d Siemens - Evel | Eesti vee- ettevõtete liit. Estonian...

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Siemens

Efficient turbocompressor technology for

waste water treatment

Short introduction

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© Siemens AG 2007. Alle Rechte vorbehalten.

Helsingør History

Siemens Turbomachinery Solutions (then HV-Turbo A/S) was acquired in beginning 2007 by Siemens together with the KK&K Group (Kuehnle, Kopp & Kausch).

The KK&K Group was renamed to “Pre-defined Compressors and Fans” (abbreviated to “PCF”) and integrated with the Oil & Gas Division of Siemens.

The HV-Turbo Group was renamed to “Municipal and Industrial Application” (abbreviated to “MIA”) and included in the PCF Group as E O C&S PCF MIA.

1882 1947 1954 1973 1978-81 2000 2007

Helsingør Ship Yard founded

First and only gas turbine is produced

A series of turbo-chargers

is launched

The first s-type aeration turbo compressor is

launched

The first WWTP installations in

Germany & USA

KK&K acquires HV-Turbo from NTR

Holding

KK&K group incl. HV-Turbo acquired

by Siemens AG

Closing of shipyard

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Applications within Waste Water Aeration (Biochemical), Flue Gas Desulphurization, Sulphur Recovery, Fermentation and other industrial applications.Product Portfolio:

9 Basic compressor types with various customization possibilitiesNew product development: Direct Drive and Compact versions

Reference list of more than 7,500 units installedServices, e. g. spare parts, maintenance and repair, installations, modernization and upgrades

ACC Site InformationLocation: Helsingør

Business area and products

Units delivered in 2012: 210Office area: Approx. 2.500 sqmEmployees in 2013: 70 hereof 22 in Service

Numbers

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Steam turbines used as generator drives for power generation up to 10 MW and as mechanical drives for e. g. pumps and compressorsSingle stage turbo compressors and blowers for industrial applications and processesServices, e. g. spare parts, maintenance and repair, installations, modernization and upgrades

Extended workbench for Power Fans

ACC is a Service Provider to Manufacturing Site Frankenthal

Business area and products

Volker Neumann (CEO)Dr. Klaus Jacoby (CEO)Frank Langner (CFO)

Management

600 (2011) Thereof approx. 300 in manufacturing

Employees

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Aeration-ProcessesBiological Waste Water Treatment and floatation

Flue gas Desulphurization (FGD)

Fermentation (e.g. Enzymes for Bio fuel production, Yeast)

Marine applications

Siemens Turbomachinery SolutionsA suitable product portfolio to cover the main aeration applications

Siemens Applications

Siemens Solutions

Single stage centrifugal turbo compressorsFlow range 1.500 m3/h – 125.000 m3/h

Pressure range from 0.5 – 2.4 barg

Power range 50 KW – 3.300 KW

Air Supply Systems (automation)

Consultancy (energy optimization studies)

Service/ Upgrades and Revamps

Financing (energy saving motivated)

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Siemens Turbomachinery SolutionsMarket leader in supply of aeration turbocompressors

1978 1983 1988 1993 1998 2003 20071978 1983 1988 1993 1998 2003 2007

1.000

3.500

1.300

500

Number of references Installed units status 2007

Market leader with < 7.000 referencesEstablished regional coverage (CN, US, EU) and constantly expandingOnly supplier which can offer all technologies (geared & direct driven)

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Siemens Turbomachinery Equipment

Siemens Turbomachinery Solutions

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Siemens Turbomachinery SolutionsSelection of Municipal Wastewater treatment references

Changi WRP (SIN)2.4 mio m3/day10 x KA80SV, 2002

Tillmann WRP (US)5 x KA100SV, 2006

Seine Aval WWTP (FR)1.7 mio m3/day15 x KA22SV, 2004

Xiaoshan Dong Pian (CN)9 x KA44SV, 2005

La Farfana Santiago (CI)760.000 m3/day; 50% of population of Santiago6 x KA66SV, 2001

Shaoxing WRP (CN)700.000 m3/day8 x KA44SV, 2003

Sulaibiya WRP (KU)375.000 m3/day5 x KA66SV, 2003

Nashville Central (US)7x KA66SV, 1992

Southside WWTP, Dallas (US)4x KA66SV, 2003

Baix Llobrigat, Barcelona (ES)420.000 m3/day5 x KA66S, 2002

As Samra WWTP (JO)267.000 m3/day10x KA22SV, 2005

Pudong Bailonggong (CN)2.0 mill m3/day12 x KA22SV, 2007

Milano South WWT (IT)1.050.000 P.E. capacity50% population of Milano4x KA66SV, 2003

