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Productsand Systemsfor the Process Industry

news productsprocess

June 2012

C o n t e n t s

Publisher

Siemens Aktiengesellschaft,

Gleiwitzer Str. 555,

90475 Nuremberg, Germany

www.siemens.com/automation

Drive Technologies Division CEO Ralf-Michael Franke

Industry Automation Division

CEO Anton S. Huber

Editorial Responsibility in Accordance with the German Press Law

Arno Hoier

Responsible for Technical Content

Cornelia Dürrfeld

Concept

Christian Leifels

Editor Cornelia Dürrfeld, Siemens AG, I IA AS S MP 7 Siemensallee 84, 76187 Karlsruhe, Germany Tel.: +49 (0) 7 21 5 95-25 91 Fax: +49 (0) 7 21 5 95-63 90 [email protected]

Editorial Committee Kerstin Bürger, Ute Forstner, Kjell Francois, Ingo Kaiser, Doina Pamfilie, Stefan Rausch, Svitlana Schmidt

Publishing House Publicis Publishing P.O. Box 3240, 91050 Erlangen, Germany Tel.: +49 (0) 91 31 91 92-5 01 Fax: +49 (0) 91 31 91 92-5 94 [email protected]

Editor in chief: Kerstin Purucker

process news products 2012

p Fair Highlights

3 Focus on Plant Lifecycle Management

“ Guiding You through Change:” ACHEMA 2012

p Process Control Technology

4 High-Performance Data Handling

Simatic PCS 7 Process Historian

p Engineering

6 The Next Generation of Plant Management

Comos 10 Software Generation

p Software

8 Next-Generation PAT

Sipat 4.0

p Industrial Switching Technology

10 Simocode pro Goes Ethernet

Sirius Motor Management for Profinet

p Industrial Communication

11 Communication without Limits

Wireless

p Drive Technology

12 Designing Suitable Turbomachines

Energy-Efficient Drive Concepts

14 Safe Even in an Explosive Environment

Explosion-Proof Motors in Efficiency Class IE3

Layout: Nadine Wachter

Copy editing: Sabine Zingelmann

DTP: Mario Willms

Printing: Wünsch, Neumarkt, Germany

Cover photo: Siemens AG

Job number: 002100 41739

© 2012 by Siemens Aktiengesellschaft Munich and Berlin

All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper.

The following products are registered trademarks of Siemens AG:

COMOS, DYNAVERT MAXUM, PROFIenergy, SIMATIC Batch, SIMATIC PCS 7, SIMATIC S7, SIMOCODE, SIMOTICS, SINAMICS, SIPAT, SIRIUS, SITRANS.

If trademarks, trade names, technical solutions, or similar are not listed here, this does not imply that they are not registered.

The information provided in this magazine contains merely general descriptions or characteristics of performance, which in the case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall exist only if expressly agreed in the terms of contract.

IWI: TPOG

Printed in Germany

Cover: Version 8.0 of the Simatic PCS 7 process control system offers a number of new functions, underlining once more the advantages of an efficient and future-proof central coordination point that reliably performs the many different tasks required during the entire lifecycle of a modern plant. One new feature is the integrated, scalable Simatic PCS 7 Process Historian for archiving process data from multiple projects centrally and in real time (page 4)

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p “Guiding You through Change”: ACHEMA 2012

Focus on Plant Lifecycle Management

Right now, the process industry is facing many challenges like cost

constraints, global competition, a constantly and rapidly changing

technological landscape, and the need to meet environmental

demands. Siemens is a trusted partner for a sustainable business in

dynamic times and provides answers to these challenges.y g

The Siemens ACHEMA theme is “Guiding you through change – your trusted partner for life-

cycle innovation.” Siemens presents a comprehensive lifecycle manage-ment portfolio covering the entire spectrum of process instruments and analytics, drive technology, pro-cess control technology, and manu-facturing execution systems (MES). The exhibits are complemented by plant and process engineering ser-vices and tailored solutions and ser-vices for the chemical and phar-maceutical industries.

