System-based higher productivity

Transcription

1 System-based higher productivity Increasing energy costs, increasingly more stringent environmental regulations or achieving certification according to the EN16001 energy management standard there are several excellent reasons that speak for well-functioning energy management in industrial plants and systems. However, one factor is especially important: The bottom line is that energy management plays a decisive role in increasing the productivity of plants and systems, and in turn, significantly increases the competitiveness of a company and that, in any sector.

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3 Energy efficiency: Project for the future For plant and machinery construction, energy efficiency is becoming an increasingly more important subject: On one hand, because energy is a significant and ever-increasing cost factor for the manufacturing industry. On the other hand, because of the increasingly more stringent standards and legislation, at both the domestic and international levels, which must be complied with.

4 Intro The energy management process at a glance The energy management process in detail Intro The most comprehensive portfolio for an efficient energy management process Energy efficiency the specifics: Examples from the field Outro

5 The energy management process at a glance Everybody is talking about energy management. However, Siemens is comprehensively and systematically tackling this topic. We subdivide the energy management process into three phases, and and support you in each of these process phases. To do this, we can offer you intelligent hardware and software solutions, which allow you to transparently display and effectively control your energy-related resources. The optimum hardware and software acquire, visualize and analyze the energy flows in the plant or system: Energy flows become more transparent and this means that the process can be optimally configured from an energy-related perspective. The measured data retrieved allow a first evaluation of the existing cost-saving potential and at the same time, form the basis for intelligent and efficient energy management. Energy efficiency consulting Corresponding to EN Based on plant and system parameters, powerful software tools calculate the precise cost-saving potential for the specific application and the cost-effectiveness of possible measures for the drive system at the field level, for the control and supervisory level and for the higher management level. Financing and leasing options allow energy-saving plant and system components to be purchased at a favorable price. The process in detail Specific measures allow the existing cost-saving potential to be fully utilized. In this case, there is a special focus on drive technology. Drives represent two thirds of the industrial energy demand. Potential cost savings of up to 70% per drive are definitely realistic.

6 The energy management process in detail

7 The energy management process in detail : Make energy flows transparent throughout the complete company Data can be retrieved in this phase, which already allows an initial evaluation to be made of the existing energy-saving potential, and create the basis for intelligent and efficient energy management assuming a transparent energy usage. Whether for electrical energy or for other media such as water, gas, compressed air etc. Factual comparisons can only be made, and sensible and realistic optimization measures defined, if precise usage values and power data are available over a longer period of time. Efficient energy monitoring is indispensable in production and process automation as well as in the building sector especially when it comes to complex applications. Only then can the relevant measured quantities be precisely monitored and analyzed for example, current drawn, load profiles, temperature and volume flows. We can offer you well conceived and powerful hardware and software solutions for all of these tasks. Overview

8 The energy management process in detail : Precisely determining energy-saving potential Once the energy flows have been acquired, evaluated as well as visualized, and the large energy consumers identified, the concrete energy-saving potential must be calculated. The cost-effectiveness of possible measures for the specific application and a decision-making basis for investors can be derived from this result. Across all levels of the plant or system from the field up into the management level we supply tools that provide you with meaningful results to ensure a high degree of reliability when making decisions. Overview

9 The energy management process in detail : Fully utilize optimization potential After defining the appropriate measures based on the economic analysis, the name of the game is to then utilize the potential that has been determined as effectively as possible. Within the scope of our comprehensive portfolio, we offer you the optimum products, systems and technologies for this purpose highly efficient levers that play a role in drastically reducing the energy demand in your Overview

10 The most comprehensive portfolio for an efficient e PROFIenergy B.Data SIMATIC powerrate SENTRON powermanager SIMATIC WinCC and SIMATIC PCS 7 SENTRON PAC multifunctional measuring devices SENTRON switching and protection devices SINAMICS converters SINAMICS and ROBICON medium-voltage converters DYNAVERT T frequency converter SinaSave SIZER SIMATIC ET 200S FC, ET 200pro FC SITOP power supply SIRIUS innovations SIRIUS motor starters and soft starters SIMOCODE pro motor management system Low-voltage induction motors and explosion-proof motors HT-direct motors MOTOX geared motors

