process news products June 2012

Products and Systems for the Process Industry

Contents

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

Siemens / TM Studios

p Engineering

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 futureproof 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)

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

process news products 2012 Publisher

Editor

Layout: Nadine Wachter

Siemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg, Germany www.siemens.com/automation

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]

Copy editing: Sabine Zingelmann

Drive Technologies Division CEO Ralf-Michael Franke Industry Automation Division

CEO Anton S. Huber Editorial Responsibility in Accordance with the German Press Law

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

Concept

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]

Christian Leifels

Editor in chief: Kerstin Purucker

Arno Hoier Responsible for Technical Content

Cornelia Dürrfeld

2  process news products 2012

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

Fair Highlights

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

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he Siemens ACHEMA theme is “Guiding you through change – your trusted partner for lifecycle innovation.” Siemens presents a comprehensive lifecycle management portfolio covering the entire spectrum of process instruments and analytics, drive technology, process control technology, and manufacturing execution systems (MES). The exhibits are complemented by plant and process engineering services and tailored solutions and services for the chemical and pharmaceutical industries.

The four highlights of this year’s appearance at ACHEMA are: the new Version 8.0 of the Simatic PCS 7 process control system, with its numerous new functions and various innovations 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 engineering costs; a comprehensive service 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-

Siemens AG

The highlights

tainable energy supply, allowing further cost savings. The ACHEMA presentation emphasizes 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

i nfo c ont a c t

www.siemens.com/achema [email protected]

process news products 2012 3

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

p Simatic PCS 7 Process Historian

High-Performance Data Handling Production plants generate an enormous volume of historical and real-time data. With efficient 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 specific reports from production data.

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

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

Siemens AG

With Process Historian, Simatic PCS 7 Version 8.0 provides an efficient, longterm 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 “longterm 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 single stations, servers, or server pairs is unrestricted. In addition, the system performs calculations and postprocessing and reporting tasks. The information server, the other main component

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

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Siemens AG

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ield 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 reporting systems, users can generate meaningful information on energy balance, material consumption, or alarm evaluations – for example, for process optimization purposes.

Individually processed reports speed up decision making

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 significantly 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 Information 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 available throughout the plant, thanks to the consistent support of Microsoft’s SQL platform.

Task-specific reports Reports can be prepared and generated via Microsoft Reporting Services. When this is done, relevant information 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 tabular or graphic content can be produced as PDFs, but dynamic data presenta-

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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

tions can also be created in various formats such as HTML, XML, or the MS Office–specific 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 Office applications.

Company-wide process optimization Shift supervisors, quality assurance personnel, process engineers, and production managers receive the data they need for monitoring and optimizing production: alarm reports, down-

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

User administration and access protection Automated report dispatching via e-mail

time reports for maintenance, information about the efficiency of production lines, and material consumption reports for production management strategies. Well-structured presentations of energy consumption data for electricity, steam, and refrigeration energy form a good basis for improving 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 Historian ensures this with high availability and reliability. Generating meaningful information from apparently unconnected data, archiving, and providing companywide access in real time are the prerequisites for fast decisions that result in higher productivity and lower costs. p

i nfo c ont a c t

www.siemens.com/pcs7 [email protected]

process news products 2012 5

Siemens AG

Engineering

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

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 p plant management. g

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omplex industrial plants generate huge volumes of data, with the volume during plant operation reaching the order of several terabytes. EPCs and owneroperators are constantly being challenged to make sustainable improve-

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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 efficient manner.

Integrated data and document management With the new Comos 10 software generation, Siemens Industry Automation is offering a solution for all aspects of modern-day plant management. At the heart of this solution

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Highlights: Integrated and efficient

plant management Transparent 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

is the unique Comos enterprise platform with its integrated data and document 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 efficiency in terms of both engineering and asset management processes. The new Comos iPad app also gives engineers and operators the kind of mobility and flexibility they need, offering an up-to-date insight into current plant processes at any time and at any location. Comos was designed as an open system right from the start. Comos 10 enables various software solutions, such as ERP (enterprise resource planning), and process control systems to be linked even more easily.

