Answers for industry.

Innovative technology for the highest availability and cost-effectiveness

Drives for Water Industry

No compromises when it comes tosupplying water with the highest quality

In the water industry, topmost priority is given to achieving the optimum water quality and an absolutely

reliable supply. At the same time, ever-increasing cost pressure demands water plants with the highest

degree of cost-effectiveness. As a consequence, the technology used must operate reliably, efficiently

and with a high degree of precision.

The demands placed on the drive technology are especially high. Drives play a key role when it comes to

supply reliability and plant efficiency. Pump drives maintain the water pressure at the right level around

the clock, always adapt the pumped quantity to the actual demand and regulate, where required, the

mixing ratio. Further, their energy demand is the most significant element of the overall energy costs.

With this as background, drive converters offer enormous cost-saving potential: The precise and con-

tinuous closed-loop speed control ensures that the drive runs at the optimum operating point – and

that energy costs can be significantly reduced.

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First-class solutions for all tasks

Whether small distribution pumps, blower compressors in water treatment plants or multi-Megawatt drives in large main pump-ing stations. As partner to the water indus-try, Siemens offers a unique and extensive range of products and systems that ad-dresses all of the sector-specific drive appli-cations encountered in the water industry.

With our solutions we consequentially en-sure the highest reliability and efficiency. We offer individual components as well as products and systems that are perfectly harmonized and coordinated with one another; these are based on proven stan-dards and tailored solutions – from a single source. Our portfolio includes motors and drive converters with a power rating of a few Watts up into the high double-digit Megawatt range, low-voltage drives as well as medium-voltage drives.

Perfectly tailored to the requirements of the sector

Our motors and converters ensure opti-mum pumping – with the maximum de-gree of availability and with minimum operating costs. In fact, these advantages can be further expanded if our drive com-ponents work together as a system. This is because we develop and manufacture our motors and drive converters right next to another, we perfectly harmonize them and subject them to a grueling test under real operating conditions in one of our state-of-the-art system test facilities.

The result: Drive systems that distinguish themselves as a result of the highest degree of availability and maximum efficiency.

Typical applications

In water supply• Retrieving drinking water• Transporting water• Dosing• Treating drinking water• Distributing water• Irrigation systems

In wastewater• Transporting wastewater• Transporting sludge• Aerating and mixing the

activated sludge• Centrifuges• Equipment in wastewater handling

such as rakes etc.

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The key to the highest supply availability: Reliability in continuous use

The complete bandwidth of motors

Our motors set standards when it comes to reliability and efficiency. Our portfolio extends from standard motors for pump-ing stations up to special submersible pump motors with degree of protection IP68. We also offer explosion-protected motors e.g. for the settling process. They have a flameproof enclosure and on the pump side they have a rotating axial seal.

Our portfolio includes motors with every possible conceivable cooling type and de-gree of protection to comply with almost any specification – such as pump motors with locating bearings on the drive side and integrated PTC thermistors – as well as high-power torque motors. These gear-less permanent-magnet synchronous mo-tors are especially reliable, require little maintenance but have an extremely high efficiency. They are especially suitable for slow-running pumps.

Rugged with a long service life

Our motors distinguish themselves as a result of their rugged mechanical design, long lifetime as well as low maintenance and reliable operation. Enclosures, bear-ings, active parts, ventilation and cooling system are perfectly harmonized with one another. Innovative insulation sys-tems in conjunction with the VPI tech-nique ensure a high voltage strength when either connected directly to the line supply or fed from a drive converter. These insulation systems also result in stiff winding overhangs and excellent co-rona protection for maximum switching and reversing strength. Our motors play a decisive role in achieving a higher degree of plant availability and a more reliable water supply.

Additional advantages:• High mechanical strength and

thermal endurance• Extremely long lifetime and

low-maintenance bearings

A water supply must be guaranteed

around the clock. This is the reason

that in many applications the name

of the game is reliable long-term and

continuous use. Put in another way:

Absolute fault-free operation is manda-

tory – the same goes for the highest

efficiency. This is because the energy

costs are especially important for

motors that continually run.