11 PROFIenergy B.Data SIMATIC powerrate SENTRON powermanager SIMATIC WinCC and SIMATIC PCS 7 SENTRON PAC multifunctional measuring devices SENTRON switching and protection devices SINAMICS converters SINAMICS and ROBICON medium-voltage converters DYNAVERT T frequency converter SIMATIC ET 200S FC, ET 200pro FC SIRIUS innovations SIRIUS motor starters and soft starters SIMOCODE pro motor management system

12 B.Data SIMATIC powerrate SENTRON powermanager SIMATIC WinCC and SIMATIC PCS 7 SinaSave SIZER engineering tool

13 PROFIenergy B.Data SIMATIC powerrate SENTRON powermanager SENTRON PAC multifunctional measuring devices SENTRON switching and protection devices SINAMICS converters SINAMICS and ROBICON medium-voltage converters DYNAVERT T frequency converter SIMATIC ET 200S FC, ET 200pro FC SITOP power supply SIRIUS innovations SIRIUS motor starters and soft starters SIMOCODE pro motor management system Low-voltage induction motors and explosion-proof motors HT-direct motors MOTOX geared motors

14 PROFIenergy Energy costs under control with PROFIenergy Another key to reducing the energy costs: Shutting down loads that are not required in non-productive periods as well as acquiring measured energy values at a favorable price and in a granular fashion.with this as objective, PROFIBUS & PROFINET International (PI) have developed a standardized data interface based on PROFINET: Using PROFIenergy, loads can be shut down centrally in a coordinated fashion indepen dent of the manufacturer and device. Manual switching a time-consuming procedure is eliminated so that energy can even be saved in short non-productive periods. Using PROFIenergy, existing hardware and software can be simply integrated in the energy management via PROFIenergy-capable ET 200S power modules as well as function blocks in the controller. In conjunction with the PROFINET functionality I-Device, PROFIenergy also allows complete plant and system sections to be shut down and powered up again in a coordinated fashion. These function blocks, which can be subsequently loaded, ensure low associated configuring and engineering costs. Application examples Measuring functionality to acquire energy values Loads are specifically shut down in non-productive periods More information under

15 B.Data The management system for a transparent energy balance With B.Data, we offer a comprehensive tool for effective energy management at the company level. B.Data allows users to implement an optimized and cost-effective operational energy management in the areas of controlling, planning and energy purchasing therefore covering all three phases of the energy management process. Energy controlling: B.Data offers seamless data acquisition and processing. It ensures a transparent energy balance and simpli fies maintaining legal stipulations, e.g. monitoring and reporting greenhouse gas emissions. Determining specific parameters and integrating production data allows substantiated statements to be made regarding increased efficiency. Determining energy costs: The flexible allocation of tariffs and modeling energy and material flows in B.Data allow energy costs linked to the actual loads to be determined and invoiced to cost centers. It also transfers the energy quantities/costs into the ERP system (e.g. SAP R/3 CO). Energy planning: B.Data allows the energy demand and load profile to be precisely forecast. This optimizes the budget planning and allows, when required, ongoing production to be quickly adapted at any time with the highest degree of decision-making reliability. Energy procurement: B.Data always supplies all of the relevant up-to-date information for the required energy quantity over the year and over the day: This forms the basis for optimum conditions when purchasing energy. Application examples Seamless acquisition and company-wide visualization of energy flows. Display of trends and reporting Transparent energy balancing and determination of specific KPIs. Energy cost allocation and invoicing according to the particular load Optimization potential by precisely forecasting energy demand and load profile More information under

