How are increasing requirements placed on energy ... · How are increasing requirements placed on...

Answers for industry.

With a comprehensive and seamless portfolio of energy-efficient products, systems and solutions

How are increasing requirements placed on energy efficiency an opportunity for OEMs?

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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, both at the domestic and international levels, which must

be complied with.

Energy efficiency: Project for the future

Contents

The energy management process to continuously increase the energy efficiency of a plant or system 4

Products in the energy management process

Standardized data interface: PROFIenergy 6

Management system for a transparent energy balance: b.data 6

Energy management for WinCC and PCS 7: SIMATIC powerrate 7

SENTRON powermanager software: For applications in commercial buildings 7

Intelligent energy optimization with SIMATIC PCS 7 and SIMATIC WinCC 7

SENTRON PAC multifunction measuring devices 8

SENTRON switching and protection devices 8

Variable-speed operation of pumps, fans and compressors 8

Frequency converters capable of energy recovery 9

Frequency converters for low and medium voltage 9

SINAMICS S120 energy-efficient drive technology 10

Calculating the cost-saving potential in drive technology: SinaSave 10

Communication-capable motor starters and soft starters 11

SIRIUS switching and protection devices 11

SIMOCODE pro motor management system 12

Low-voltage induction motors 13

HT-direct high-torque motors 13

High-efficiency geared motors in IE2 13

Siemens AGIndustry SectorP.O. Box 48 4890026 NÜRNBERGGERMANYwww.siemens.com/energy-efficiency-machinebuilder

Subject to change without prior notice 04/10Order No. E20001-A20-M117-X-7600DISPO 21505WÜ/26815 GC.GC.HI.EEFF.52.0.01 WS 04103.Printed in Germany© Siemens AG 2010

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. 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.

Achieve more with less

It has always been the case that machines and plants must set themselves apart through optimum function-ality, performance and therefore productivity. Nothing will change in this regard. However, in the future, pro-ductivity growth will be considered more and more under the aspect of sustainability. As a consequence, the objective must be to implement solutions that achieve a maximum result but with a minimum use of resources.

Challenge and opportunity for plant and machinery construction

Siemens can offer you everything you need to fulfill the ever-increasing requirements of companies operat-ing plants: The world’s most comprehensive portfolio to achieve the highest energy efficiency. Our innovative products, systems and solutions create the precondi-tions for intelligent and efficient energy management. This involves a continuous process in plant or system operation, where also the initial concept, the engineer-ing and the implementation of a machine or plant are of significant importance. Here, we can provide an ex-tensive range of support and consulting services.

We can offer you the technology required to achieve this within the scope of Totally Integrated Automation – our open system architecture.

■ Hardware and software to acquire, visualize and analyze energy flows

■ Programs to precisely determine the cost-saving potential at all levels of factory automation

■ Products and systems that actually reduce the energy demand

Discover for yourself just how you can address new opportunities in international markets with our portfolio – to sustainably improve your competitiveness.

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The energy management process at a glance

We can offer you everything that is required for focused energy management. Products

and systems, which decisively play a role in significantly reducing operating costs – and

at the same time, reducing the stress on our environment. As continuous process, our

well-conceived concept ensures a continuous reduction in the energy demand. Our

energy management is based on the following phases – Identify, Evaluate and Realize.

We can offer you the perfect solutions for each and every one of these phases.

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Identify

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 config-ured 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 an intelligent and efficient energy management.

Evaluate

Based on plant and system parameters, powerful software tools calculate the precise cost-saving potential for the spe-cific application and the cost-effective-ness of possible measures – for the drive system at the field level, for the control and supervisory levels and for the higher management level. Financing and leasing options allow energy-saving plant and system components to be purchased at a favorable price.

Realize

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% are definitely realistic.