PCS 7 optimally integrated A 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 configurations

and plant structures, as well as typebased generation of the individual control level. The expanded interface functionality also favors expansion of specific aspects of control logic within the individual control level, and hardware redundancy is now supported as well. This integrated approach to engineering allows even greater parallelization of previously serial engineering processes, from the initial process-related development stage, through the subsequent 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 documentation throughout the entire lifecycle of the plant make things easier from a qualification perspective.

Specific pharma solution Together with well-known corporations, the new software generation of Comos has been expanded specifically for the pharmaceutical industry. The result is a solution that addresses the peculiarities of this industry. For example, the required document structure is created automatically in the design and engineering phase. Complemented by a clear allocation of respon-

sibilities and schedules, this creates the basis for successful project controlling. Documents are therefore processed promptly by the responsible persons and forwarded to the respective appropriate authorities. In addition, the Comos solution for the pharmaceutical industry favors qualification 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 specifications relating to materials and suppliers. Test results relating to function qualification can be documented and archived and are easy to retrieve. All the documents required are available at any time in an up-to-date version. This ensures that the various steps before release are completed efficiently and properly, from the first drawing right through to daily operation. As a result, pharmaceutical companies can enter the market more quickly and minimize both risks and costs, thereby significantly improving their overall competitiveness. The release of the new Comos 10 generation will take place in several steps. The first version is available as of May 2012. p i nfo c ont a c t

www.siemens.com/comos [email protected]

process news products 2012 7

Software

p Sipat 4.0

Next-Generation PAT In 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.

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rocess Analytical Technology (PAT) has become a reality for the pharmaceutical and life science industries. To facilitate its implementation, Siemens has developed 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 development. The software must be able to make reliable predictions to contin-

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

Focus on integration and usability

sions, and Sipat also supports Windows Server 2008, SQL Server 2008, and Oracle 11.2. Additionally, the latest version offers more options for chemometrical integration, supporting MATLAB 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.

With several new features for data acquisition and communication, Version 4.0 of the Sipat software is easier to use and implement. The software now supports the latest IT platforms, while remaining compatible with previous platform versions. Windows 7 is supported in both 32- and 64-bit ver-

Thanks to innovative features for analyzer communication and more intelligent 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,

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, enabling 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 specification. The first drivers using the new technology will be released soon.

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

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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 benefit from a new license model that is based on active methods and the highly improved performance and robustness of the software.

Sipat Express is fully configurable 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 integrated into the Sipat environment in the plant.

Continuous improvements based on real-world projects

Sipat Version 4.0 supports easy configuration of devices and methods

Siemens AG

Fotolia – DLVV

Dedicated 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 findings 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

i nfo c ont a c t

www.siemens.com/sipat [email protected]

process news products | 2-2012 9

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

p Sirius Motor Management for Profinet

Simocode pro Goes Ethernet The proven Simocode pro Sirius motor management system can now be connected to higher-level automation systems via the Profinet Industrial Ethernet standard. This offers users not only new functions for diagnostics, control systems, and the protection of motors, but also improved energy p gy management. g

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

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he 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 Profinet. 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 availability The 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 increasingly important role. In addition to communication via the control system, Simocode pro for Profinet offers new and easy-to-implement diagnostics and control options. For example, the system’s new Profinet basic device provides an integrated server for web diagnostics, as well as an integrated server for OPC UA, the standard for

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Siemens AG

The Sirius motor management system Simocode pro

manufacturer-independent communication in automation technology. Through the web server alone, all diagnostics 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 field level by the higher SCADA system. In addition, it is

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Energy efficient with Profienergy Thanks to the connection via Profinet, Simocode pro can now also realize Profienergy functions. This way the motor can be turned off during downtimes, 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 significantly reduced. p

i nfo c ont a c t

www.siemens.com/simocode [email protected]

Highlights: Simple integration into Profinetbased controllers Enhanced functions for diagnostics, control, and motor protection Improved energy management

Industrial Communication

p Wireless

Communication without Limits

Siemens AG

WirelessHART has become well established as a wireless communication system for the process level. Siemens shows select process instrumentation products for wireless communication in the Field Communication Lounge g at ACHEMA 2012.