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• The vibration quality surpasses stringent IEC and NEMA standards

• Innovative cooling systems for uniform cooling and minimizing the thermal load

• Enclosure that is resistant to shocks and vibration and with a high vibrational stiffness

• Corrosion protection for humid and aggressive environments

Highest power in the smallest space

Our motors are unbeatable when it comes to envelope dimensions and weight at any power rating. This means that they require significantly less space and can be simply integrated into a complete plant. Further, they are also extremely quiet – additional noise-reducing measures are not required.

Significantly lower maintenance costs

As a result of their service-friendly design, our motors distinguish themselves due to the extremely long maintenance intervals. Further, the high efficiencies improve the energy consumption therefore reducing

operating costs. We offer energy-saving motors in the “High Efficiency” version for the range up to 200 kW – that is especially efficiency-sensitive. Up to 90 kW, these motors are designated as efficiency class EFF1. When compared to conventional motors, they have losses up to 40% less – which often means that they have a pay-back time of just a few months.

Energy-saving motors

The best example for cost-saving, effi-ciency and environmental friendliness: Our energy-saving motors that require less energy for the same power output. In fact, this can even be proven with the appropriate calculations using SinaSave®. This is a software tool that we developed, which allows you to calculate the pay-back time of your investment.

The advantages – an overview:• Complete product range according to

EU/CEMEP, EPAct and NEMA• Simple motor selection using an effi-

ciency classification system (EFF1/EFF2)

• 1LE1, 1LA9 and 1LG6 motors fulfill both EFF1 as well also EPAct efficiencies

• Lower operating costs as a result of the high EFF1 efficiency

• High motor and lubricant lifetime thanks to the lower motor temperature for EFF1, EPAct and NEMA motors

• CO2 reduction in operation reduces the environmental impact

Geared motors: Concentrated power, compact design

Our MOTOX series of geared motors have output torques up to 20,000 Nm and higher rated gear unit torques than conventional geared motors but with the same envelope dimensions. All gear unit types are available in the power range from 0.09 kW to 200 kW – from helical through offset shaft, helical bevel and helical worm up to worm geared motors.

They are admirably suited for applications such as longitudinal and rotary scrapers, rakes, mixers or spiral conveyers.

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A farsighted investment: Drive converters for variable-speed operation

Flow rates can be controlled far more precisely and faster with variable-speed drive

systems than when using mechanical control concepts – and can be adapted to the

actual demand. The advantage: A significantly higher degree of reliability and qual-

ity for water and wastewater systems. Further, variable-speed operation opens up

enormous cost-saving potential. This is the reason that a drive converter often has

a payback time of just a few months.

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The clever alternative to fixed speeds

For conventional control techniques, the motors always run with the speed required for the maximum flow rate. Excessive flow rates are mechanically “throttled” – which means that energy is simply thermally dissi-pated. Contrary to this, state-of-the-art drive systems with drive converters precisely adapt the speed – and therefore the energy drawn – to the actually required flow rate. The motor therefore only draws the actually required power. Power factor and efficiency remain almost constant. This avoids over-dimension-ing the motor and the energy requirement is significantly reduced. The cost-savings are especially high for positive displacement machines – such as pumps or blower com-pressors and depending on the plant char-acteristic, can be up to 50%, even up to 70% in extreme cases .

Low-stress operation reduces maintenance costs

The starting characteristics of a variable-speed drive also have a positive impact: Only the rat-ed current is drawn, which means that current peaks – that typically occur when starting – are eliminated along with the associated high torque surges. The soft starting and stopping reduces the stress on the complete mechani-cal drive transmission line. Further, operating conditions that can damage the machine or

system – such as cavitation, the inclusion of gas, compression surges and vibration – can be eliminated. By slightly adapting the motor speed, cavitation bubbles that damage the pump impeller blades can be eliminated and continuous streams of gas being pumped along with the medium are avoided. Not only this – ultrasonic compression surges typical for compressors are also eliminated. Suppress-ing certain pump speeds also avoids undesir-able vibration and oscillation. Additional advan-tages include: Mechanical control elements are eliminated, the power factor is improved and the process control optimized when compared to mechanical control techniques.