The highlightsThe four highlights of this year’s appearance at ACHEMA are: the new Version 8.0 of the Simatic PCS 7 pro-cess control system, with its numer-ous new functions and various inno-vations from the field up to the MES level for process automation; a benchmark approach to integrated engineering of plant design and automation technology to create data consistency and reduce engi-neering costs; a comprehensive ser-vice portfolio to increase profitability and reduce risk in all aspects of your system and process lifecycle; and solutions and services for energy management that help ensure a sus-

tainable energy supply, allowing fur-ther cost savings.

The ACHEMA presentation empha-sizes the strong commitment of Siemens to the process industry. As a trusted partner, Siemens supports its customers with the knowledge and expertise they need to create oppor-

tunities from change: by increasing plant productivity and efficiency, driving down costs, and shortening time to market. p

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p Simatic PCS 7 Process Historian

High-Performance Data Handling

Production plants generate an enormous volume of historical and real-time data.

With effi cient archiving systems, these data can be utilized for plant optimization

and to increase plant productivity. Simatic PCS 7 Process Historian reliably records

and archives data and generates specifi c reports from production data.

Field devices, bus systems with high transfer rates, and hard disks with enormous storage

capacities are the main components that are processing the continuous volume of data from process plants. With company-wide production report-ing systems, users can generate mean-ingful information on energy balance, material consumption, or alarm evalu-ations – for example, for process opti-mization purposes.

With Process Historian, Simatic PCS 7 Version 8.0 provides an effi cient, long-term archiving server solution embed-

ded in the control system. Without additional energy expenditure, process data, tags, alarms, and batch data from Simatic Batch can be archived centrally in real time with the “long-term archiving” tag in tag logging. The scalability of Process Historian allows the recording and storage of the data of single OS stations or OS servers from a PCS 7 project or from multiple projects. The number of archivable sin-gle stations, servers, or server pairs is unrestricted. In addition, the system performs calculations and postprocess-ing and reporting tasks. The informa-tion server, the other main component

besides the Process Historian, provides the user with archived data through a web interface.

Effi cient database for comprehensive data archiving The Microsoft SQL Server 2008 R2 rela-tional database management system permits the reliable storage of process parameters, alarms, and batch data, as well as confi guration and diagnosis data as a time-varying sequence of val-ues. These data are divided into groups and broken up across the time axes into several partitions. The user can access the stored information through

P r o c e s s C o n t r o l T e c h n o l o g y

The user can access the information server (IS) via web interface

Individually processed reports speed up decision making

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the SQL database, and the data can be read and written via standard database interfaces such as ODBC, OLE DB, and ADO.NET. If required, the volume of data can be signifi cantly reduced using the compression method of the OS server.

The user receives the data from the SQL database from the information server via Microsoft's Internet Informa-tion Services. From a security point of view, Siemens recommends that users operate the front-end information server with their own hardware and controlled access options, although Process Historian and the information server can also be operated on the same hardware. All the data are avail-able throughout the plant, thanks to the consistent support of Microsoft’s SQL platform.

Task-specifi c reportsReports can be prepared and gener-ated via Microsoft Reporting Services. When this is done, relevant informa-tion such as production and process data can be processed individually as required and provided as reports to the respective target groups cyclically, when needed, or based on events. Users can generate their own reports with the help of report templates. For example, traditional reports with tabu-lar or graphic content can be produced as PDFs, but dynamic data presenta-

tions can also be created in various formats such as HTML, XML, or the MS Offi ce–specifi c Word or Excel. Access to administration and report output is carried out via a web-based standard interface, either through Internet Explorer or – for the data output – via MS Offi ce applications.