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pplications with WirelessHART can be grouped in two clusters. The first cluster deals with providing diagnostics data and device functions centrally in the process 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 parameters, diagnostic information, and device functions can be transmitted through wireless communication. Siemens offers a broad device portfolio for WirelessHART: Sitrans P280 and TF280 transmitters, the Sitrans AW200 adapter, and the IE/WSN-PA LINK gateway. All devices can be easily integrated into the Simatic PCS 7 process control system and Simatic S7-300 and S7-400 controllers.

Industrial WLAN In addition to WirelessHART, Industrial Wireless LAN (IWLAN) is an established wireless communication option for process automation. IWLAN features reliable and deterministic data transmission, guaranteed data transfer rates ,and robust, secure transmission. The Scalance W family of products for wireless communication via IWLAN comprises access points, clients, and dedicated accessories for industrial applications. The latest addition to the family is the 277 F IWLAN mobile panel, which can be used to implement wireless

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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

Highlights: Simple and flexible Current data and information

Lower investment and operation costs safety solution in combination with Scalance W786-RR outdoor access point with rapid roaming. This enables implementing applications such as safety stop with wireless communication, proving IWLAN is reliable and robust. The ET 200pro IWLAN complements the IWLAN safety solution.

More control with Telecontrol For wireless communication in distributed networks of remote systems, Siemens offers the Telecontrol basic system for simple monitoring and control of distributed systems via cellular networks. Telecontrol Professional is

optimized for fully automated monitoring and control of distributed process units. Both systems can be easily combined. Some of the Siemens wireless products will be on exhibition in the ACHEMA Field Communication Lounge, area 11.via B29. p

i nfo c ont a c t

www.siemens.com/ wirelesshart [email protected]

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

p Energy-Efficient 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 efficiency for individual flow profiles can be achieved with dedicated drive solutions.

tion. An electromechanical throttle valve regulates the flow rate. The motor is operated continually at nominal speed. In the case of fluctuating flow rates, this concept results in distinctive partial load losses. As a result, the solution is worthwhile in the long run only if the flow rate is continuously close to the maximum and fluctuates very little.

Cascade control in case of higher fluctuations

Siemens AG

Motors in the highefficiency classes IE2 and IE3 enable energy-efficient drive solutions

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our fundamental drive concepts are suitable for the most diverse applications of pumps, ventilators, and compressors. Whether a throttle control, a two-point regulator with a soft starter, a soft-starter frequency-converter cascade, or a pure frequency-converter control is used depends on various factors. An analysis of the application based on investment costs, the plant-specific features,

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and the individual flow profile can show which drive concept is most energy efficient and most economical in a specific case.

Throttle control for uniform flow rate Throttle control is regarded as the simplest and most economical solution. A combination of a power switch and contactor runs in continuous opera-

A soft-starter frequency-converter cascade or pure frequency-converter control is suitable for varying flow rates. Compared to throttle control, both enable energy savings of up to 50 percent or even 70 percent with strongly fluctuating flow rates. For a partly controlled cascade, one or more soft starters are combined with a frequency converter for fine control. For example, if the cascade consists of a soft starter and a frequency converter, the soft starter is switched on automatically with a fixed speed when the maximum performance of the speed-controlled first 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 fixed base load and 100 percent. Control fluctuations, which can occur at the transfer from the frequency converter

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-efficient delivery, since the pumps run at the optimal operating point. Frequency-converter cascades are often the better choice for processes

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that require high control precision and speed. The frequency converters adjust the motor speed to the currently required quantity quickly and accurately, even in the case of strongly fluctuating flow 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.