16 SIMATIC powerrate Intelligent energy management for WinCC and PCS 7 SIMATIC powerrate in the versions for the SIMATIC PCS 7 process control system and the SIMATIC WinCC visualization software ensures that the energy usage in your plant or system is transparent. Not only this, it allows energy-intensive equipment to be specifically identified. To achieve this, our software acquires all of the energy-relevant usage data of the plant and system and allocates it to the various consumers before it is compressed by the SIMATIC S7 control system (mean values) and is stored in the memory in the case of a communication failure. Usage data is clearly and transparently visualized in SIMATIC WinCC and SIMATIC PCS 7 archived and integrated in the operator and visualization interfaces of the basis system. The automatic allocation to cost centers allows hidden cost-saving potential to be tracked down and utilized by comparing usage profiles and costs. As a consequence, SIMATIC powerrate permits efficient process configuration and optimization of the energy efficiency as originally planned. Visualization and transparency of the energy flows of a plant. Archiving, reporting More information under Evaluation of intensive loads are evaluated Load management, efficient process configuration

17 SENTRON powermanager SENTRON powermanager: for applications in commercial buildings SENTRON powermanager is suitable for applications in commercial buildings or in smaller and medium-sized industrial facilities, in which SIMATIC automation is not being used or where it is necessary to separate the automation and power distribution. Energy management with functions such as the provision and evaluation of various measured values as well as their monitoring can already be simply implemented in the standard package of our SENTRON powermanager software. Additional customerspecific requirements can be implemented using option packages. This means that a project can be subsequently expanded by additional functions or additional devices at any time without losing any data last but not least, thanks to a flexible license concept. More information Stand-alone software for visualization for transparent energy flows of a plant, archiving, reporting Support to analyze energy consumption using trends and curves (load curves) Provide support for efficient process configuration, cost center allocation, monitoring operating states powermanagementsystem More information under

18 SIMATIC WinCC and SIMATIC PCS 7 Intelligent energy optimization with SIMATIC PCS 7 and SIMATIC WinCC SIMATIC PCS 7 and SIMATIC WinCC already offer standard functions, which effectively support energy optimization. On one hand, basic functions are used such as alarm system or archive functions to compress the energy values that are used by SIMATIC powerrate as basis. In addition, SIMATIC PCS 7 offers higher-level closedloop control functions (Advanced Process Control APC), which can be used to implement sustainable energy optimization and to reduce energy costs by between 3 and 10%. An additional example: Plant Asset Management. Here, in addition to the system components, mechanical components such as pumps and heat exchangers are also monitored. This means that maintenance measures can be taken in plenty of time before a decreased efficiency starts to have a negative impact on the energy consumption. Application examples More information Measured value acquisition and archiving of the electrical and non-electrical energies Trend and curve displays reports and logs of energy usage simatic-wincc More information under

19 SENTRON PAC multifunction measuring devices SENTRON PAC multifunctional measuring devices: extensive information at any time using an intelligent measuring system If you wish to sustainably reduce energy costs, then you first require an overview of the energy usage and the energy flows in the plant or system. And this is precisely what our SENTRON PAC multifunction measuring devices do and that, for all applications: They precisely and reliably acquire the energy values for electrical branches or individual loads. Beyond this, they also supply important measured values to evaluate the plant or system status and the quality of the line supply. Thanks to their diverse range of communication options, these devices can be very simply integrated into higher-level automation and energy management systems so that the measured data can be further processed. Equipped as standard with digital inputs and outputs, both switching devices as well as pulse counters for any media can be simply integrated into the energy management system and correspondingly evaluated. More information Precise and reliable acquisition and archiving of electrical and other energy values More information under Measured values to evaluate the plant state and the line supply quality powermanagementsystem