Company-wide process optimizationShift supervisors, quality assurance personnel, process engineers, and pro-duction managers receive the data they need for monitoring and optimiz-ing production: alarm reports, down-

time reports for maintenance, infor-mation about the effi ciency of produc-tion lines, and material consumption reports for production management strategies. Well-structured presenta-tions of energy consumption data for electricity, steam, and refrigeration energy form a good basis for improv-ing the energy balance of a plant. Even user-specific key performance indicators (KPIs) such as retention period, exploitation, and productivity can be calculated and displayed. For many industrial sectors with regulated processes, it is necessary to document and archive process and batch data, alarms, and events completely and accurately. Simatic PCS 7 Process His-torian ensures this with high availabil-ity and reliability.

Generating meaningful information from apparently unconnected data, archiving, and providing company-wide access in real time are the prereq-uisites for fast decisions that result in higher productivity and lower costs. p

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Real-time archiving with Process Historian: Fully integrated long-term archiving solution for large volumes of data without additional engineering effort

Interruption-free plant expansion capability

Quick and simple access to plant data

Reporting with Information Server: Simple access to historical plant data from MS Offi ce environment and quick report creation

User administration and access protection

Automated report dispatching via e-mail

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http://www.siemens.com/pcs7


E n g i n e e r i n g

p Comos 10 Software Generation

The Next Generation of Plant Management

For years now, a number of prestigious companies within the process

industry have been successfully using the Comos software solution. The

Comos 10 software generation provides a high-performance enterprise

platform for plant engineers and operators that successfully manages

enormous volumes of data and revolutionizes plant management. p g

Complex industrial plants gen-erate huge volumes of data, with the volume during plant

operation reaching the order of sev-eral terabytes. EPCs and owner-operators are constantly being chal-lenged to make sustainable improve-

ments to their work processes to meet mounting pressures for reduced time and costs. That means processes have to run in parallel, and productivity must be increased, all while managing the plant in a safe and effi cient manner.

Integrated data and document managementWith the new Comos 10 software generation, Siemens Industry Auto-mation is offering a solution for all aspects of modern-day plant man-agement. At the heart of this solution

The new Comos 10 software generation offers more integration, interoperability, and innovation

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is the unique Comos enterprise plat-form with its integrated data and docu-ment management functionality, which can be adapted on an individual basis to suit a wide variety of industrial sectors. This means very large volumes of data can be controlled both quickly and easily, without users experiencing any restrictions at their workstations. New options for an integrated approach to collaboration, across both systems and sites, support extensive parallelization of work processes and thereby considerably increase effi-ciency in terms of both engineering and asset management processes. The new Comos iPad app also gives engi-neers and operators the kind of mobil-ity and fl exibility they need, offering an up-to-date insight into current plant processes at any time and at any loca-tion. Comos was designed as an open system right from the start. Comos 10 enables various software solutions, such as ERP (enterprise resource plan-ning), and process control systems to be linked even more easily.

PCS 7 optimally integratedA new interface ensures a consistent, bidirectional exchange of information between Comos and PCS 7 to optimize the integration of the control and automation systems. This includes the transfer of hardware confi gurations

and plant structures, as well as type-based generation of the individual con-trol level. The expanded interface func-tionality also favors expansion of spe-cifi c aspects of control logic within the individual control level, and hardware redundancy is now supported as well. This integrated approach to engineer-ing allows even greater parallelization of previously serial engineering pro-cesses, from the initial process-related development stage, through the sub-sequent engineering of the mechanical and electrical systems, and right down to the automation level. The initial pilot projects achieved time savings of up to 11 weeks (12.5 percent) and cost savings of up to 315 work weeks (9 percent). In addition, error-free data transmission and secure plant docu-mentation throughout the entire life-cycle of the plant make things easier from a qualifi cation perspective.