Highlights: Energy-efficient drive solutions with motors in efficiency classes IE2 and IE3 Energy-optimal solutions for level control through pure

soft-starter concepts Energy savings of up to 70 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

Controlling tank levels through two-point regulators Tank levels can be monitored via sensors. Two-point regulation ensures that sufficient 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 relatively long in and out phases are possible, then permanent switching procedures 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 efficient operation. This concept also scores with low costs for purchase, assembly, operation, and maintenance. Almost any applicable drive solution can be designed to be energy efficient using components and systems from the product families Sirius switching systems, Sinamics and Dynavert frequency converters, and Simotics or Loher motors in efficiency 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

coordination i nfo c ont a c t

www.siemens.com/pcs7 www.siemens.com/pumps jutta.pfi[email protected]

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

W 000 kW 00 0,,0 1 0 10

Ignition Protection Type

Ignition Protection Type

Ex p

Ex n

kW 0 kW 00 0 00 0,0 80 Ignition Protection Type

Ignition Protection Type

0 kW 00 00 0 0.0 40

100 – 100,000 kW

0.25 – 6,500 kW

Ex e 0.12 – 3,500 kW

W 0 kW

0.09 – 100,000 kW

Available g range ce ra nce rman orma perfo p

Ignition Protection Type

0.09 – 6,500 kW

W kW 0k 00 0 00 0 60,0

kW 0 kW 00 0 00 0 20.0

Ex tD

Ex d

p Explosion-Proof Explosion P Explosio Prooff Moto Motors Mo s in Efficiency cien ncy y 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 y Ex d and Ex e are now also available in the IE3 efficiency y class.

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he Loher Chemstar series of explosion-proof motors in the Siemens portfolio were developed 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-specific

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process news products | 2-2012

versions with a wide operating temperature range against, for example, aggressive atmospheres.

Required ignition protection types guaranteed The 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 explosive gases is prevented through a pro-

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

Prepared p for extreme situations Siemens also s offers Loher motors with double protection for particular sites of do ep t operation op ation – for example, if fine dust and explosive gases appear at the p same time,, or in the case of extremely high explosi explosion hazard, as is prevalent hig in liquefi ed natural gas (LNG) tankers. q Maximum safety is achieved for the latsa ter through roug a combination of Ex d and Ex e p protection. The pressure-resistant ote encapsulation p o is achieved in this case through th gh the housing and is combined with temperature-limited active th the te em ignition protection type Ex e. parts of igni pressure-resistant Ex motor designs All pres ure

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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 fin-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 atmospheres, 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 standard designs, individual drive solutions are available that are adapted to the respective plant, application, or customer specification.

Highly efficient under all conditions Motors in efficiency class IE2, which have been mandatory since 2011 in the European Economic Area, have an efficiency factor that is up to 7 percent higher than that of conventional models. Siemens offers all Ex motors with ignition protection types Ex n, Ex e,

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

Worldwide use possible thanks to international and country-specific certificates Many of the Ex e motors fulfill 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

Ex p, and Ex d in efficiency class IE2, across the entire scope of the norm, from 0.75 kW up to 375 kW. Many are also available in efficiency class IE3. These drives have an efficiency 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 fulfill the new IEC norm 60034-30.

Certified for worldwide use All 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 PhysikalischTechnischen Bundesanstalt (PTB, Federal Institute for Physics and Technology). Versions meeting the specifications of the Verband der Industriellen Energie- und Kraftwirtschaft (VIK, Association of the Energy and Power Industry) are also available. For worldwide use, the motors and drives have additional country-specific certificates, such as NEPSI (China), CCOE (India), and Rostekhnadzor (Russia), including operation in regions with cold climates. Certification under the new international IECEx scheme enables the use of the motors as explosion-proof electrical equipment even under extreme conditions in many important industrial nations worldwide.

ATEX also for converters The Loher Dynavert T converters, developed for the chemical and petrochemical industry, are especially tailored to Ex motors and are ATEX certified for operation in Zones 1 and 2. An optional ATEX-certified motor temperature monitor enables the operation of the motor without the external net contactor that would otherwise be required. Furthermore, all industryspecific features for the process industry are integrated as standard in the Dynavert T converters. p

i nfo c ont a c t

www.siemens.com/drives [email protected]

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