media newsletter dt april 2012
TRANSCRIPT
April 2012
1
Drive Technologies Division
DT Media Newsletter
Siemens has recently delivered mechanical drives
for a jacking system for a wind turbine installation
vessel. The customer is Shipyard Crist SA headquar-
tered in Gdansk, Poland, which is currently building
the high performance heavy-lift jack-up vessel
Innovation for HGO InfraSea Solutions. As of mid
2012, Innovation will be the largest of its kind and
will install heavy foundations and offshore wind
turbines in the North Sea at water depths of up to
50 meters.
The potential for offshore wind in Europe is estimated
at around 100 gigawatts, which equal two-thirds of the
power plant capacity currently installed in Germany. At
present, only approximately two percent of that poten-
tial is being utilized. The time required to transport and
install wind turbines is a crucial factor when setting
up an offshore wind farm. A new generation of spe-
cial ships has been developed and consists of a large
self-propelled vessel with the capacity to accommodate
numerous complete wind turbines or jackets on board.
A heavy-lift crane lowers the jackets on the predeter-
mined position and places the equipment precisely and
safely on the stable, previously installed, foundation
pile or structure.
To ensure a safe and precise operation of the crane the
ship can be lifted out of the water on four legs. The
Complete delivery of mechanical drive for jacking system of the world’s largest heavy-lift jack-up vessel
Siemens delivers the complete mechanical drive for the jacking system of Innovation, which will be the largest heavy-lift jack-up vessel of its kind. Image (computer animation): HGO.
Special feature
April 2012
2
Drive Technologies Division
DT Media Newsletter
ship thus offers a stable working platform for installa-
tion of jackets or wind turbines. For this jacking system
Siemens supplied 96 mechanical drives with heavy-du-
ty Flender planetary gearboxes. Due to their high-quali-
ty and durable gearing, the planetary gears are desig-
ned for high concentrated loads, thus enabling stability
when the boat is lifted in and out of the water. Siemens
also supplied the same number of individually VSD
operated electric motors in marine version together
with watercooled Sinamic S120 frequency converters.
Furthermore, the Simatic PCS7 control system will be
used for overall automation. Siemens supplied as well
four Geafol medium voltage transformers. As single
source supplier, Siemens offers VSD controlled com-
plete Rack and Pinion Systems particularly suitable for
frequently operated jacking systems on lift boats. „This
project shows how we developed an integrated system
for the customer clearly demonstrating our strengths
in optimizing the entire drive train.“ says Dr. Bernhard
Hoffmann, VP of Drive Applications at Siemens Busi-
ness Unit Mechanical Drives.
HGO InfraSea Solutions is a joint venture of HOCHTIEF
Solutions and GeoSea, a company of the Belgian DEME
Group. HGO InfraSea Solutions develops, constructs,
manages and charters special-purpose vessels used
to build and maintain offshore wind farms as well as
offshore oil and gas facilities.
Further information regarding Flender gear units for lift
boats:
www.siemens.com/jack-up
Due to their high-quality and durable gearing, the heavy-duty Flender planetary gearboxes are designed for high concentrated loads, thus enabling stability for heavy-lift jack-up vessels.
April 2012
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Drive Technologies Division
DT Media Newsletter
The need to transport large quantities of goods and
high numbers of people remains undiminished.
The world‘s largest ferryboat will start running
between the continents of Africa and Europe later
this year. Among the factors crucial to the success of
such technical achievements are reliable, efficient
propulsion solutions, such as the Flender gearboxes
used by Siemens. They are not only characterized
by their performance capability and efficiency, but
also provide safety and comfort for the passengers
on board.
The largest ferryboat in the world to date will start run-
ning later this year between Tunisia and Italy/France. It
has a capacity of 3,200 passengers and 1,060 vehicles.
