of functions – that have
been specifically designed for pumps –
can be implemented using a software
macro. This simplifies the operator control and parameterization of the drive
converter. The pumps functions are
already pre configured.
EnergySaving: If the motor is not required
it can be completely shut down using this
function. This is done automatically if the
system deviation of the technology controller lies below a defined limit value for a
time that can be parameterized.
EnhancedEnergySaving: This function
can be used to extend the time for which
the drive converter is powered down as a
result of the EnergySaving function – in
order to save more energy and to avoid
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unnecessarily starting and stopping the
pumps. And an additional spin-off – the
pipes are also purged.
MaintenanceCleaning: A constant flow
rate means that suspended particles in the
liquids being pumped can be deposited
over time. This can reduce the effective
pipe diameter or even block the pumps.
The MaintenanceCleaning function is used
to briefly increase the pump speed to
counteract this sediment build-up.
WallDepositsPrevention: If tank levels
are kept constant over a longer period
of time in wastewater treatment systems
deposits occur at the edge of the tank. To
avoid these deposits, the WallDepositsPrevention function always varies the set
point for the technology controller so that
the tank level is permanently raised and
lowered.
Additional SINAMICS functionalities
for the water industry
MICROMASTER low-voltage converters
Medium-voltage drive converter:
ROBICON Perfect Harmony
The MICROMASTER family of drive converters addresses drive applications in the
power range from 0.12 kW to 250 kW
and distinguishes itself as a result of the
extremely easy handling – from installation & mounting through commissioning
up to operation. These drive units are
suitable for pump drives up to 250 kW
and can control up to three motors. They
are equipped with an integrated dry running protection for pump drives – as well
as additional features for specific applications that can be implemented using
freely assignable function blocks.
ROBICON Perfect Harmony rounds off our
drive portfolio in the medium-voltage level. It is the undisputed No. 1 worldwide
in medium-voltage drive converters regarding both market share as well as installed power. With this drive unit, lowvoltage cells are connected in series so
that a medium-voltage drive converter is
created that can be extremely precisely
scaled – over a wide voltage and power
range. Presently, this drive unit is considered to be the most compact mediumvoltage drive converter in the market:
Transformer, power unit and control are
combined in one unit. The complete
system can be commissioned in a plug
& play fashion without requiring any
assembly work on-site.
The extremely high voltage quality avoids
losses due to harmonics, reduces the level of stress both on the line supply and
the motor and also fulfills the most stringent regulations relating to harmonics.
The proven core topology ensures the
highest degree of compactness, voltage
quality and availability. The innovative
cell-bypass concept in conjunction with
the process-tolerant ProToPS® protective
system guarantees the highest degree of
reliability. This is because even if a cell
fails, the drive still remains operational as
the defective cell is simply bypassed. If a
fault develops, instead of simply powering down the drive, ProToPS® provides a
graduated system of alarms. This means
that operating companies have more
time to appropriately respond and take
suitable countermeasures.
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Best-practice
water supply examples
Baden-Württemberg state water supply
Schwetzinger Hardt waterworks
Task
The Baden-Württemberg state water supply
was to be modernized – with the objective
to increase flexibility and efficiently use the
groundwater reservoirs. This involves one of
the largest long-distance water supply utilities in Germany: More than three million
people are supplied with drinking water
through an extensive network of pipes
770 km long. This is for an area that in addition to Stuttgart also includes Aalen, Esslingen, Göppingen, Ludwigsburg, Schwäbisch
Gmünd and Ulm.
Task
A higher degree of safety, reliability and
cost-effectiveness. This is what the City of
Mannheim expected when it came to modernizing their water supply. This was to be
done based on innovative operating control
methods with process visualization and remote access.
Solution
The groundwater reservoirs were equipped
with variable-speed low-voltage drive systems for the pumps. The extremely precise
and flexible drive concept always guarantees
the correct mixing ratio – and therefore the
optimum drinking water quality. It also ensures the maximum availability and reliability of the water supply. The variable-speed
operation simultaneously saves energy and
reduces the level of stress on the system.