The complete range of drive converters

We supply the ideal drive converter for every application and every motor. As a result of their modular design and wide range of avail-able components and options these drive units can be optimally adapted to the specific appli-cation requirements and be combined to form perfectly harmonized, reliable and highly-effi-cient systems. The drive units are designed so that their energy-saving potential can be espe-cially effectively utilized. With their rugged closed-loop vector control that does not re-quire an encoder they are specifically tailored to drive tasks without regenerative feedback into the line supply – this makes them ideal for applications in the water industry.

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With SINAMICS, Siemens is offering an innovative family of drives that sets

standards in every perspective. In addition to a standard and simple operator

control philosophy, the members of the SINAMICS family all use the SIZER

engineering tool for selecting and dimensioning as well as STARTER for commis-

sioning and diagnostics. The following drive units are precisely predestined

for the water industry: SINAMICS G120, G130, G150, GM150 and GL150. And

for especially stringent requirements on the line supply quality, the S series

with SINAMICS S150 or S120.

Simple to operate

Whether low voltage or medium voltage: All of the SINAMICS cabinet units are equipped with the user-friendly AOP 30 operator panel that displays simple oper-ator control and commissioning functions in plain text. This means that no addition-al manuals are required when commis-sioning the drives. Drive parameters such as current, actual speed and speed set point are displayed in operation using bar-type displays.

Numerous interfaces and highest avail-ability

SINAMICS drives are equipped with numerous interfaces: PROFIBUS, PROFINET and various analog and digital inputs and outputs. This en-sures that the drive units can be easily integrated into higher-level automation systems. All SINAMICS drive units distin-guish themselves as a result of their high-est degree of availability. Their simple, clearly structured design makes them rugged and reliable. When service is re-quired, modules can be replaced with just a few manual operations – special tools are not required. Further, intelligent maintenance functions can be integrated, e.g. in the medium-voltage

SINAMICS: The unified and integrated drive family

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SINAMICS GM150 drive converters that automatically issue a signal if mainte-nance is required. Service and mainte-nance work can always be optimally planned. This means that unpredictable and sudden pump failures are a thing of the past – which also goes for the result-ing supply bottlenecks.

Space-saving and quiet

Our drive converter cabinets have a foot-print that is up to 70% less than conven-tional units thanks to their exceptional compactness. This means that electrical rooms can be dimensioned significantly smaller – which has a positive impact on the costs. Integration into existing plants and systems is also simplified. Our drive converters are the first choice when it comes to low noise: Only 69 db(A) at full load – even for cabinet units with power ratings of several 100 kW, additional noise-reducing measures are simply not required.

First choice for pump drives

• Rounding-off times avoid overpressure conditions and water hammer there-fore reducing the level of stress on the hydraulic and mechanical systems

• To ensure safe, reliable operation, mechanical resonance frequencies are skipped, locked rotors are detected and loads monitored

• The efficiency is optimized for no-load operation; the flux set point of the control is adapted depending on the load. Under no-load conditions, this reduces the rated motor flux by up to 50% and saves the corresponding amount of energy

• Operation can be monitored onlineIt is being increasingly specified that pumps must also be disconnected from the line supply in a controlled fashion if the flow rate is to be reduced. This is mainly done to avoid oscillations in the hydraulic system.

Bypass function: Using this function inte-grated in the drive converter, a pump mo-tor can be connected to the line supply – either when a specific speed is reached or using a separate command with a con-tactor. There are two versions of this by-pass circuit: Without (cold synchroniza-tion) or where the motor is synchronized to the line supply (hot synchronization). This means that the drive converter can be used as starting and stopping convert-er and staging functionality can be more simply implemented. The staging function permits a drive converter to be used to

feed several motors and pumps – the per-fect solution especially when it comes to pumping large quantities of water. A typi-cal example of such an application: The drive converter starts the first pump and monitors its speed. As the rate of flow increases this pump drive is synchronized and connected to the line supply. The same drive converter is then used to start a second pump – that is then used to pre-cisely control the flow rate. This means that pumps are not directly connected to the line supply (direct start) therefore avoiding undesirable high starting cur-rents. With this constellation, theoretical-ly, an unlimited number of pumps can be monitored using just one drive converter.