Specifi c pharma solution Together with well-known corpora-tions, the new software generation of Comos has been expanded specifi cally for the pharmaceutical industry. The result is a solution that addresses the peculiarities of this industry. For exam-ple, the required document structure is created automatically in the design and engineering phase. Comple-mented by a clear allocation of respon-

sibilities and schedules, this creates the basis for successful project control-ling. Documents are therefore pro-cessed promptly by the responsible persons and forwarded to the respec-tive appropriate authorities. In addi-tion, the Comos solution for the phar-maceutical industry favors qualifi ca-tion of the entire plant in terms of the various engineering and operational phases. Thanks to the software, it is easy to check the plant against the plans and to check specifi cations relat-ing to materials and suppliers. Test results relating to function qualifi ca-tion can be documented and archived and are easy to retrieve. All the docu-ments required are available at any time in an up-to-date version. This ensures that the various steps before release are completed effi ciently and properly, from the fi rst drawing right through to daily operation. As a result, pharmaceutical companies can enter the market more quickly and minimize both risks and costs, thereby signifi -cantly improving their overall competi-tiveness. The release of the new Comos 10 generation will take place in several steps. The fi rst version is avail-able as of May 2012. p

infocontact


Highlights:

Integrated and effi cient plant managementTransparent and consistent data management through object orientation

Open system architecture for optimal integration of external systems

Reduced development times for planning and operation of plants

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http://www.siemens.com/comos


S o f t w a r e

p Sipat 4.0

Next-Generation PATIn its latest release, Version 4.0, the scalable and modular Sipat software provides

greater reliability, improved performance, and tighter integration with

chemometric systems, as well as support for the new OPC UA ADI standard.

Another highlight is Sipat Express, a PAT data management solution for OEMs.

Process Analytical Technology (PAT) has become a reality for the pharmaceutical and life

science industries. To facilitate its implementation, Siemens has devel-oped the Sipat software solution. In addition to requiring a set of tools, such as process analyzers, process control tools, and reporting tools, supporting PAT principles in both development and manufacturing plants, PAT also asks for software that provides absolute data transparency by feeding correlated data back to processes, starting from product de-velopment. The software must be able to make reliable predictions to contin-

uously improve quality and effi ciency from the unit operation level up to the enterprise resource planning (ERP) sys-tem, manufacturing execution system (MES), and laboratory information management system (LIMS).

Focus on integration and usabilityWith several new features for data acquisition and communication, Ver-sion 4.0 of the Sipat software is easier to use and implement. The software now supports the latest IT platforms, while remaining compatible with previ-ous platform versions. Windows 7 is supported in both 32- and 64-bit ver-

sions, and Sipat also supports Windows Server 2008, SQL Server 2008, and Oracle 11.2. Additionally, the latest version offers more options for chemo-metrical integration, supporting MAT-LAB 2009 a&b and 2010 a&b as well as integration into Umetrics SBOL, CAMO Unscrambler X, and the new online generation-X calculation engines.

Thanks to innovative features for ana-lyzer communication and more intelli-gent memory management, Sipat has become more robust and offers higher performance. Data can be loaded directly into the Sipat data miner via a direct import option for XML data,

8 process news products | 2-2012

offering an easy and selective means of recovering archived information. Furthermore, users can access the basic Sipat settings more easily through the graphical user interface. Sipat also supports managed user access rights to support safe and easy operation and provides several operator screen options for integration into Simatic PCS 7 or for Intranet, en-abling improved usability.

One major update in Version 4.0 relates to the integration of process instruments and analytics. These systems can now be connected to the Sipat software via the new OPC UA ADI standard. OPC UA, the next-generation communication protocol for PAT data management, provides all the services needed for the standard exchange of data between different applications. The new OPC UA ADI specification enables complex analyzers, such as the Maxum II process gas chromatograph, to be easily connected to the master control technology based on the OPC UA spe cifi cation. The fi rst drivers using the new technology will be released soon.

A dedicated PAT solution for OEMsAnother major feature of the new ver-sion is Sipat Express, a one-stop PAT data management solution for OEMs.