Orange Country, CA (US)4x KA66SV, 1995

Al Ansab WWTP (OM)220.000 m3/day; 900.000 P.E. 3x KA80SV, 2005

Berlin-Ruhrleben (DE)247.500 m3/day2x KA100SV, 2005

Manukau (NZ)300.000 m3/day5 x KA44SV, 1999

Ulun Pandan (SI)6x KA44SV, 2003

Largest in Europe

Largest in S. America

Largest in world

Largest in China

Largest in Italy

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Aeration Product Portfolio

Short introduction

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Siemens Turbomachinery SolutionsA comprehensive product portfolio for your aeration needs

Air flow [m3/h]

Diff

eren

tial P

ress

ure

[bar

g]

0,25

0,75

1,25

1,75

2,25

1.000 10.000 100.000

3,0

GO

(2)

GO

(5)

GO

(10)

GO

(22)

GO

(44)

GO

(66)

GO

(80)

GO

(100

)

Integrally geared dual-one stage STC-GO

1,0

0,5

150 kW

200 kW

100 kW

50 kW30 KW

300 kW

400 kW

1.000 kW 2.000

kW20 kW

10 kW

kW figures are showing shaft power at 30 degC, 60% RH and 1,013 bar

Integrally geared, one stage

GO(2-c) GO(5-c) GO(10-c)

DO(1) DO(2) DO(5) DO(10)

Direct drive, one stage

Siemens Turbocompressors (STC) for Aeration

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Siemens Turbomachinery SolutionsHow can Siemens Turbomachinery Solutions support your project?

Design

Construction

Operation

Design Support:

Mechanical, Civil, Electrical Plans, 3D Modeling, Technical Specifications, Design Solutions, On-time documentation

Civil Savings; Mechanical Savings; Electrical Savings:

Optimal number of aeration compressors/ High voltage motors; Correct sizing of pipes, valves

Energy Savings

By most efficient Dual-Point-Control and correct selection of compressor technology

Other operational savings:

Maintenance Savings. Extended lifetime

Your challenges Our answers

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Hard-ware

Siemens Turbocompressors (STC)

Integrally geared (STC-GO)

STC-GO(GK) STC-GO(GK-c)

STC-GO (GL/GB/GC)

Direct drive (STC-DO)

Base frame configuration

Console configuration

Full enclosure configuration

Sales & Execution concept

Fully customizablePre-engineered

Fully customizablePre-engineered

Appli-cations

Waste Water Oil & Gas & FGD

Fermentation

Waste Water Fermentation

Waste Water Fermentation

Frame size range

GO(2)-GO(100) Up to 2 bar diff.

GO(2)-GO(10) up to 1.0 bar diff.

DO(1)-DO(10) up to 0.9 bar diff.

Level of customizing

Air-foil-bearings

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Ambient temperature

Design

Package Assembly

Core

Drive System

Bearings/Lubrication

Impeller Design

Cooling

Capacity Control

Dual-Point Control

Controller

Lead Time

Instrumentation

Process Control

Motor/Voltage

Motor kW (Max)

Starter

Turndown (mass flow)

Enclosure Design

Optional Material

Ambient temperature

Design

Package Assembly

Core

Drive System

Bearings/Lubrication

Impeller Design

Cooling

Capacity Control

Dual-Point Control

Controller

Lead Time

Instrumentation

Process Control

Motor/Voltage

Motor kW (Max)

Starter

Turndown (mass flow)

Enclosure Design

Optional Material

IGV Inlet guide vanesVD Variable diffuserVFD Variable frequency driveMCP Master control panelSS Stainless steel

STC-GO(GL) STC-GO(GK) STC-DO

Not limited

Custom Engineered

Customizable

Air-end/gearbox

Geared

Sleeve, Forced Lube/Oil

Job Specific & Optimized

Water or Air

IGV or VD

Optional w/ VD & IGV

Specifiable (PLC)

30-40 weeks

Specifiable

MCP or DCS

Specifiable/Specifiable

3,000

SSRVS/VFD (stand alone)

45%

Optional & Specifiable

SS impeller & guide vanes

Not limited

Custom Engineered

Customizable

Air-end/gearbox

Geared

Sleeve, Forced Lube/Oil


Water or Air

IGV or VD


Specifiable (PLC)

30-40 weeks

Specifiable

MCP or DCS

Specifiable/Specifiable

3,000

SSRVS/VFD (stand alone)

45%

Optional & Specifiable

SS impeller & guide vanes

Air-end/gearbox

Geared

Ceramic Ball/Oil


Inlet Guide Vanes IGV or VD


MCP or DCS

Limited Selection/Low

315

45%

Optional Standard Upgrade

None

Air-end/gearbox

Geared

Ceramic Ball/Oil


MCP or DCS


315

Optional VFD

45%


None

<45 degree C

Pre-Engineered w/options

Limited Customization

Air-end/motor

Direct-Drive w/VFD

Air foil/none

Standard

Closed Loop Coolant

Variable diffuser (VD)