Identify energy flows

Identify hidden energy-saving potential

Determine cost-saving potential

Evaluate the complete life cycle costs

Concrete measures Implement and realize the energy-saving potential

En

ergy efficiency consulting

Realize

Evaluate

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Corresponding to EN 16001

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Product overview

b.data: The management system for a transparent energy balance

With b.data, we offer an extensive tool for effective energy management at the company level. b.data allows users to implement an op -timized and cost-effective operational energy management in the areas of controlling, planning and energy purchasing – and in so doing, covers 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 simplifies maintaining legal stipulations, e.g. moni-toring and reporting greenhouse gas emis-sions. Determining specific parameters and integrating production data allows substan-tiated statements to be made regarding increased efficiency.

■ Determining energy costs: The flexible allo-cation of tariffs and modeling energy and material flows in b.data allows energy costs linked to the actual loads to be determined and invoiced to cost centers. It also trans-fers 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 plan-ning 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.

Identify Evaluate Realize

Energy costs under control with PROFIenergy

Another key to reducing the energy costs: Shutting down loads that are not re-quired in nonproductive 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 devel-oped a standardized data interface based on PROFINET:Using PROFIenergy, loads can be shut down centrally in a coordinated fashion independent of the manufacturer and device. Manual switching – a time-con-suming 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 function-ality 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 that can be subsequently loaded ensure low associated configuring and engineering costs.


b.data: The management systefor a transparent energy balanc

With b.data, we offer an extensive tool f effective energy management at the com

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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 visu -a lization software ensures that the energy usage in your plant or system is transparent. Not only that, 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 – saved in archives and integrated in the operator and visualiza-tion interfaces of the basis system. The automatic allocation to cost centers al-lows hidden cost-saving potential to be tracked down and utilized by comparing usage profiles and costs. As a conse-quence, SIMATIC powerrate permits efficient process configuration and optimization of the energy efficiency as originally planned.

t SIMATIC powerrate: Intelligent energy managemfor WinCC and PCS 7

SIMATIC powerrate in the versions

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SENTRON powermanager software: For applications in commercial buildings

SENTRON powermanager is suitable for applications in residential buildings or in smaller and medium-sized industrial facil-ities, 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 monitor-ing can already be simply implemented in the standard package of our SENTRON powermanager software. Additional cus-tomer-specific requirements can be im-plemented 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.


SIMATIC PCS 7 and SIMATIC WinCC for intelligent energy optimization

SIMATIC PCS 7 and SIMATIC WinCC al-ready 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 closed-loop 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 managementHere, in addition to the system compo-nents, 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.


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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 multi-function 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 commu-nication 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 stan-dard 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.

Product overview

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 port-folio 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 break-ers 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 manage-ment 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 addi-tional status data (ON/OFF/fuse rupture) are transferred to the management 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 achiev-ing sustainable energy-related optimiza-tion for user-friendly, safe and reliable operation – as well as optimizing mainte-nance.



Predestined for cost savings: Pumps, fans and compressors

Pumps, fans and compressors that are operated with mechanical throttles and valves, represent a huge cost-saving potential. In this case, the changeover to variable-speed drives with frequency converters provides enormous economic benefits: Different than with mechanical controls, the power drawn is always im-mediately adapted to the actual demand. This means that energy is no longer wasted, which in turn permits savings of up to 60% – in extreme cases, even up to 70%.

Also when it comes to service and main-tenance, variable-speed drives offer some significant advantages when compared to mechanical controls: Current peaks when the motor accelerates and high torque surges are a thing of the past. This also applies to pressure waves in piping systems (water hammer), cavitation and vibration that continually take their toll on the plant or system. The soft starting and stopping relieves the load on the mechanical system and ensures a longer service life of the complete drive train.


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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 Integrat-ed, 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 avail-able 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.

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. The DYNAVERT T frequency converter is especially suitable for sector-specific applications – especially in the chemical industry and in the power station sector.


Even higher cost savings with energy recovery

Whether in hoisting applications, centri-fuges or conveyor belts: Wherever large masses must be frequently braked, our frequency converters capable of energy recovery significantly reduce the energy demand. The reason for this is that in contrast to conventional drive systems, the braking energy is not simply dissi-pated and wasted in braking resistors. In-stead, it is fed back into the line supply. By using this so-called intelligent infeed technology, for instance, in hoisting ap-plications up to 50% of the energy can be saved. An additional positive spin-off: Components such as line reactors and braking resistors can be eliminated and the required current drain is reduced by approx. 20%. The amount of space re-quired for the drive system is also corre-spondingly lower and the amount of heat generated is reduced. We have converters capable of energy recovery for installa-tion in control cabinets as well as in a high degree of protection for use in dis-tributed architectures.