20 SENTRON switching and protection devices SENTRON switching and protection devices: more than just switching and protection devices The seamless and integrated concept of communication-capable products from our low-voltage power distribution portfolio forms a reliable basis to acquire, evaluate and optimize the energy flow therefore permitting professional energy management for effective cost savings. Our open SENTRON 3WL circuit breakers and compact SENTRON 3VL circuit breakers are more than just pure switching and protection devices. Depending on the functionality required, measured data and switch states are made available to the higher-level automation or management systems via standard bus systems. Our plug-in 3NJ62 and 3NJ4 SENTRON in-line switch disconnectors are not only used to protect plants and loads. With their integrated current transformers, they also supply current values. Supported by the SENTRON PAC multifunction measuring device or the SIMOCODE pro motor management, this data and additional status data (ON/OFF/fuse rupture) are transferred to the manage- ment level for further processing for instance to our SENTRON powermanager software or the add-ons SIMATIC powerrate for WinCC or PCS 7. All of these products play a role in achieving sustainable energy-related optimization for user-friendly, safe and reliable operation as well as optimizing maintenance. More information Measuring functionality to acquire energy values Measured values to evaluate the plant condition More information under

21 SINAMICS converters The basis for innovative drive solutions that are fit for the future Our complete SINAMICS family has the optimum frequency converter for each and every application. For instance, the G series of SINAMICS converters are especially suitable for applications with a high energy-saving potential: e.g. SINAMICS G110 in the low-voltage range for low power ratings, SINAMICS G120, with energy recovery and Safety Integrated, for applications up into the medium-power range and SINAMICS G120 P for pump, fan and compressor applications. SINAMICS G110D and SINAMICS G120D as single-axis drive up to 7.5 kw are available for distributed applications in a high degree of protection. SINAMICS G130 chassis units and G150 cabinet units have been specifically tailored to address high-rating single-motor drives, which do not require energy recovery. Application examples More information Acquisition of the power drawn by the drive system Up to 70% energy saving for pump, fan and compressor applications. Up to 50% cost saving when using converters capable of energy recovery in e.g. conveyor and hoisting applications sinamics More information under

22 SINAMICS and ROBICON medium-voltage converters The basis for innovative drive solutions that are fit for the future In the medium-voltage range for power ratings up to 120 MW, we offer SINAMICS GM150, SINAMICS GL150 and ROBICON Perfect Harmony. ROBICON Perfect Harmony is a transformer, power unit and closed-loop control in one unit. Its innovative concept ensures that the highest availability values are reached. More information Acquisition of the power drawn by the drive system Up to 70% energy saving for pump, fan and compressor applications. Up to 50% cost saving when using converters capable of energy recovery in e.g. conveyor and hoisting applications robicon-perfect-harmony More information under

23 DYNAVERT T frequency converter The basis for innovative drive solutions that are fit for the future The DYNAVERT T frequency converter is especially suitable for sector-specific applications especially in the chemical industry and in the power station sector. Application examples More information Acquisition of the power drawn by the drive system More information under Up to 70% energy saving through variable-speed operation loher-dynavert-t

24 SinaSave SinaSave: determining the energy-saving potential in drive technology Drive applications represent up to 70% energy-saving potential. SinaSave calculates just how high the energy- and cost-saving potential is in a specific case. This is based on plant and system parameters. Our software tool, which is just as innovative as it is user-friendly can be download ed at no charge from the Internet and informs you just how fast the payback time is when investing in an energy-efficient motor either for line operation or frequency converter operation for variablespeed operation. The payback time is often just a few months. For line operation, SinaSave calculates the cost saving and payback time of our energy-saving motors in the high IE2 efficiency class or NEMA Premium when compared to motors in the standard efficiency class IE1 or EPAct, individually se lected and known motors or known motors within a complete plant evaluation. Comparing the efficiency of conventional motors and HT-direct torque motors is also an integral component of SinaSave. As direct drives using permanent magnet technology, HT-direct torque motors set themselves apart as a result of their especially high efficiency. For frequency converter operation for which all of the important low-voltage and medium-voltage products are included in SinaSave the tool takes into account all of the necessary plant- or systemspecific parameters as well as the values required for the pro cess. Additional basic data that the program requires are the number of working days and working shifts as well as the load profile over a day and a year, which are decisive for the energy-saving impact. Using the plant- or system-specific data, SinaSave identifies the optimum drive system, calculates the price of a suitable frequency converter and determines the energy demand of the variable-speed drive system in comparison to all other alternative concepts that could possibly be considered. SinaSave itself not only offers user-friendly functions, such as the automatic update, but also all of the languages important worldwide, electrical and mechanical units as well as currencies. The latter are dynamically updated through the Central European Bank. More information The cost-saving potential of energy-efficient drive technology and its payback time sinasave More information under