Daewoo Shipbuilding & Marine is building the ocean
giant in its South Korean shipyard for CoTuNav, the
Tunisian state shipping line. Daewoo chose Siemens
type Navilus GVLQ 2500 Flender propulsion gearbo-
xes which are designed for both high power and quiet
running.
The giant ferry is propelled by means of a multi-engine
design. Two of the ship‘s four diesel engines transmit
the required power via the Flender gearbox to the cor-
responding propulsion drive with adjustable propellers.
A design with four engines and two propellers provides
a good combination of safety and comfort for passen-
ger ships. Selecting one or two-engine mode enables
the propulsion drive to be run at different speeds. Each
engine can be engaged and disengaged via a multiple-
plate clutch. This enables the power to be increased so
that the ship can reach a top speed of 27.5 knot, which
corresponds to about 50 km/h.
As well as the efficiency and power of the propulsion
system, the flexibility of the service work also plays
an important role, after all a giant ferryboat cannot
simply be „parked“ on the open sea. The advantages of
a multi-engine solution combined with Flender gear-
boxes pay off here again. The selectable multiple-plate
clutch enables one engine to be disengaged at any
time it requires service, while the other engine continu-
es to propel the ship.
Additional special features of the Siemens gearboxes
are the built-on oil supply system and the monitoring
system, which allows unsupervised operation. Further-
more, the propeller thrust bearings are integrated into
the gearbox, so the gearbox housing has very high tor-
sional rigidity. This means that the teeth mesh perfectly
under all conditions, even with rapid load changes
during bad weather.
Full speed ahead! Siemens gear technology in the world‘s largest ferryboat
With a width of 7.35 m, a height of 4.92 m and a length of 3.7 m, the giant Flender gearboxes weigh 89 tons, which makes them the largest marine gearboxes ever built in the Siemens Voerde Works.
Special feature
April 2012
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Drive Technologies Division
DT Media Newsletter
For more than one hundred and thirty years, Siemens has been specializing in the planning,
manufacture and assembly of electrical equipment for all types of merchant and naval vessels, as well
as submarines. This covers turnkey projects and conversions throughout a ship‘s life cycle. The Siemens
„Marine & Shipbuilding“ Division offers shipyards and shipping lines solutions which sustainably increase
the environmental compatibility and commercial efficiency of the entire shipping operation.
Energy-efficient ship propulsion systems from Siemens
Exhaust gas heat conversion on board ship to supply the on-board power network and to boost the propulsion with hybrid drives (Waste Heat Recovery System – WHRS)
Fuel consumption is one of the major cost items in ship
operation. Highly efficient propulsion solutions and intel-
ligent energy management are crucial to remaining com-
petitive in the long term. At the same time, technologies
that are more environmentally compatible are required to
meet the ever stricter worldwide environmental protec-
tion regulations. The Waste Heat Recovery System (WHRS)
helps to meet both of these demands optimally.
Clean, efficient, flexible
The WHRS uses exhaust gases from the diesel propul-
sion engine to produce additional electrical power
from the ship‘s fuel in a clean and efficient manner.
The system offers decisive competitive advantages by
cutting energy costs by up to 12 percent, reducing CO2
and NOX emissions, and significantly lowering main-
tenance costs. The user also gains more flexibility in
the ship design. Smaller fuel tanks give greater scope
in the design of the ship‘s lines and its interior, and the
main propulsion system can have a lower rated power.
Reliable, internationally available standard components
and well-established spare parts logistics make main-
tenance easier and ensure maximum safeguarding
against failure.
Diagram of the WHRS from Siemens
Special feature
April 2012
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Drive Technologies Division
DT Media Newsletter
The many on-board technical installations and sys-
tems supply informative data about their status,
performance and efficiency. The EcoMain communica-
tions platform helps to utilize the commercial poten-
tial of the ship by optimizing its operation. Through a
wide range of on-board interfaces, EcoMain collects
data from as many technical systems as possible, pre-
pares it in a standardized format, and makes it availa-
ble on a common data platform. Energy consumption,
emissions, bunkering with liquids, maintenance sche-
dules, document and knowledge management and a
great deal more can be evaluated and subsequently
optimized. The greatest potential for improvement lies
in energy consumption, environmental compatibility
and maintenance intervals.