Flying restart function: This function is used to connect a drive converter to a mo-tor that is still running. If the drive con-verter was to be powered up without this function, then the motor would not be able to establish its flux. This could cause the drive system to trip due to an overcur-rent condition. The flying restart function first determines the motor speed.

Technology controller: The technology controller integrated as standard controls process quantities such as pressure, quantity, temperature, level.

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Customized SINAMICS functions

unnecessarily starting and stopping the pumps. And an additional spin-off – the pipes are also purged.

MaintenanceCleaning: A constant flow rate means that suspended particles in the liquids being pumped can be deposited over time. This can reduce the effective pipe diameter or even block the pumps. The MaintenanceCleaning function is used to briefly increase the pump speed to counteract this sediment build-up.

WallDepositsPrevention: If tank levels are kept constant over a longer period of time in wastewater treatment systems deposits occur at the edge of the tank. To avoid these deposits, the WallDeposits-Prevention function always varies the set point for the technology controller so that the tank level is permanently raised and lowered.

Specific pump functions

A whole raft of functions – that have been specifically designed for pumps – can be implemented using a software macro. This simplifies the operator con-trol and parameterization of the drive converter. The pumps functions are already pre configured.

EnergySaving: If the motor is not required it can be completely shut down using this function. This is done automatically if the system deviation of the technology con-troller lies below a defined limit value for a time that can be parameterized.

EnhancedEnergySaving: This function can be used to extend the time for which the drive converter is powered down as a result of the EnergySaving function – in order to save more energy and to avoid

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MICROMASTER low-voltage converters

The MICROMASTER family of drive con-verters addresses drive applications in the power range from 0.12 kW to 250 kW and distinguishes itself as a result of the extremely easy handling – from installa-tion & mounting through commissioning up to operation. These drive units are suitable for pump drives up to 250 kW and can control up to three motors. They are equipped with an integrated dry run-ning protection for pump drives – as well as additional features for specific appli-cations that can be implemented using freely assignable function blocks.

Medium-voltage drive converter: ROBICON Perfect Harmony

ROBICON Perfect Harmony rounds off our drive portfolio in the medium-voltage lev-el. It is the undisputed No. 1 worldwide in medium-voltage drive converters re-garding both market share as well as in-stalled power. With this drive unit, low-voltage cells are connected in series so that a medium-voltage drive converter is created that can be extremely precisely scaled – over a wide voltage and power range. Presently, this drive unit is consid-ered to be the most compact medium-voltage drive converter in the market: Transformer, power unit and control are combined in one unit. The complete system can be commissioned in a plug & play fashion without requiring any assembly work on-site.

Additional SINAMICS functionalities for the water industry

The extremely high voltage quality avoids losses due to harmonics, reduces the lev-el of stress both on the line supply and the motor and also fulfills the most strin-gent regulations relating to harmonics. The proven core topology ensures the highest degree of compactness, voltage quality and availability. The innovative cell-bypass concept in conjunction with the process-tolerant ProToPS® protective system guarantees the highest degree of reliability. This is because even if a cell fails, the drive still remains operational as the defective cell is simply bypassed. If a fault develops, instead of simply power-ing down the drive, ProToPS® provides a graduated system of alarms. This means that operating companies have more time to appropriately respond and take suitable countermeasures.

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Baden-Württemberg state water supply

TaskThe Baden-Württemberg state water supply was to be modernized – with the objective to increase flexibility and efficiently use the groundwater reservoirs. This involves one of the largest long-distance water supply utili-ties in Germany: More than three million people are supplied with drinking water through an extensive network of pipes 770 km long. This is for an area that in addi-tion to Stuttgart also includes Aalen, Esslin-gen, Göppingen, Ludwigsburg, Schwäbisch Gmünd and Ulm.