Products used:
• 1LG6 low-voltage motors
• SINAMICS G150 drive converters
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Solution
The drinking water pumping stations were
equipped with variable-speed low-voltage
drive systems – for precise, reliable energysaving operation that also reduced the
stress on the system. The drive system is
integrated in a SIMATIC WinCC-based supervisory control system. This means that it
can be operated and monitored from everywhere – also via remote access.
Products used:
• N-compact low-voltage motors
• SINAMICS G150 drive converters
Madrid water supply
Jakarta water supply
Task
The Spanish capital wanted to guarantee a
safe, reliable and cost-effective water supply
for approximately one million people living in
the southern part of the city. This represents
approximately 250 liters per day for each person – also during the dry summer period.
Task
The pumping stations were to be retrofitted
in order to secure reliable and cost-effective
water supply for the ever-growing metropolis of Jakarta with its population of millions.
The existing motors, switchgear technology
and cabling were to be kept.
Solution
The main drinking water pumping stations
were equipped with variable-speed, medium-voltage drive systems in order to secure
precise and flexible usage of the water reserves. The existing motors were only partially replaced. Those in a good condition
were upgraded for variable-speed operation.
The flow rate can now be quickly and precisely adapted to the actual water demand
using the motor speed. Further, variablespeed operation reduces the level of stress
on the mechanical system of the complete
pumping station – and when compared to
conventional control concepts – now allows
double-digit energy savings to be realized.
Solution
With the modernization, the existing technology was kept in operation (motors, cabling, switchgear and instrumentation).
However, low-voltage and medium-voltage
drive converters were integrated into the
existing system. Further, additional components from Siemens ensure safe and absolutely reliable operation. These components
include an incoming contactor, main control
switch with fuses to protect the semiconductors as well as a line reactor to limit
harmonics.
Products used:
• H-compact PLUS high-voltage motors
• Liquid-cooled SINAMICS GM150
medium-voltage drive converters
Products used:
• SINAMICS G150 drive converter
• Medium-voltage drive converter
(previous SINAMICS GM150 series)
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Best-practice water
treatment examples
Basel water treatment
Task
The energy usage was to be further reduced
for one of the largest wastewater treatment
plants in Switzerland located close to Basel.
The existing motors were to be replaced by
motors with especially high efficiencies.
Solution
450 kW high-efficiency low-voltage motors
are now used to drive large Archimedes
screw-type pumps that are used to transport
the incoming wastewater into the treatment
system located approximately 10 meters
higher. Thanks to their special bearings they
can handle the high cantilever forces. In the
especially efficiency-sensitive power range
below 200 kW, energy-saving motors with
the highest efficiency Class EFF1 are used –
especially there where the wastewater is
transported into the biological stage of the
settling plant after mechanical precleaning.
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From here, the water flows just by gravity
into the postsettling basins. The activated
sludge comprising bacteria and microbes
settles out. Part of the sludge is returned to
the biological stage using so-called return
sludge pumps. Energy-saving motors are
also used here. Calculations have shown
that the payback time of the energy-saving
motors is a maximum of three years.
Products used:
• N-compact low-voltage motors
• 1LA9, 1LE1 and 1LG6 EFF1
energy-saving motors
Overview of motors for the
water industry
Low-voltage motors
Induction
Aluminum frame
Power range
in kW
0.06 – 45
Voltage classes
in V
230 – 690
Shaft heights
in mm
56M – 225M
Low-voltage motors
Induction
Gray cast-iron
frame
Low-voltage motors
Synchronous
High-Torque
gearless
High-voltage motors
Induction
0.75 – 4,000
Up to 2,150
200 – 30,000
High-voltage motors
Synchronous
Power range
in kW
5,000 – 100,000
Voltage classes
in V
230 – 690
400, 460, 690
2,000 – 13,200
6,000 – 13,200
Cooling type
100L – 630
400, 450, 500
315 – 1,250
710 – 1,250
Pole No.