Sipat Express is fully confi gurable by the OEM to connect to analyzers and handle process data and calculations. The plant operators receive a complete PAT package from their suppliers that works as plug and play. The OEM can use the Sipat Engineering Pack

to easily implement the entire Sipat functionality, complete with methods configuration, model generation, and administration. It can also test the software through an integrated console. Sipat Express can be smoothly inte grated into the Sipat environment in the plant.

Continuous improvements based on real-world projectsDedicated teams of Siemens experts have been continuously improving Sipat since its inception, providing a perfect match for the PAT requirements of the pharmaceutical market and to incorporate the fi ndings of completed projects into the solution. The latest version of Sipat features a broad set of enhanced, as well as new, features, ensuring that PAT can be deployed even more quickly and easily. p

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New in Sipat 4.0 The new version features Sipat Express, an OEM solution for PAT data management. Version 4.0 also utilizes the new OPC UA ADI standard to bring a new dimension to instrument interfacing. The Siemens teams have added various features to facilitate data handling and processing and chemometrical integration and have readied the software for the latest generation of Windows and database platforms. Users also benefi t from a new license model that is based on active methods and the highly improved performance and robustness of the software.

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Sipat Version 4.0 supports easy confi guration of devices and methods

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process news products | 2-2012 9

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p Sirius Motor Management for Profi net

Simocode pro Goes Ethernet

The new Simocode pro for Profinet has two integrated RJ45 interfaces, allowing the

user to connect the system to higher control systems such as Simatic S7. In addition, media redundancy functions can be realized thanks to Profi net. This means that data are available in a ring topology network structure, even when a communication channel fails, resulting in higher plant availability and thus an increase in productivity.

Uniformity, openness, and high availabilityThe needs of today’s customers with respect to communication ability are not limited to pure control functions. Aspects such as uniformity, open design, and availability play an increas-ingly important role. In addition to communication via the control system, Simocode pro for Profi net offers new and easy-to-implement diagnostics and control options. For example, the system’s new Profi net basic device pro-vides an integrated server for web diagnostics, as well as an integrated server for OPC UA, the standard for

manufacturer-independent communi-cation in automation technology. Through the web server alone, all diag-nostics and service data of the motor branch circuit are available – directly on-site or remotely via the Internet – by using a PC with a standard web browser. The integrated OPC UA server also enables these data to be called up via HMI panels at the fi eld level by the higher SCADA system. In addition, it is

possible to send control signals with OPC UA via a secured connection from the control system. This makes moni-toring and controlling motors, and thus protecting the drives, even more effective, easy, and fl exible.

Energy effi cient with Profi energyThanks to the connection via Profi net, Simocode pro can now also realize Profienergy functions. This way the motor can be turned off during down-times, and measured values and status information can be retrieved and passed on to the energy management system during operation. The energy requirements and costs in the plant are signifi cantly reduced. p

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The Sirius motor management system

Simocode pro

Highlights: Simple integration into Profi net- based controllers

Enhanced functions for diagnostics, control, and motor protection

Improved energy management

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The proven Simocode pro Sirius motor management system can now be connected to

higher-level automation systems via the Profi net Industrial Ethernet standard. This offers

users not only new functions for diagnostics, control systems, and the protection of

motors, but also improved energy management.p gy g

I n d u s t r i a l S w i t c h i n g T e c h n o l o g y


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I n d u s t r i a l C o m m u n i c a t i o n

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p Wireless

Communication without Limits

Applications with WirelessHART can be grouped in two clus-ters. The fi rst cluster deals

with providing diagnostics data and device functions centrally in the pro-cess control system through wireless communication, thus saving on wiring expenses and additional changes. The second cluster is triggered by a desire to eliminate the 4–20 mA wiring to the control system, as all data such as process parameters, system parame-ters, diagnostic information, and device functions can be transmitted through wireless communication. Siemens offers a broad device port-folio for WirelessHART: Sitrans P280 and TF280 transmitters, the Sitrans AW200 adapter, and the IE/WSN-PA LINK gateway. All devices can be eas-ily integrated into the Simatic PCS 7 process control system and Simatic S7-300 and S7-400 controllers.