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Product overview

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 downloaded at no charge from the Internet and informs you just how fast the pay-back time is when investing in an energy-efficient motor – either for line operation or frequency converter operation for variable-speed opera-tion. 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 effi-ciency 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 eva l uation. Compar-ing the efficiency of conventional motors and HT-direct torque motors is also an integral com ponent of SinaSave. As direct drives using per-manent magnet technology, HT-di-rect 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 neces-sary plant- or system-specific para-meters – as well as the values re-quired 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 auto-matic 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.


Energy-efficient drive technology using SINAMICS S120 with energy-saving system functionsThe modular SINAMICS S120 drive system addresses high-performance applications in plant and machinery construction – in the power range from 0.12 kW to 4500 kW. Whether continuous material webs or cyclic high-dynamic processes, SINAMICS S120 packs more performance in machine tools and production ma-chines. In addition to integrated safety functions, this is achieved using energy-saving system functions:

■ Optimum energy utilization through energy recovery, automatic energy equalization in the drive group and energy-saving system functions

■ High line supply compatibility and elimination of losses by compensating harmonics

■ Closed-loop flux control for optimum energy utilization of converter-fed induction motors

■ Line reactors and braking resistors are not required

■ Integrated reactive power com-pensation


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Communication-capable motor starters and soft starters: To avoid current peaks

Communication-capable SIRIUS motor starters and soft starters are the optimum choice when it comes to switching, pro-tecting and monitoring motors. Direct and reversing starters, as well as also soft starters, cover the complete range – from the high number of switching oper-ations 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 dis-tributed 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 commu-nication capability, SIRIUS 3RW44 soft starters, M200 D motor starters and SIMATIC ET 200S can supply measured energy data to higher-level energy man-agement systems. This makes them a simple and practical solution for continu-ous duty and for fixed-speed operation. This plays a decisive role in reducing the energy costs.


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 energy-efficient 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 con-ventional 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

In the Identify phase, all of the communi-cation-capable switching and protection devices supply continuous energy values without incurring any additional installa-tion costs, e.g. to a higher-level energy management system. As a consequence, they provide the necessary transparency of the energy usage.


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Product overview

SIMOCODE pro: Flexible, modular motor management system

SIMOCODE pro optimizes the connection between the process control and motor feeder, increases the plant and system availability and at the same time facili-tates significant energy saving in the construction, commissioning, operation and maintenance of a plant or system. Installed in the low-voltage switchgear, our flexible, modular motor management system for constant-speed, low-voltage motors is the intelligent link between higher-level automation system and the motor feeder.

The measuring functionality integrated in SIMOCODE supplies the required mea-sured energy data – without any addi-tional cabling – for the energy manage-ment system. The load can be shut down using the integrated actuator.

SIMOCODE pro: Fl ibl d l t


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The most comprehensive range of efficient low-voltage induction motors

We can offer you high-efficiency alu-minum and cast-iron motors for the widest range of applications and for all international markets: For voltages from 230 V to 30.2 kV and power rat-ings from 0.12 kW up to 100 MW – and in versions that comply with the differ-ent international efficiency classes.

Our spectrum according to the new international efficiency standard IEC 60034-30 includes a seamless range of induction motors with power ratings from 0.75 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 mo-tors 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 con-verter ope ration – and perfectly match our SINAMICS converters and SIRIUS motor starters. Siemens and its daugh-ter 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 60034-30 stan dard – from 0.75 to 375 kW.For Zones 2 and 1, in all of the usual types of protection.


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 bene-fits 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 imple-mented 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 gear mount ing using a slip-on design also results in more efficient drive solutions.