Targeted decision support for green fleet management
The system assists the ship management by providing
specific information for optimization: Lower-level mo-
dules below EcoMain, such as the power management
system, help in the making of decisions to improve
the performance of a ship or an entire fleet. As a
result, EcoMain enables significant cost savings to be
made with „green“ fleet management, which safegu-
ard the investment and the future of the fleet. These
are crucial competitive advantages.
Optimization of ship operation with the EcoMain communication platform
Versatile, powerful, safe
In two-stroke direct propulsion systems, the WHRS uses hot exhaust gases to generate superheated steam, which drives a two-stage steam turbine. An exhaust gas turbine can be fed with excess exhaust gas that is not needed for turbocharging. Together with the steam turbine, it drives the electricity generator (waste heat conversion princip-le), which generally supplies the entire on-board power network. Surplus electric power can be used to boost the propulsion system by means of an electric drive that acts directly on the propeller shaft. At a low machine load, the waste heat recovery system can be run in parallel with a diesel generator set. Parallel operation with a shaft ge-
nerator, also known as power take-off operation, is easily implemented, because this electric machine is in any case installed to feed in excess energy. This is a slow-running electric machine mounted directly on the propeller shaft without gears, which can work both as a generator and as a motor.
All the functionalities of the WHRS are controlled by a power management system that ensures optimal use of the available energy, and automatically adjusts the shaft generator operation to match respective requirements. This utilizes reserve power, reduces the wear on the main propulsion system, and increases the reliability of the on-board power supply.
Kay Tigges, the expert for „Green Ship“ technology at Siemens and the „Siemens Inventor of the Year 2009“, commented: „Efficiency and environmental sustainability are not opposites in the shipping industry; on the contrary, together they form a competitive factor.“
April 2012
6
Drive Technologies Division
DT Media Newsletter
Siemens has once again been certified by Germa-
nischer Lloyd (GL) as an inspection agency for con-
dition monitoring systems for wind energy plants.
For the second time, the Field Remote Service
department has received certification confirming
that the diagnostic competence of its inspection
engineers, remote monitoring processes and
quality management all meet the requirements of
Germanischer Lloyd.
Condition monitoring systems (CMS) are used for the
vibration-based status monitoring of drive trains. As
drive systems, particularly in wind energy plants, must
offer maximum availability at all times, the work on
prescribing corresponding monitoring systems started
at a very early stage in this industry. When the need
arises, it is essential to have competent and prompt
support available. This can be provided to an increa-
sing extent by the use of modern, high-performance
communication media via remote service.
In order to anticipate possible failures in wind ener-
gy plants before they develop and thereby avoid
the costly consequences, the Field Remote Service
department in the Siemens Industry Sector offers
comprehensive diagnostics and status monitoring
of wind energy plants by remote access. Utilization
of the Siplus CMS4000 condition monitoring system
facilitates the status-oriented maintenance of entire
wind farms. The inspection agency was re-certified in
February of this year following in-depth examination
by Germanischer Lloyd Industrial Services GmbH. The
associated condition monitoring system had already
been certified prior to this.
The certification by Germanischer Lloyd attests to the
long-term expertise of Siemens in the use of condition
monitoring systems, as well as the qualification of
its service personnel active in this area. This not only
benefits the wind farm operators, but in particular the
manufacturers of wind energy plants. This is because
certification of CMS and the corresponding inspection
agencies is, in turn, a prerequisite for the certification
of wind energy plants and therefore of their operation
as well.
In the course of the assessment, the GL inspectors first
examined the Siemens condition monitoring system
and the corresponding inspection agency theoreti-
cally, and then in practice on site. The certification
focused on structures, processes and documentation.