Standard w/ VD & VFD

Limited Selection (PLC)

12-16 weeks

Limited Selection

MCP or DCS

Standard/Low

315

VFD included

35%

Standard

None

<45 degree C



Air-end/motor

Direct-Drive w/VFD

Air foil/none

Standard; 13 types available

Closed Loop Coolant

Standard w/ VD & VFD


12-16 weeks

Limited Selection

MCP or DCS

Standard/Low

315

VFD included

35%

Standard

None

STC-GO(GK-c)

<45 degree C



Air-end/gearbox

Geared

Ceramic Ball/Oil


Air

Inlet Guide Vanes IGV or VD



16-20 weeks

Limited Selection

MCP or DCS


315

45%


None

<45 degree C



Air-end/gearbox

Geared

Ceramic Ball/Oil


Air


16-20 weeks

Limited Selection

MCP or DCS


315

Optional VFD

45%


None

Custom Engineered

Customizable

Specifiable (PLC)

30-40 weeks30-40 weeks

Specifiable

Not limited

Water or Air

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Dual Point Control PhilosophyShort introduction

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“Energy efficiency is not just low-hanging fruits – it is fruits that is lying on the ground” US Secretary of Energy, Steven Chu

How can we pick up this fruit in municipal sewage treatment?

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Change process to reduce DO-set point to reducerequired air-volume

Exchange aeration equipment with higherefficiency equipment (dual point control)

More extensive process changeswith structural changes to plant

Upgrade and increase level of air distribution automation

Siemens Turbomachinery SolutionsPossibilities to reduce energy consumption in WWT process

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Siemens Turbomachinery SolutionsFruits on the ground: Where is the biggest fruit to be pick up?

Electricity consumption for waste water treatment plant (activated sludge)

Source: Water Environment Federation Energy Conservation Task Force. Energy Conservation in Wastewater Treatment Facilities. 1997

Aeration54.3 %

Wastewater pumping14%

Screens, Grid1.4%

Clarifier3%

Lighting & Building8%

Return sludge pumping & Gravity

thickening1%

Anaerobic digesting

14 %

Belt Press4%

Chlorination0,3%

Aeration54.3 %

Wastewater pumping14%

Screens, Grid1.4%

Clarifier3%

Lighting & Building8%

Return sludge pumping & Gravity

thickening1%

Anaerobic digesting

14 %

Belt Press4%

Chlorination0,3%

In the secondary treatment phase waste water is treated by means of bacterial breakdown of the dissolved biological waste.

In order to foster this bacterial break-down, the oxygen level of the waterneeds to be increased. Aeration is the process by which the area of contact between water and air is increased, either by natural or mechanicalmeans, resulting in air being suspended in water.

Scope of evaluation without distribution pumping stations

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Technology

Lagoon

Mechanical Aeration

Combination Systems

Diffused aeration

Type

Facultative

Aerobic

Aerated

Rotors

Low speed

High Speed

Turbine

Jet

Course

Fine

OTE kgO2/kW.hr

1,52 – 2,13

1,82 – 2,13

1,52 – 1,98

0,91 – 1,52

1,22 – 2,13

1,22 – 2,13

2,43 – 4,36

Retention time10,000 m3 water7-50 days

3-6 days

2-3 days

4-12 hours

4-12 hours

4-12 hours

4-12 hours

4-12 hours

4-12 hours

4-12 hours

Limitations

Space

Retention time

Water depthLife cycle costsPossibly inhomogeneous qualityMoving parts

Possibly inhomogeneous quality

Moving parts

Capital costs

Increasing maintenance of system

Generally more complex system

Siemens Turbomachinery SolutionsWhat sources of aeration are possible? And what is the efficiency?

Most efficient choice

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Short Introduction in Dual Point vs. Single Point controlTurbo compressor control methodology differences

s i n g l e – s t a g e

p o s i t i v e d i s p

m u l t i - s t a g e

d i r e c t d r i v e

Speed controlled (VFD)

i s

e

n t

r

o p

i

c

e

f

f i

c i

e

n c

y

-%

% c a p a c i t y

Dual point control



Usual operating range of WWTP

Decision criteria's:

• Design point efficiency

• Turndown capability for maximum flexibility

• Efficiency over whole turndown range

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Siemens Turbomachinery SolutionsDual Point Control with STC-GO series

Air flow = f(n)Diff. pressure = f(n²)

Impeller speed = n

Single Point speed controllimits the turndown range as the pressure drops much faster than the flow by reduced speed. In order to reach a decent turndown, it is necessary to design the compressor for a much higher value with the result of overall lower efficiency.