25 SIMATIC ET 200S FC, ET 200pro FC Communication-capable motor starters and soft starters: Avoid current peaks As a result of their measuring and communication capability, SIRIUS 3RW44 soft starters, M200D motor starters and SIMATIC ET 200S can transfer measured energy data to higher-level energy management systems. This means that they are a simple and practical solution for continuous operation and fixed speeds, which plays a decisive role when it comes to reducing energy costs. More information Acquisition of the power drawn by the drive system Energy saving using variable-speed operation. Energy saving using energy recovery More information under

26 SIRIUS innovations SIRIUS switching and protection devices SIRIUS innovations has an extremely low intrinsic power loss. An additional and significant reduction which is on the average 10% has been achieved with the new generation. This means that you not only save energy costs, but also reduce the amount of heat generated in the control cabinet. As a consequence, you can achieve a higher packing density in the control cabinet and reduce the cooling power required. Examples: Contactors: Our most energyefficient contactors have an electronic coil control. This significantly reduces the power loss by up to 92%. Soft starter: Our soft starters have an intelligent, integrated power bypass function. This reduces the power loss in operation by up to 92%. Overload relay: Overload relay with electronic release instead of a bimetal release set themselves apart not only as a result of the wider setting range, but also due to the fact that their intrinsic power loss is reduced by up to 98%. Compact load feeder: Contrary to conventional load feeders, the power loss in the compact load feeder has been reduced by up to 80%. The basis for this is the product combination of the most efficient technologies in one device. Circuit breakers: Our energyefficient circuit breakers are convincing also as a result of the new bimetallic trip, which reduces the intrinsic device power loss by 14%. This means that a wider power range can be covered with the same device size. In the phase, all of the communication-capable switching and protection devices supply continuous energy values without incurring any additional installation costs, e.g. to a higher-level energy management system. As a consequence, they provide the necessary transparency of the energy usage. More information Measuring functionality to acquire energy values Reduced and extremely low intrinsic power losses result in energy savings for example for the new circuit breakers, contactors with UC coil, electric overload relays and compact load feeders. Active switching, e.g. using load management permits savings of up to 25 % More information under

27 SIRIUS motorstarts and soft starters Communication-capable motor starters and soft starters: avoid current peaks Communication-capable SIRIUS motor starters and soft starters are the optimum choice when it comes to switching, protecting and monitoring motors. Direct and reversing starters, as well as also soft starters, cover the complete range from the high number of switching operations up to soft starting and stopping without mechanical and electrical peaks. This allows peak loads to be reduced by up to 60%. The extremely low intrinsic power loss of SIRIUS innovations is also convincing. From basic SIRIUS contactor combinations through pre-wired, fuseless load feeders and soft starters up to motor starters for the distributed SIMATIC ET 200S and ET 200pro distributed I/O: All of our motor starters and soft starters are especially space-saving, fast to install and can be simply integrated into the automation level via AS-Interface, PROFIBUS or PROFINET. Thanks to their measuring and communication capability, SIRIUS 3RW44 soft starters, M200 D motor starters and SIMATIC ET 200S can supply measured energy data to higher-level energy management systems. This makes them a simple and practical solution for continuous duty and for fixed-speed operation. This plays a decisive role in reducing the energy costs. Application examples More information Measuring functionality to acquire energy values Active switching. Up to 92% energy saving using soft starters with integrated current bypass More information under