Industrial WLANIn addition to WirelessHART, Industrial Wireless LAN (IWLAN) is an established wireless communication option for process automation. IWLAN features reliable and deterministic data trans-mission, guaranteed data transfer rates ,and robust, secure transmission. The Scalance W family of products for wire-less communication via IWLAN com-prises access points, clients, and dedi-cated accessories for industrial applica-tions. The latest addition to the family is the 277 F IWLAN mobile panel, which can be used to implement wireless

safety solution in combination with Scalance W786-RR outdoor access point with rapid roaming. This enables implementing applications such as safety stop with wireless communica-tion, proving IWLAN is reliable and robust. The ET 200pro IWLAN comple-ments the IWLAN safety solution.

More control with TelecontrolFor wireless communication in distrib-uted networks of remote systems, Siemens offers the Telecontrol basic system for simple monitoring and con-trol of distributed systems via cellular networks. Telecontrol Professional is

Highlights: Simple and fl exible

Current data and information

Lower investment and operation costs

!optimized for fully automated monitor-ing and control of distributed process units. Both systems can be easily com-bined.

Some of the Siemens wireless products will be on exhibition in the ACHEMA Field Communication Lounge, area 11.via B29. p

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Siemens offers a broad device portfolio for WirelessHART (clockwise from top left): Sitrans TF280 transmitters, the IE/WSN-PA LINK gateway, the Sitrans AW200 adapter, and the Sitrans P280 transmitter

WirelessHART has become well established

as a wireless communication system for the

process level. Siemens shows select process

instrumentation products for wireless

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Lounge at ACHEMA 2012.g


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D r i v e T e c h n o l o g y

p Energy-Effi cient Drive Concepts

Designing Suitable Turbomachines

Pumps, ventilators, and compressors for conveying gas and liquids

require drive concepts that are adapted to the application. Through

perfect coordination of the components at high control accuracy,

maximum energy effi ciency for individual fl ow profi les can be

achieved with dedicated drive solutions.

Four fundamental drive concepts are suitable for the most diverse applications of pumps, ventila-

tors, and compressors. Whether a throttle control, a two-point regulator with a soft starter, a soft-starter fre-quency-converter cascade, or a pure frequency-converter control is used depends on various factors. An analy-sis of the application based on invest-ment costs, the plant-specifi c features,

and the individual fl ow profi le can show which drive concept is most energy effi cient and most economical in a specifi c case.

Throttle control for uniform fl ow rateThrottle control is regarded as the sim-plest and most economical solution. A combination of a power switch and contactor runs in continuous opera-

tion. An electromechanical throttle valve regulates the flow rate. The motor is operated continually at nomi-nal speed. In the case of fl uctuating fl ow rates, this concept results in dis-tinctive partial load losses. As a result, the solution is worthwhile in the long run only if the fl ow rate is continuously close to the maximum and fl uctuates very little.

Cascade control in case of higher fl uctuationsA soft-starter frequency-converter cas-cade or pure frequency-converter con-trol is suitable for varying fl ow rates. Compared to throttle control, both enable energy savings of up to 50 per-cent or even 70 percent with strongly fl uctuating fl ow rates. For a partly con-trolled cascade, one or more soft start-ers are combined with a frequency converter for fi ne control. For example, if the cascade consists of a soft starter and a frequency converter, the soft starter is switched on automatically with a fi xed speed when the maximum performance of the speed-controlled fi rst pump is exceeded. The base load can be set to different values, for example, to 40, 50, or 60 percent. The frequency converter regulates the exact requirement between the fi xed base load and 100 percent. Control fl uctuations, which can occur at the transfer from the frequency converter

Motors in the high-effi ciency classes IE2 and IE3 enable energy-effi cient drive solutionsSi

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to the soft starters, are not a problem for many applications. The advantages of both soft starters and frequency converters can be exploited optimally with this drive solution. In the case of a lower load, the distribution of the pump output to two smaller units can lead to considerably more energy-effi -cient delivery, since the pumps run at the optimal operating point.