High-efficiency geared motors in IE2


HT-direct high-torque motors – direct drives with a high efficiency

Our series of HT-direct motors are per-manent-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 con-verters as harmonized and coordinated system – as a drive solution with a long service life, low life cycle costs and a high efficiency. For slow-speed drives, the efficiency of these motors is ap-proximately 2 to 3% higher than com-parable, 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.

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Answers for industry.

Identify, evaluate and realize cost-saving potential in an integrated energy management process

How is energy transformed from cost factor to success factor?

2

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.

System-based higher productivity

Contents

The energy management process to continually increase the energy efficiency of a plant 4

Identify 5

Evaluate 6

Realize 7

The most comprehensive portfolio for an efficient energy management process 8

Energy efficiency – the specifics: Examples from the field 10

Siemens AGIndustry SectorP.O. Box 48 4890026 NÜRNBERGGERMANYwww.siemens.com/operational-energymanagement

Subject to change without prior notice 04/10Order No. E20001-A20-M117-X-7600DISPO 21505WÜ/26815 GC.GC.HI.EEFF.52.0.01 WS 04103.Printed in Germany © Siemens AG 2010

The information provided in this brochure contains merely general descriptions or characteristics of per formance 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.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.

*Source: VDI 4602 “Energy Management Terminology”

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Higher energy efficiency ...

Energy management is the predictive and systematic coordination of energy procurement, conversion, distribution and use – with the objective to cover the demands taking into account ecological and economic directives. Put another way: Take planned action with the purpose of efficiently handling and using energy.*

... using efficient energy management

Functioning energy management is a process, which – analog to quality management – is used to continually increase the productivity of the energy used. As your partner, we can offer you an extensive portfolio, which supports you in this process.

Energy management is used to continually monitor the energy usage of your plant or system, therefore reducing the energy and operating costs and at the same time reducing the environmental stressing. The key to all of this is the perfect interaction of our portfolio within the scope of Totally Integrated Automation, our open system architecture:

■ Hardware and software to acquire, visualize and analyze energy flows

■ Programs to precisely determine the cost-saving potential at all levels of production and process automation

■ Products and systems that actually reduce the energy demand

4

The energy management process at a glance

Everybody is talking about energy management. However, Siemens is addressing

this topic comprehensively and systematically. We split up the energy management

process into three phases – Identify, Evaluate and Realize – and support you in

each of these process phases. For this purpose, we can offer you intelligent hardware

and software solutions that allow you to transparently display your energy-related

resources and effectively control them.

Identify

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 an intelligent and efficient energy management.

Evaluate

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.

Realize

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.

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Evaluate

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Identify: Make energy flows transparent throughout the company

In this phase, data can be retrieved that already allow a first evaluation to be made regarding the energy-saving potential, and create the basis for intelligent and efficient energy management – assuming of course that the energy usage is transparent. Whether for electrical energy or for other energy forms such as water, gas, compressed air etc.: Precise usage values and power data must be available over a longer period of time so that definitive comparisons can be made as well as practical and realistic optimization measures defined.

Efficient energy monitoring is indispensable in production and process automation as well as in the building sector – this is especially true for complex tasks. Only then can the relevant measured variables be precisely monitored and analyzed – for instance, power consumption, load profiles, temperatures and flow rates.

We can offer well-conceived and powerful hardware and software solutions for all of these tasks.

Product examples

■ SIMATIC powerrate: SIMATIC energy management system for WinCC and PCS 7 to efficiently acquire, calculate and log all of your energy data for fo-cused energy usage optimization.

■ SENTRON powermanager software: The energy management software – as stand-alone solution – is suitable for applications in commercial buildings, smaller or average-sized industrial facilities, where there is no automation, or where the automation and power distribution must be separated.

■ SENTRON PAC: Compact and powerful multi-function measuring devices. These devices precisely and reliably acquire all of the usage data in the electrical power distribution and display it on a graphic LC display.

■ SENTRON load disconnectors with integrated measuring technology: Combined with SENTRON PAC, they acquire the measured data and transfer it to higher-level energy management systems.

■ Communication-capable SENTRON circuit breakers: Full transparency by providing energy data from the field level without requiring any additional installation.

■ PROFIenergy: Standard based on PROFINET for favorably-priced and granular measured value acquisition directly at the load.he load.