2–8
2–8
16
2 – 16
2–8
Speed in rpm
750 – 6,000
750 – 6,000
Up to 800
Up to 15,000
Up to 6,300
IP55, IP56, IP65
IP55
IP23, IP55
IP55
Degree of protection IP55, IP56, IP65
Cooling concept
Rib-cooled
Rib-cooled
Air/air heat
exchanger;
Air/water heat
exchanger;
Open-circuit aircooled
Rib-cooled,
water-jacket cooling
Rib-cooled
Air/air heat
exchanger;
Air/water heat
exchanger;
Open-circuit aircooled
Air/air heat
exchanger;
Air/water heat
exchanger;
Open-circuit aircooled
Converter-side
system partner
SINAMICS G120
MICROMASTER
SINAMICS G120
MICROMASTER
SINAMICS G130
SINAMICS G150
SINAMICS S150
SINAMICS G130
SINAMICS G150
SINAMICS S150
SINAMICS S120
ROBICON Perfect
Harmony
SINAMICS GM150
ROBICON
Perfect Harmony
SINAMICS GM150
SINAMICS GL150
Degree of
protection
Motors
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Overview of drive converters
for the water industry
SINAMICS G120
SINAMICS G130
SINAMICS G150
SINAMICS GM150
SINAMICS GL150
MICROMASTER
ROBICON Perfect
Harmony
0.37 – 90
75 – 1,500
75 – 1,500
600 – 27,000
6,000 – 120,000
0.12 – 250
150 – 120,000
380 – 480
660 – 690
380 – 690
380 – 690
2,300 – 7,200
1,800 – 12,000
380 – 500
2,300 – 13,800
Cooling using an
external fan,
convection cooling
Integrated fan
Integrated fan
Air- and
liquid-cooled
Air- and
liquid-cooled
Cooling using
an external fan
Air- and
liquid-cooled
IP20
IP00, IP20
IP20, IP21, IP23,
IP54
Air-cooled IP22,
optional IP42,
liquid-cooled IP43,
optional IP54
Air-cooled IP20,
optional IP41,
liquid-cooled IP41,
optional IP54
IP20
IP31, IP42, IP54
Low-voltage
induction motors
in aluminum or
gray cast iron
Low-voltage
induction motors
in gray cast iron
Low-voltage
induction motors
in gray cast iron
High-voltage
induction and
synchronous motors
High-voltage
synchronous motors
Low-voltage
induction motors
in aluminum or
gray cast iron
High-voltage
induction and
synchronous motors
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Würzburg water treatment plant
Task
In order to ensure optimum biological cleaning the amount of oxygen injected must
be continually adapted to the actual amount
of prevailing dirt and pollution. The City of
Würzburg wanted to achieve a higher degree of precision in this operation and at
the same time reduce the operating costs.
Solution
The existing fixed-speed drives were replaced by SINAMICS G150-based variablespeed systems to achieve a precise and
energy-saving operation that also reduces
the stress on the mechanical system. The
drive converters were integrated into the
existing supervisory control system of the
water treatment plant.
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The supervisory control system continually
determines the actual oxygen demand by
measuring the oxygen and ammonium concentration in the activation basins and appropriately adjusting the speed of the turbocompressor drive. This means that the amount of
oxygen injected is significantly more precisely dosed than before the modernization.
Products used:
• SINAMICS G150 drive converter
Siemens AG
Industry Sector
Large Drives
P. O. Box 47 43
90025 NÜRNBERG
GERMANY
www.siemens.com/drives
Subject to change without prior notice
Order No.: E20001-A270-P500-X-7600
Dispo 21503
21/12387 MK.LD.XX.LDAL.52.8.04 WS 04083.
Printed in Germany
© Siemens AG 2008
The information provided in this brochure contains
merely general descriptions or characteristics of performance which in actual case of 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.
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names of Siemens AG or supplier companies whose use
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