Frequency-converter cascades are often the better choice for processes

that require high control precision and speed. The frequency converters adjust the motor speed to the currently required quantity quickly and accu-rately, even in the case of strongly fl uc-tuating fl ow rates – for example, for dispensing procedures. As a result, only the energy required at the moment is used, with maximum ease of control. Fully regulated cascades of two or more converters take advantage of the dynamics as well as the improved availability.

Controlling tank levels through two-point regulatorsTank levels can be monitored via sen-sors. Two-point regulation ensures that suffi cient liquid remains in the tank in case of variable withdrawal. If the level falls below the minimum level, a pump is switched on via a soft starter and switched off again when the upper level is reached. If the pump and tank are selected in such a manner that rel-atively long in and out phases are pos-sible, then permanent switching proce-dures can be avoided. Strong shocks in the pipeline system are avoided, and mechanical components are protected by the electronic phase-controlled modulator of the soft starter. With this technique, energy consumption drops to almost that of a simple contactor. The motor and pump run at nominal speed with optimal effectiveness for effi cient operation. This concept also scores with low costs for purchase, assembly, operation, and mainte-nance.

Almost any applicable drive solution can be designed to be energy effi cient using components and systems from the product families Sirius switching systems, Sinamics and Dynavert fre-quency converters, and Simotics or Loher motors in effi ciency classes IE2 and IE3. Independent of the individual solution, these systems offer perfectly coordinated components and smooth integration into the Simatic PCS 7 higher-level process control system. p

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www.siemens.com/pcs7www.siemens.com/pumpsjutta.pfi [email protected]

Highlights:

Energy-effi cient drive solutions with motors in effi ciency classes IE2 and IE3

Energy-optimal solutions for level control through pure soft-starter concepts

Energy savings of up to70 percent via cascade control with frequency converters or in combination with soft starters

Sirius, Sinamics, Dynavert, Simotics, and Loher Chemstar provide components and systems for perfect coordination

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http://www.siemens.com/pcs7

http://www.siemens.com/pumps


p Explosion-Proof Motors in Effi ciency Class IE3

Safe Even in an Explosive Environment

Maximum reliability of explosion-prone equipment is indispensable in many industrial

sectors, particularly in the chemical and petrochemical industries, as well as in the oil

and gas industries. The complete Siemens portfolio of explosion-proof drive systems

covers applications for all types of ignition protection. Motors with ignition protection

type Ex d and Ex e are now also available in the IE3 effi ciency class.y y

The Loher Chemstar series of explosion-proof motors in the Siemens portfolio were devel-

oped and designed especially for the increased demands presented by aggressive atmospheres, extreme temperatures, and explosion hazards. Chemical-resistant coats of paint and electrolytically galvanized fan cowls protect the motors in industry-specifi c

versions with a wide operating tem-perature range against, for example, aggressive atmospheres.

Required ignition protection types guaranteedThe various types of ignition protection are taken into account in special motor designs. Thus, in the case of motors with gas explosion protection for

Zone 2, in which no sparks that can potentially trigger explosions may appear, ignition protection type Ex n is implemented. Ignition protection type Ex tD is used in dust hazard Zones 21 and 22. Ignition protection types Ex p, Ex e, and Ex d are offered for gas explosion protection in Zone 1. In the case of Ex p, the penetration of explo-sive gases is prevented through a pro-


p Explosion Proof Mo s in Effi cien yy Class IE3p Explosion P f Motop Explosio P fExplosion-Proof Motors in Effi cienncy Class IE3

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60,0000 kW60,0000 kkW60 0000 kkW60 0000 kkWW