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Evaluate: Precisely determining the cost-saving potential

Product examples

■ b.data: In addition to seamless energy and material balancing of the energy generating systems and loads, energy cost allocation depending on the particular consumer and transfer into the ERP system (e.g.: SAP R/3 CO), specific key performance indicators (KPIs) are generated using automatic data analysis. These KPIs form the basis to increase the energy efficiency of production plants and systems.

■ SIMATIC powerrate for WinCC and PCS 7 for the control and supervisory levels: Complete, seamless and integrated power management solution to visualize and analyze your complete energy data to identify energy saving potential.

■ SinaSave: The software tool for drive technology at the field level, designed for applications with motors directly connected to the line supply (fixed speed) and frequency converter operation (variable speed). This tool calculates, based on your plant characteristic values, the payback time when investing in an IE2 or IE3 energy-saving motor, a direct torque motor or a frequency converter. Frequently, these payback times are just a couple of months.

■ Energy Health Check: This is an integrated service package to optimize complete plants from an energy-related and holistic perspective, and where an optimization measure has a maximum payback time of just two years. As a consequence, energy costs can be reduced in a focused fashion with low associated costs.

■ Siemens Financial Services: Financing and leasing options for investments to increase the energy efficiency.

Once the energy flows have been acquired, evaluated as well as visualized and the large energy consumers identified, the specific energy-saving potential must be cal-culated. The cost-effectiveness of potential measures can be derived for the specific application from this result – and a decision-making basis created for investors.Across all plant levels – from the field up into the management level – we can supply you with tools that provide you with meaningful results to secure a high degree of decision-making reliability.


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Realize: Fully utilize optimization potential

Product examples

■ An extensive range of high-efficiency motors, which in comparison to standard motors, have efficiencies that are up to 7% higher.

■ The most comprehensive portfolio of fre-quency converters available in the market, which depending on the application, allow power costs to be reduced by 70% with respect to fixed-speed concepts by using variable-speed operation. This is especially true for pumps, fans and compressors to precisely adapt the speed.

■ Frequency converters capable of energy recovery with innovative infeed technology, which feed the braking energy back into the line supply. For instance, for hoisting applications, conveyor belts and centrifuges, energy costs can be reduced by up to 50%.

■ Motor starters and soft starters to reduce mechanical and electrical peak loads by up to 60% with extremely low intrinsic power loss.

■ Intelligent energy management with SIMATIC powerrate for WinCC and PCS 7 to limit load peaks and therefore reduce energy costs.

■ The b.data energy management system ensures that your operations and procedures are optimized by automating all of the pro-cesses relevant when purchasing energy and for energy supply. By specifically analyzing energy and production data, you obtain a comprehensive understanding of your energy consumption and usage, which means that you can save valuable resources. You continually optimize your cost struc-tures in this way and, on the whole, become more efficient.

■ Dynamic energy management with PROFIenergy, the nonproprietary commu-nication profile from PROFIBUS & PROFINET International (PI) reduces energy costs by completely shutting down (even briefly) loads that are not used in nonproductive periods.

■ Our Customer Support is there to support you when changing over and upgrading existing drive systems that are no longer economical to efficient motors and variable-speed drives.

After defining the optimum measures based on an economic feasibility analysis, the next step is to tap into all of the potential that has been determined as effectively as possible. Within the scope of our extensive portfolio, we can offer you the appropriate products, systems and technologies – highly efficient levers that play a role in drastically reducing the energy requirement of your plant or system.