This very extensive inspection ensures a sound organi-
zational structure as the basis for high-quality moni-
toring. Inspection points include training courses and
events for the service personnel as well as detailed job
specifications in the service area.
Siemens obtains certification for condition monitoring of wind energy plants
April 2012
7
Drive Technologies Division
DT Media Newsletter
A drive-based motion control system and servo
motors at the major axes are the „pace-setting
features“ of innovative automatic punching ma-
chines made in France. The fully electric machines
work almost twice as fast as comparable hydraulic
pendants while consuming only half the energy.
Thanks to sheet metal feed from the coil and user-
friendly programming, they are also extremely
flexible to use.
The French company Dimeco Alipresse, a member of the
worldwide acting Dimeco-Group, develops and manufac-
tures individualized coil-feeding systems, machines and
accessories for sheet metal fabrication. Flexible automa-
tic systems for punching, forming and assembly have
become another core element of their product range,
including the first fully electric, coil-loaded punching
machine, the Linapunch MC-E. It unifies productivity and
energy efficiency and is equipped with advanced control
and drive technology developed by Siemens.
The rows of hydraulic stamps which were characteristic
of Dimeco punching machines for many years are no
longer a feature of the new Linapunch MC-E. They have
been replaced by two Siemens Simotics 1FK7 servo mo-
tors operating in synchronism which control the stroke
movement (Z axis) using simple toggle lever kinematics
and a central slide plate. The top and bottom dead cen-
ters of the toggle lever system are freely programmable,
i.e. they are individually adaptable to the relevant pun-
ching task. As a result, optimized power ratios with short
cycle times are available for any application.
In total 13 electric controlled axes require fast and precise
mutual coordination. This task is performed by the Dime-
co control system Simostar, a combination of the drive-
based motion control system Simotion D and a network-
cabaple Simatic MP377 Multi Panel from Siemens. The
latter acts as interface between the control system and
the machine operator and enables set up, operation and
observation of all functions of the punching machine,
while a full overview of the process is given. The motion
controller, in turn, is stipulated during observing the
travel and hence for preventing collisions.
The core of the motion controller, i.e. the Simotion D435
control module, is an integral component of the Sinamics
S120 modular drive system in booksize format. This
solution reduces the number of interfaces and cabling
required and the overall size of the installation. Punching
programs can be loaded via the network or from a USB
stick, but can also be written, edited and transferred to
the control system at the touch of a button while the
machine is running. This capability is particularly signifi-
cant with respect to contract punching which demands
flexibility in processing very small batch sizes while conti-
nually changing between batch products.
In times of continual rising energy prises efficiency plays
a central role in addition to productivity and flexiblity.
The Dimeco-example shows, that servo-drive technology
is also efficient in the energy point of view: The Lina-
punch consumes 50% less energy than a comparable hy-
draulic machine while it doubles the number of strokes.
Fast and efficient punching – Twice the number of strokes, half the power consumption
Simotics servo motors at all axes and a motion controller simotion D435 from Siemens enable for the Linapunch MC-E from Dimeco Alipresse high productivity, flexiblity and energy efficiency.
April 2012
8
Drive Technologies Division
DT Media Newsletter
The call for industrial drives to be designed with
the environment in mind is getting ever louder. This
is also shown by the Green Automation Initiative
launched by the VDMA (German Engineering Fede-
ration), which system manufacturers, in particular,
are following to an ever greater extent. Siemens is
broadening the base of its series of energy-efficient
electric motors with the addition of versions in a
gray cast-iron housing. IE2 and IE3 motors up to 200
kW are available for the manufacturing and proces-
sing industries. They can also be used under severe
environmental conditions, and are even suitable for
export to Canada, Mexico and the USA.
Millions of motors are working throughout the world
every day in the manufacturing and processing indus-
tries, where they are often in continuous operation.