40.000 kkW400.000 kkW40 000 kkW40 00000 kkWW

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00 kW0 kWW00 kW0 kWW00 kWW

Ignition Protection Type

Ex n

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0.12

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100

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Ex e


Ex d


Ex p


Ex tD

D r i v e T e c h n o l o g y

infocontact


Ex p, and Ex d in effi ciency class IE2, across the entire scope of the norm, from 0.75 kW up to 375 kW. Many are also available in effi ciency class IE3. These drives have an effi ciency factor that is up to 10 percent higher than that of standard motors and thus offer high energy savings potential at low operating costs for industries requiring explosion-proof motors. In addition, many models fulfi ll the new IEC norm 60034-30.

Certifi ed for worldwide useAll motors are certified as per the ATEX directive of the European Union (European directive for electrical devices in an explosion-prone environment) and checked by the Physikalisch- Technischen Bundesanstalt (PTB, Federal Institute for Physics and Tech-nology). Versions meeting the specifi -cations of the Verband der Industriellen Energie- und Kraftwirtschaft (VIK, Association of the Energy and Power Industry) are also available. For world-wide use, the motors and drives have additional country-specifi c certifi cates, such as NEPSI (China), CCOE (India), and Rostekhnadzor (Russia), including operation in regions with cold climates.

Certifi cation under the new interna-tional IECEx scheme enables the use of the motors as explosion-proof elec-trical equipment even under extreme conditions in many important indus-trial nations worldwide.

ATEX also for convertersThe Loher Dynavert T converters, developed for the chemical and petro-chemical industry, are especially tai-lored to Ex motors and are ATEX certi-fi ed for operation in Zones 1 and 2. An optional ATEX-certifi ed motor temper-ature monitor enables the operation of the motor without the external net contactor that would otherwise be required. Furthermore, all industry-specifi c features for the process indus-try are integrated as standard in the Dynavert T converters. p

Highlights: Premium effi ciency class IE3 for motors with ignition protection type Ex e and Ex d

Worldwide use possible thanks to inter-national and country-specifi c certifi cates

Many of the Ex e motors fulfi ll IEC norm 60034-30

Custom-built models available for voltages from 230 to 690 V for use in zones with dust or gas, from –55°C to +70°C operating temperatures

For the oil and gas industry: high-voltage motors of the Loher Vario series up to the megawatt range

tective gas inside the motor by means of excess pressure. In order to ensure increased safety with ignition protec-tion type Ex e, inadmissibly high tem-peratures are avoided in all parts of the motor. Pressure-resistant encapsulated Ex d motors are designed in such a manner that an explosion inside the motor cannot penetrate to the outside. Even the motor housing can withstand any explosion pressure that may occur.

Prepared for extreme situationsSiemens also offers Loher motors with double protection for particular sites of operation – for example, if fine dust and explosive gases appear at the same time, or in the case of extremely high explosion hazard, as is prevalent in liquefi ed natural gas (LNG) tankers. Maximum safety is achieved for the lat-ter through a combination of Ex d and Ex e protection. The pressure-resistant encapsulation is achieved in this case through the housing and is combined with the temperature-limited active parts of ignition protection type Ex e. All pressure-resistant Ex motor designs

are tested individually in the factory to ensure that they are pressure tight. Pressure-resistant motors up to 2,800 kW are offered in a fi n-cooled design or with tubular cooling for improved performance. Operating temperatures of –55°C to +70°C and protection types up to IP68 provide for safe operation, even under extreme conditions such as aggressive atmo-spheres, dirt, heat, or cold, which can appear in addition to the hazard of explosion in, for example, deserts or polar regions. In addition to the stan-dard designs, individual drive solutions are available that are adapted to the respective plant, application, or cus-tomer specifi cation.

Highly effi cient under all conditionsMotors in efficiency class IE2, which have been mandatory since 2011 in the European Economic Area, have an effi ciency factor that is up to 7 percent higher than that of conventional mod-els. Siemens offers all Ex motors with ignition protection types Ex n, Ex e,

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