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The most comprehensive portfolio for an efficient energy management process:

Identify Evaluate Realize More information

PROFIenergy

Measuring functionality to acquire energy values

Loads specifically shut down in nonproductive periods

www.siemens.com/profinet

b.data

Seamless acquisition and company-wide visualization of energy flows.Display of trends and reporting

Transparent energy balancing and determining specific KPIs.Energy cost allocation and invoicing according to the particular load

Optimization potential by precisely forecasting energy demand and load profile

www.siemens.com/bdata

SIMATIC powerrate

Visualization and trans-parency of the energy flows of a plant.Archiving, reporting

Energy-intensive loads are evaluated

Load management, efficient process configuration/arrangement

www.siemens.com/powermanagementsystem

SENTRON powermanager energy management software

Stand-alone software for visualization – for trans-parent energy flows of a plant, archiving, reporting

Provide support for efficient process configuration, cost center allocation, monitoring operating states


SIMATIC WinCC and SIMATIC PCS 7

Measured value acquisi-tion and archiving of the electrical and nonelectrical energies

Trend and curve displays – reports and logs of energy usage

www.siemens.com/simatic-wincc

www.siemens.com/simatic-pcs7

SENTRON PAC multifunction measuring devices

Precise and reliable acquisi-tion of electrical and other energy values

Measured values to evaluate the plant state and the line supply quality


SENTRON switching and protection devices


www.siemens.com/sentron

SINAMICS frequency converters

The power drawn by the drive system is acquired

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

www.siemens.com/sinamics

SINAMICS and ROBICON medium-voltage converters


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

www.siemens.com/robicon-perfect-harmony

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DYNAVERT T frequency converter


Up to 70% energy saving through variable-speed operation

www.siemens.com/loher-dynavert-t

SinaSave

The cost-saving potential of energy-efficient drive technology and its payback time

www.siemens.com/sinasave

SIMATIC ET 200S FC, ET 200pro FC


Energy saving using variable-speed operation.Energy saving using energy recovery

www.siemens.com/et200

SIRIUS Innovations


Reduced and extremely low intrinsic power losses result in reduced energy consumption.Active switching, e.g. for load management facilitates cost savings of up to 25%

www.siemens.com/sirius-innovations

SIRIUS motors, starters and soft starters


Active switching. Up to 92% energy saving by using soft starters with integrated power bypass

www.siemens.com/sirius

SIMOCODE pro motor management system


Active switching. Higher plant availability through increased transparency of the complete control. Up to 25% energy saving

www.siemens.com/simocode

Low-voltage induction motors and explosion-proof motors

Extensive range of high-efficiency low-voltage 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. Also explosion-proof motors are available across the board from 0.75 to 375 kW in the high IE2 efficiency class

www.siemens.com/motors

www.loher.com

HT-direct motors

Very high efficiency through a direct drive – up to 3% higher than conventional motors. Further, higher system efficiency with SINAMICS

www.siemens.com/ht-direct

MOTOX geared motors

High efficiency across the board, IE2 (or IE3) up to 375 kW

www.siemens.com/motox

Siemens Financial Services

Financing solutions with plannable costs for investments in energy-efficient Siemens technology

www.siemens.com/financing

Energy Health Check

Energy optimization for industrial plants and systems – integrated and holistic approach to sustainably improve the energy efficiency of industrial plants and systems

www.siemens.com/industry-solutions

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Energy efficiency – the specifics: Examples from the field

Using the following specific application examples, we will show you the

cost-saving potential that our energy-efficient products, systems and solutions

offer. These examples will also demonstrate how quickly an investment in

leading-edge technology is paid back.

An energy management system for 30,000 energy data trends

For Infracor GmbH managing energy efficiently is a central function when it comes to supplying energy to the Marl Chemiepark. In this huge facility, the average demand of all of the plants is approximately 300 Megawatt of electric power and between 700 and 1100 tons of steam per hour. Three dedicated power stations with a total of five generating units and three 110 Kilovolt feeder stations from the public grid are used to supply this facility. Infracor has been using the b.data energy management system for eight years now in this remarkable energy environment. b.data is used to acquire and optimize the energy flows. Since it was introduced, b.data has been continually developed and expanded. Today, approximately 30,000 energy data trends are acquired, and when required, called up. In some cases, the archives go back over 15 years. This integrated and holistic perspective creates the basis for extensive opti-mization. Today, b.data is the central control tool for all energy planning processes relating to supply and disposal and allows the usage of all of the energy consumed to be optimized.