SolutionThe groundwater reservoirs were equipped with variable-speed low-voltage drive sys-tems for the pumps. The extremely precise and flexible drive concept always guarantees the correct mixing ratio – and therefore the optimum drinking water quality. It also en-sures the maximum availability and reliabili-ty of the water supply. The variable-speed operation simultaneously saves energy and reduces the level of stress on the system.

Products used: • 1LG6 low-voltage motors• SINAMICS G150 drive converters

Schwetzinger Hardt waterworks

TaskA higher degree of safety, reliability and cost-effectiveness. This is what the City of Mannheim expected when it came to mod-ernizing their water supply. This was to be done based on innovative operating control methods with process visualization and re-mote access.

SolutionThe drinking water pumping stations were equipped with variable-speed low-voltage drive systems – for precise, reliable energy-saving operation that also reduced the stress on the system. The drive system is integrated in a SIMATIC WinCC-based super-visory control system. This means that it can be operated and monitored from every-where – also via remote access.

Products used:• N-compact low-voltage motors• SINAMICS G150 drive converters

Best-practice water supply examples

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Madrid water supply

TaskThe Spanish capital wanted to guarantee a safe, reliable and cost-effective water supply for approximately one million people living in the southern part of the city. This represents approximately 250 liters per day for each per-son – also during the dry summer period.

SolutionThe main drinking water pumping stations were equipped with variable-speed, medi-um-voltage drive systems in order to secure precise and flexible usage of the water re-serves. The existing motors were only par-tially replaced. Those in a good condition were upgraded for variable-speed operation. The flow rate can now be quickly and pre-cisely adapted to the actual water demand using the motor speed. Further, variable-speed operation reduces the level of stress on the mechanical system of the complete pumping station – and when compared to conventional control concepts – now allows double-digit energy savings to be realized.

Products used:• H-compact PLUS high-voltage motors• Liquid-cooled SINAMICS GM150

medium-voltage drive converters

Jakarta water supply

TaskThe pumping stations were to be retrofitted in order to secure reliable and cost-effective water supply for the ever-growing metropo-lis of Jakarta with its population of millions. The existing motors, switchgear technology and cabling were to be kept.

SolutionWith the modernization, the existing tech-nology was kept in operation (motors, ca-bling, switchgear and instrumentation). However, low-voltage and medium-voltage drive converters were integrated into the existing system. Further, additional compo-nents from Siemens ensure safe and abso-lutely reliable operation. These components include an incoming contactor, main control switch with fuses to protect the semicon-ductors as well as a line reactor to limit harmonics.

Products used:• SINAMICS G150 drive converter• Medium-voltage drive converter

(previous SINAMICS GM150 series)

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Best-practice water treatment examples

Basel water treatment

TaskThe energy usage was to be further reduced for one of the largest wastewater treatment plants in Switzerland located close to Basel. The existing motors were to be replaced by motors with especially high efficiencies.

Solution450 kW high-efficiency low-voltage motors are now used to drive large Archimedes screw-type pumps that are used to transport the incoming wastewater into the treatment system located approximately 10 meters higher. Thanks to their special bearings they can handle the high cantilever forces. In the especially efficiency-sensitive power range below 200 kW, energy-saving motors with the highest efficiency Class EFF1 are used – especially there where the wastewater is transported into the biological stage of the settling plant after mechanical precleaning.

From here, the water flows just by gravity into the postsettling basins. The activated sludge comprising bacteria and microbes settles out. Part of the sludge is returned to the biological stage using so-called return sludge pumps. Energy-saving motors are also used here. Calculations have shown that the payback time of the energy-saving motors is a maximum of three years.