However, not least the stricter general conditions
imposed by current legislation are causing changes in
the electric motor industry. Since June 15, 2011, motor
manufacturers in the European Economic Area can only
market induction motors which fulfill the requirements
of efficiency class IE2. Similar strict conditions also
apply in countries such as Brazil and even stricter ones
in the USA.
A broad base of efficient drives
Siemens has already been supplying the 1LE1 induction
motors within its Simotics general purpose motor range
for a number of years. They are highly energy-efficient
motors in an aluminum housing. Further versions have
been added to the series which substantially widen its
range of applications. With the addition of the Simotics
Severe Duty motors in cast-iron housing to the 1LE1
series in efficiency classes IE2 and IE3, Siemens covers
the entire spectrum of industrial applications between
0.75 kW and 200 kW. Great importance was placed on
Energy-efficient motors for a wide range of applications
The energy-saving Simotics Severe Duty Motors in the 1LE1 family have a gray cast-iron housing, which enables them to be used in severe environments, such as those encountered in the process industry.
April 2012
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Drive Technologies Division
DT Media Newsletter
Operation accounts for about 90 percent of the lifecycle costs of an electric motor. When one considers that an
IE3 is up to ten percent more efficient than an IE1, it can be seen that the investment in energy-saving motors will
pay off in a correspondingly short time. The Siemens energy-saving calculator shows how quickly this can actually
be achieved at www.siemens.com/enery-saving-calculator.
The savings potential of specific applications - such as pumps, fans and compressors - can be precisely calculated
at www.siemens.com/sinasave with the Sinasave calculation tool.
Energy-saving statistics
a fully compatible frame size in the development of
these versions, which are designed for use under seve-
re conditions. This means that existing designs do not
need to be modified, which saves machine and system
manufacturers not only time but also the risk of making
unnecessary errors.
Safe in all respects
The energy-saving motors in a gray cast-iron housing
are available in a Basic Line for standard applications
and in a Performance Line for very severe environmen-
tal conditions, such as are frequently encountered in
the chemical and process industries. This is where the
PTC motor protection, which is integrated as standard,
is beneficial from the economic and ecological points
of view. It monitors the temperature of the windings to
detect thermal stress arising from the effects of unex-
pected process or mechanical faults at an early stage.
This prevents motors being irreparably damaged by
overload. The T-Drains drainage system has also proven
itself in practice. A motor can be drained by simply
turning the cover.
Modular system approach for greater flexibility
Just like the aluminum versions of the 1LE1 generation,
the gray cast-iron motors also follow a standardized,
practically oriented series concept. For example, the
mounting feet, which are a standard part of the cast
housing, are also available in a convertible, screw-on
version. The modular system approach to the built-on
components also enables the cast-iron motors to be
equipped as required with additional pulse encoders,
brakes and external fans. The obliquely divided termi-
nal box, which can be turned in 90 degree steps, has
also proved to be very useful for installing the motors,
as it allows the cable to the terminal board to be laid
according to the space available.
The very wide range of applications for the motor
versions is also demonstrated by the addition of a
number of important standard-compliant details to the
technical specifications. These allow machine and sys-
tem manufacturers to fulfill export orders to the USA,
Mexico and Canada just as easily as deliveries within
the European Economic Area.
April 2012
Drive Technologies Division
DT Media Newsletter
Media Contact:
Siemens Industry Sector
Drive Technologies
Julia Kauppert
Phone +49 (0)911 - 895 7952
Siemens Industry Sector
Drive Technologies
Franz-Ferdinand Friese
Phone +49 (0)911 - 895 7946
The Siemens Industry Sector (Erlangen, Germany) is
the world’s leading supplier of innovative and environ-
mentally 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
www.siemens.com/industry
The Industry Sector and Drive Technologies Division in brief
The Siemens Drive Technologies Division (Nurem-
berg, 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 mar-
kets 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
www.siemens.com/drives
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