Independent regulation of capacity and head:Capacity regulation via variable diffuser vanes: diffuser vanes are gradually closed, reducing the nozzle area, whereby a continuous turndown to 45% by keeping the maximum efficiency is achieved.

Head regulation: Inlet guide vanes (IGV) are adjusting the performance map acc. to fluctuations in temperature/ humidity and pressure changes

Dual Point control

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Siemens Turbomachinery SolutionsIntegrally geared: Dual-Point vs. Single Point Control

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Siemens Turbomachinery SolutionsDirect drive: Dual-Point vs. Single Point Control

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A small 75 kW unit and a large 2000 kW unit during test run

Every compressor will go through an 8 - 16 hours full load performance test including measuring of vibrations and noise emission and a performance certificate will be issued for every compressor unit leaving the factory

Siemens Turbomachinery SolutionsQualified Performance test, based on ISO and ASME-PTC-10

Performance test Based on Performance Data Sheet (PDS)

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STC-GO series

Short introduction

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Siemens Turbomachinery SolutionsThe fully customizable integrally geared STC-GO-series

Integrally geared STC-GO

Well proven design with over 7.000 installed references in over 2.300 WWT and Power plants

Fully customizable to fit the plants and project requirements

Each unit undergoes a performance test before delivery, in accordance to ISO and PTC-10

This series covers the full flow and pressure requirements

1.500 m3/hr to 125.000 m3/hr0.5 – 2.4 barg50 to 3.300 kW

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Siemens Turbomachinery SolutionsThe fully customizable integrally geared STC-GO-series

Integrally geared STC-GO

Well proven design with over 7.000 installed references in over 2.300 WWT and Power plants

Fully customizable to fit the plants and project requirements

Each unit undergoes a performance test before delivery, in accordance to ISO and PTC-10

This series covers the full flow and pressure requirements

1.500 m3/hr to 125.000 m3/hr0.5 – 2.4 barg50 to 3.300 kW

Inlet filter and silencer

Compressor air end

Speed increasing gearbox

Cone diffuser

Base plate with

auxiliaries

Local control panel with Dual point

control

Silencer hood for noise reduction and several upgrade and customization options available depending on project and plant requirement

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Siemens A/S Turbomachinery SolutionsPre-engineered geared compact units

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Air Bio Control (ABC)Automation solutionShort introduction

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Siemens Turbomachinery SolutionsAir Bio Control (ABC): Automation solutions for WWTP

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Siemens Turbomachinery SolutionsABC solution for two aeration lines with 12 zones

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Pay-as-you benefit Financial SolutionsShort introduction

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Siemens Turbomachinery Solutions“Pay as you benefit” solution

“Pay as you benefit” shows our confidence in the achievable energy savings for your plant

With our partner Siemens Financial Services (SFS) we take over the initial investments in our products, allowing you to:

save liquidity in turbulent times

free investments for other purposes

put energy savings back into your facility

increase effluent quality & stability

save the environment w.o. putting pressure on your credit line

Payback via the agreed energy savings over the payback time

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Siemens Turbomachinery SolutionsSiemens “Pay as you benefit” solution

Where is it possible with Siemens Financial Services

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Siemens Turbomachinery SolutionsSiemens “Pay as you benefit” solution

The “Pay as you benefit” concept

Baseline

Ener

gy

& O

per

atio

nal

co

sts

Time (years)

Reduced operational costs after installation of Siemens blowers

Customer savings

Duration of program

Savings used for initial investment repay

Additional savings due to energy price increase

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Thank you for your attention

Thank You

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m a n u a l a e r a t i o n c o n t r o l

Manual Control

Siemens Turbomachinery SolutionsEvolution of Automation Solutions for WWTP

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f i x e d p r e s s u r e a e r a t i o n c o n t r o l

Constant Pressure Aeration Control


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s e m i – a u t o m a t i c a e r a t i o n c o n t r o l

Semi-Automatic Aeration Control


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f u l l y a u t o m a t i c a e r a t i o n c o n t r o l

Fully-Automatic Aeration Control


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PIDPIDsp

cv8500 m3h 2 ppm sp

1.85 ppm

pv

Valve position

cv

6800 m3h

pv

PIDcv

Vane Position 634 mBar sp

627 mBar

pv

Siemens Turbomachinery SolutionsABC solution: Working principal

Automatic Set Point Control…

O2

PID

M

Set point O2

PID

FT

NH4

PIDSet point NH4

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Siemens Turbomachinery SolutionsThe ABC solution

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