28 SIMOCODE pro motor management system SIMOCODE pro: flexible, modular motor management system SIMOCODE pro optimizes the connection between the process control technology and the motor feeder, increases the plant availability and the same time results in significant cost savings in construction, during commissioning, in operation and when maintaining a plant or system. Installed in the low-voltage switchgear, our flexible and modular motor management system for constantspeed, low-voltage motors. It is the intelligent link between a high-level automation system e.g. with a load management system and the motor feeder. The measuring functionality integrated in SIMOCODE supplies the energy measured data required for the energy management without any additional cabling. Using the integrated actuators, loads can be shut down, e.g. using a load management system. More information Measuring functionality to acquire energy values Active switching. Higher plant availability through increased transparency of the complete control. Up to 25% energy saving simocode

29 Low-voltage induction motors and explosion-proof motors The most comprehensive range of efficient low-voltage induction motors We can offer you high-efficiency aluminum and cast-iron motors for the widest range of applications and for all international markets: For voltages from 230 V to 13.2 kv and power ratings from 0.09 kw up to 100 MW and in versions that comply with the different international efficiency classes. Our spectrum according to the new international efficiency standard IEC includes a seamless range of induction motors with power ratings from 0.75 up to 375 kw, with 2 up to 6 poles in efficiency classes IE1 to IE3. When compared to IE1 motors, these high-efficiency IE2 motors have an efficiency that is up to 7% higher. This has been achieved by using a sophisticated mechanical design and special materials. Based on the same technological platform, we offer motors with EPAct and NEMA Premium efficiencies for the NEMA market. Our motors are available up to 690 V both for line as well as frequency converter operation and perfectly match our SINAMICS converters and SIRIUS motor starters. Siemens and its daughter company, Loher GmbH have a seamless range of explosion-proof motors in the high IE2 efficiency, which extends over the complete range of validity of the IEC standard from 0.75 up to 375 kw. For Zones 2 and 1, in all of the usual types of protection. Application examples More information Extensive range of high-efficiency lowvoltage motors from 0.09 kw, which when compared to standard motors have efficiencies up to 7% higher with an efficiency classification IE2 and IE3 in the range from 0.75 to 375 kw. Explosion-proof motors are also available across the board from 0.75 up to 375 kw in the high IE2 efficiency class. motors

30 HT-direct motors High-torque motors HT-direct direct drives with a high efficiency Our series of HT-direct motors are permanent-magnet synchronous motors. They provide high torques at low speeds directly at the driven machine. As a result of the permanent-magnet rotors, high efficiencies and good power factors can be achieved even at low speeds. We offer these motors together with our SINAMICS frequency converters as harmonized and coordinated system as a drive solution with a long service life, low life cycle costs and a high efficiency. For slowspeed drives, the efficiency of these motors is approximately 2 to 3% higher than comparable, conventional drive concepts. In a power range extending up to 2080 kw, HT-direct can provide torques of up to 42,000 Nm and in addition to its energy efficiency it also sets itself apart as a result of its high reliability and low maintenance. More information Very high efficiency through a direct drive up to 3% higher than conventional motors. In addition, higher system efficiency with SINAMICS. ht-direct

31 MOTOX geared motors High-efficiency geared motors in IE2 We have a complete range of MOTOX geared motors in the power range from 0.09 to 200 kw. You can reap the benefits of these units in all applications and in any sector from the extremely high rated gear torques, wide range of options and high efficiencies. The efficiency for helical, parallel shaft and helical bevel gear units is generally 98% (1-stage), 96% (2-stage) or 94% (3-stage). From frame size 180 and higher, the geared motors are implemented as standard in efficiency class IE2. In addition to the energy costs, the operating costs over the complete life cycle are important. These can be optimized when precisely engineering the application (mounting position, gear ratio, drive speed etc.). The gearbox is mounted using a slip-on design, which also results in more efficient drive solutions. More information High efficiency across the board, IE2 (or IE3) up to 375 kw