Products used:• N-compact low-voltage motors• 1LA9, 1LE1 and 1LG6 EFF1

energy-saving motors

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Low-voltage motorsInductionAluminum frame

Low-voltage motors InductionGray cast-ironframe

Low-voltage motors Synchronous High-Torquegearless

High-voltage motorsInduction

High-voltage motorsSynchronous

Power range in kW

0.06 – 45 0.75 – 4,000 Up to 2,150 200 – 30,000 5,000 – 100,000

Voltage classes in V

230 – 690 230 – 690 400, 460, 690 2,000 – 13,200 6,000 – 13,200

Shaft heights in mm

56M – 225M 100L – 630 400, 450, 500 315 – 1,250 710 – 1,250

Pole No. 2 – 8 2 – 8 16 2 – 16 2 – 8

Speed in rpm 750 – 6,000 750 – 6,000 Up to 800 Up to 15,000 Up to 6,300

Degree of protection IP55, IP56, IP65 IP55, IP56, IP65 IP55 IP23, IP55 IP55

Cooling concept Rib-cooled Rib-cooled Air/air heat exchanger;Air/water heat exchanger;Open-circuit air-cooled

Rib-cooled,water-jacket cooling

Rib-cooled Air/air heat exchanger;Air/water heat exchanger;Open-circuit air-cooled

Air/air heat exchanger;Air/water heat exchanger;Open-circuit air-cooled

Converter-side system partner

SINAMICS G120MICROMASTER

SINAMICS G120MICROMASTERSINAMICS G130SINAMICS G150SINAMICS S150

SINAMICS G130SINAMICS G150SINAMICS S150SINAMICS S120

ROBICON Perfect Harmony SINAMICS GM150

ROBICON Perfect Harmony SINAMICS GM150SINAMICS GL150

Power range in kW

Voltage classes in V

Cooling type

Degree of protection

Motors

Overview of motors for the water industry

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SINAMICS G120 SINAMICS G130 SINAMICS G150 SINAMICS GM150

SINAMICS GL150 MICROMASTER ROBICON Perfect Harmony

0.37 – 90 75 – 1,500 75 – 1,500 600 – 27,000 6,000 – 120,000 0.12 – 250 150 – 120,000

380 – 480660 – 690

380 – 690 380 – 690 2,300 – 7,200 1,800 – 12,000 380 – 500 2,300 – 13,800

Cooling using an external fan,convection cooling

Integrated fan Integrated fan Air- and liquid-cooled

Air- and liquid-cooled

Cooling using an external fan

Air- and liquid-cooled

IP20 IP00, IP20 IP20, IP21, IP23, IP54

Air-cooled IP22, optional IP42, liquid-cooled IP43, optional IP54

Air-cooled IP20, optional IP41, liquid-cooled IP41, optional IP54

IP20 IP31, IP42, IP54

Low-voltageinduction motors in aluminum orgray cast iron

Low-voltageinduction motors in gray cast iron

Low-voltageinduction motors in gray cast iron

High-voltageinduction and synchronous motors

High-voltage synchronous motors

Low-voltageinduction motors in aluminum orgray cast iron

High-voltage induction and synchronous motors

Overview of drive converters for the water industry

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Würzburg water treatment plant

TaskIn order to ensure optimum biological cle-aning the amount of oxygen injected must be continually adapted to the actual amount of prevailing dirt and pollution. The City of Würzburg wanted to achieve a higher de-gree of precision in this operation and at the same time reduce the operating costs.

SolutionThe existing fixed-speed drives were re-placed by SINAMICS G150-based variable-speed systems to achieve a precise and energy-saving operation that also reduces the stress on the mechanical system. The drive converters were integrated into the existing supervisory control system of the water treatment plant.

The supervisory control system continually determines the actual oxygen demand by measuring the oxygen and ammonium con-centration in the activation basins and appro-priately adjusting the speed of the turbocom-pressor drive. This means that the amount of oxygen injected is significantly more precise-ly dosed than before the modernization.

Products used:• SINAMICS G150 drive converter

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www.siemens.com/drives

Subject to change without prior noticeOrder No.: E20001-A270-P500-X-7600Dispo 2150321/12387 MK.LD.XX.LDAL.52.8.04 WS 04083.Printed in Germany © Siemens AG 2008

Siemens AGIndustry SectorLarge DrivesP. O. Box 47 4390025 NÜRNBERGGERMANY

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.

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