Soft starters reduce the operating costs by 20 – 25%

In order to reduce their energy costs, the company operating the Minden-Leteln wastewater treatment plant invested in a control for the new aerator turbines in order to avoid usage peaks as far as possible. Within the scope of the modernization, the electric turbine drives were equipped with 3RW44 soft starters and the supervisory control system upgraded to state-of-the-art technology using SIMATIC PCS 7. As a result of the modernization, the power used in the biological area of the wastewater treatment plant was reduced by 20–25%. In addition, the soft starter solution mini-mized the danger of failures as well as the gear unit service times. This investment paid for itself in a very short time and over the next 10 to 20 years, will play a role in significantly reducing the operating costs.

Efficient drive control saves 70,000 Swiss Franks – year in, year out

The Dutch company DSM Nutritional Products AG replaced the fixed-speed pumps equipped with valve control by variable-speed pumps at their factory located in the Swiss Canton of Wallis. MICROMASTER 440 frequency converters, which are con-nected to the main control room in the factory via PROFIBUS, adapt the flow rate. The new solution not only allows the closed-loop control of the plant to be significantly increased, but also reduces the usage of primary energy. The expected cost savings are 70,000 Swiss Franks per annum.

Chemical industry: Infracor GmbH Marl,Germany

Water industry: Wastewater treatment plant Minden-Leteln, Germany

Pharmaceutical industry: DSM Nutritional Products AG, The Netherlands

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Energy costs slashed by 3000 Euros per month using frequency converters

In its large tank farm in Kaiserwörthhafen, Germany, Shell Deutschland no longer wanted to simply waste energy in mechanical valves. In order to ensure that the main diesel fuel pumps always operate at their optimum operating point, Siemens frequency converters each with a rating of 132 kW and 1LG4 motors for the redundant pump system were used. The SinaSave software clearly proved that the frequency converters had already paid for themselves after about 14 months. The plant has slashed its energy costs by 3000 Euros per month. An additional advantage is the fact that the various processes have been optimized and the stress on the piping network as a result of mechanical surges has been reduced. In turn, this has minimized maintenance costs and increased the plant availability.

35% energy cost saving through modernization

As a result of the fluctuating demand from the district heating station, the Stadtwerke Chemnitz (public utility in Chemnitz, Germany) planned to optimize the energy balance in its district heating station that supplies heating to the local community. The overdimensioned hot water circulating pump drives with fluid coupling were replaced by variable-speed drive sys-tems based on rugged, high-efficiency N-compact low-voltage motors and the matching SINAMICS G150 frequency converters. The power costs for the hot water circulating pumps were reduced by about 35% by using variable-speed drive systems and the fact that it was no longer necessary to over-dimension the motors. An additional advantage is the more precise closed-loop flow rate control and operation with lower stress on the mechanical system as pressure surges have been eliminated.

Almost 20,000 Euros of cost savings per month by using frequency converters

In its Genk plant, the Belgian Company ALRO investigated the energy-saving potential of pumps and fans for a painting system for automobile parts. Initially, a stochastic potential analysis was performed for all of the installed pumps and fans with a power rating of 5 kW or more – which were previously controlled with throttles and valves. These were then replaced by Siemens frequency converters. The analysis indicated that 19,870 Euros could be saved annually by using frequency converters for the 12 drives. The payback time is less than 1.5 years.

New wood chip heating system: Heating demand is covered 100% using waste materials

While renovating the heat and energy supply, the “Murimoos, werken und wohnen” association were looking for a leading edge control technology that could also control a new wood chip heating system with a thermal rating of 600 kW. The solution: A SCADA system based on SIMATIC WinCC, which con-trols all of the energy-producing systems and energy users. The optimum en-ergy supplier is used depending on the actual situation, e.g. the availability of energy and the actual prices. The advantage of the new wood chip heating system: the wood waste from its own woodworking operations and the regional compost dump completely covers the heat demand without having to purchase any wood chips. Being able to substitute the heating oil not only had a positive financial impact, but emission values were also reduced.

Oil and gas industry: Shell Deutschland Oil GmbH,Germany

Supply and disposal utility:Stadtwerke Chemnitz, Germany

Automobile industry: ALRO Group,Belgium

Public sector, Murimoos association,Switzerland

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