32 Energy efficiency the specifics: Examples from the field back Chemical industry: Infracor GmbH Marl, Germany An energy management system for 30,000 energy data trends Efficiently managing energy is a very central task within Infracor GmbH for the energy supply in the Marl-Chemiepark Power Station. Here, the average demand across all of the plants and systems is approximately 300 MW of electric power and between 700 and 1100 tons of steam per hour. This location has three of its own power stations with a total of five blocks and 110 kv infeed from the public grid. In this remarkable energy environment, for the last eight years Infracor has been using the B.Data energy management system to acquire and optimize energy flows. Since it was first introduced, B.Data has been continually developed and expanded. Today, approximately 30,000 energy data trends are acquired and called-up as necessary with archives, which in some cases, go back 15 years. This holistic and integrated perspective forms the basis for extensive optimization. Today, B.Data is the central control tool for all energy planning processes for supply and disposal and allows the complete energy usage to be optimized. Overview Applikation examples

33 Energy efficiency the specifics: Examples from the field back Water industry: Water treatment plant, Minden-Leteln, Germany Soft starters reduce operating costs by 20 25% In order to reduce energy costs, the company operating the Minden-Leteln water treatment plant invested in a control system for the aeration turbines, which should avoid usage peaks as far as possible. As part of the modernization program, the electric turbine drives were installed with 3RW44 soft starters and the process control system upgraded to the latest state-of-the-art technology using SIMATIC PCS 7. The electric power consumption was able to be reduced by 20 25% in the biological part of the water treatment plant as a result of the modernization. Not only this, the soft starter solution minimizes the danger of failures as well as gearbox service times. The investment was paid back in the shortest time and over the next 10 to 20 years will play a significant role in keeping the operating costs low. Overview Applikation examples

34 Energy efficiency the specifics: Examples from the field back Pharmaceutical industry: DSM Nutritional Products AG, The Netherlands Efficient drive control saves 70,000 Swiss francs every year In its plant in the Swiss Canton of Wallis, the Dutch DSM Nutritional Products AG replaced its fixed speed pumps with valve control by variable-speed pumps. MICROMASTER 440 frequency converters, which are linked to the main control room in the plant via Profibus, are used to adjust the flow rate. This new solution not only allows the plant to be controlled with a far higher dynamic performance, but also reduces the use of primary energy. The expected annual savings are 70,000 Swiss francs. Overview Applikation examples

35 Energy efficiency the specifics: Examples from the field back Oil and gas industry: Shell Deutschland Oil GmbH, Germany Energy costs of 3000 euros less per month using frequency converters In its large tank farm in Kaiserwörthhafen, Germany, Shell Germany no longer wanted to simply waste energy by using mechanical valves. In order to ensure that the main diesel pumps are always operated at the optimum operating point, Siemens frequency converters each with a power rating of 132 kw and 1LG4 motors were used for the redundant pump system. Using the SinaSave software, it was verified that the frequency converters had already paid for themselves after approximately 14 months. This frequency converter-based solution reduces the monthly energy costs by 3000 euros. Additional advantages: Optimized processes and less stress on the pipe network caused by mechanical surges, which in turn minimizes maintenance costs and increases plant availability. Overview Applikation examples

36 Energy efficiency the specifics: Examples from the field back Supply and disposal utility: Stadtwerke Chemnitz, Germany 35% energy-saving through modernization As a result of the fluctuating district heating demand, the Stadtwerke Chemnitz (public utility company in Chemnitz, Germany) planned to optimize the energy balance in their cogeneration plant. To achieve this, the overdimensioned hot water circulating pump drives equipped with fluid flow couplings were replaced by variable-speed drive systems with rugged, high-efficiency N-compact low-voltage motors and the matching SINAMICS G150 frequency converters. By using variable-speed drive systems and the fact that it was no longer necessary to overdimension the motors, the energy consumption of the hot water circulating pumps was slashed by approximately 35%. Additional advantages: A more precise closed-loop flow control and operation with low associated stressing on the equipment without any pressure surges. Overview Applikation examples

37 Energy efficiency the specifics: Examples from the field back Automobile industry: ALRO Group, Belgium Cost savings of almost 20,000 euros per month by using frequency converters At its Genk location, the Belgian ALRO company wanted to investigate the energy-saving potential of pumps and fans for a painting system for automobile parts. For this purpose, a stochastic potential analysis was initially carried out on all of the installed pumps and fans up to a power rating of 5 kw or more, that up until now were controlled using throttles. These were then changed over to Siemens frequency converters. The analysis indicated that by using frequency converters for the 12 drives they were able to save 19,870 euros each year. The payback time is less than 1.5 years. Overview Applikation examples

38 Energy efficiency the specifics: Examples from the field back Public sector, Murimoos association, Switzerland New wood chip heating system: Heat demand 100% covered by waste materials Within the scope of upgrading the heat and energy supply, the «Murimoos, factories and living» Association were looking for a leading edge control system that also included a new wood chip heating system with a thermal rating of 600 kw. The solution: A SIMATIC WinCC based SCADA system that allows all of the energy producers and consumers to be controlled. Depending on the actual situation, e.g. the availability of energy and the associated prices, the optimum energy supplier is switched in. The advantages of the new wood chip heating system: The wood left over from their own woodworking operation and from the regional compost plant completely covers the demand for heat without having to purchase wood chips. In addition to reducing emission values, substituting the heating oil also had a positive financial impact. Overview Applikation examples The process in detail

39 Siemens AG Industry Sector P.O. Box NUREMBERG GERMANY Subject to change without prior notice 06/11 Siemens AG 2011 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.

40 Energy efficiency the specifics: Examples from the field Product overview Efficient drive control saves 70,000 Swiss francs every year An energy management system for 30,000 energy data trends New wood chip heating system: Heat demand 100% covered by waste materials Cost savings of almost 20,000 euros per month by using frequency converters Energy costs reduced by 3000 euros per month using frequency converters Soft starters reduce operating costs by 20 25% 35% energy-saving through modernization

41 SITOP power supply SITOP power supply Controlled SITOP power supplies operate according to the principle of primary clocking and therefore achieve a significantly higher efficiency than uncontrolled power supplies. An example: The new 3-phase SITOP PSU300M 24 V/20 and 40 A power supplies are convincing as a result of their high 93% efficiency. This saves energy and reduces the amount of heat that is generated which in turn facilitates an extremely compact design. The new series of SITOP compact power supplies set themselves apart as a result of the high efficiency over the complete load range. They save 28% energy when compared to conventionally controlled power supply units. The low power loss under no load conditions slashes energy usage by 53%. More information Save energy as a result of the high-efficiency and low power loss under no-load conditions. SITOP compact power supplies save up to 35% in operation.

42 SIZER Comparing the energy efficiency of drive solutions Our SIZER engineering software supports you when selecting the optimum drive configuration also when it comes to energy efficiency. Drive solutions can be quickly and simply compared and the energy-saving potential determined. The result: a transparent comparison for two drive configurations. The expected annual energy demand for the specified load profile is displayed for each drive version. In addition, using the practical conversion function, you can check whether significant energy savings can be achieved with a modified drive configuration. Presently, the functionality is available for SINAMICS G120, G130 and G150 frequency converters as well as the SINAMICS S120 and S150 motion control systems. The standard 1LA and 1LE motors as well as the 1FK7, 1FT7 and 1PH8 series of servo motors from Siemens are also taken into consideration. More information The energy efficiency of two drive solutions is compared and the solution with the highest energy efficiency is automatically generated.