ingenuity for pulp and paper industry - siemens 2 angel cilleruelo / pulp & paper ... qadvanced...

siemens.com/sipaper© Siemens SA 2016 All rights reserved.

SIPAPER Siemens answer for Paper Industry 4.0Next Trend, Innovation and Portfolio for Fiber Industry

Siemens Days | Madrid, Spain | September 28, 2016

Ingenuity for Pulp and Paper Industry

© Siemens SA 2016 All rights reserved.

Fiber Industry –Siemens has a broad portfolio to support the new developments

Instruments Quality Control Sectional Drives Process Motors & Drives

siemens.com/sipaper

Industrial ETHERNET

Converting,Packaging, Shipping

SheetCutter

Reel CutterRewinderPaper MachineHeadboxStock PreparationGrinding

Profibus DP

Calander

TMPWoodWastepaper

Pulp

LV Power Distribution

Process Control SystemPower Generation HV/MV Power Distribution Engineering Financing

Gears

M MM MM M MM MM M

Angel Cilleruelo / Pulp & Paper


• Lower energy consumption• Better product quality and accuracy• Highest availability – more throughput

• Integrated drive train applications with safety concept in accordanceto DIN EN-1034

• Integrated sensor-less web break detection• Stable power network design

(harmonic reduction, power factor improvement etc.)• Investment protection by tool-supported migration concept to future

DCS system versions• Totally integrated solution by mill-wide uniform user-friendly operator

interface

Increase efficiency, improve quality, reduce energy consumption.With SIPAPER – tailored products and solutions for the fiber industry

• Products: Large range of Motors & Converters, Mechanical drives,HV/MV Switchgears, Motor Control Centers, Transformers, Automationand Instrumentation

• Vertical specific IDS (Integrated Drive Systems):Sectional drives applications for Paper Machines, Coaters, Calenders,Winders or Pulp Drying Machines, refiner applications and othervertical specific drives systems for all production processes

• Mill-wide Integrated SIPAPER Solutions:Added value of world-class products utilized by the SIPAPERstandard platform (vertical specific IDS):

SIPAPER Drives APL SIPAPER Winder APL SIPAPER DCS APL SIPAPER QCS APL

SIPAPER APC SIPAPER IT MIS SIPAPER Power SIPAPER Service

Key portfolio SIPAPER within the Fiber Industry Customer benefits



SIPAPER Drives / Winder APL –solution that helps you surge ahead

• Sectional drives solutions• Winder solutions• Drives for all production

and manufacturingprocesses

• Refiner drives andautomation

• Low Energy consumption• Better quality and

accuracy• Highest availability• More throughput

BenefitsOur solutions



qLong-term investment security by guaranteed PCS7 compatibility –Use of APL-conform blocks and faceplates and F-Systems

qSafety concept in accordance to DIN EN 1034-3, -16, -17, -21

qSame basic software modules for paper and coating machinesand for finishing machines

qExtended diagnostic functions (signal quality, block jump etc.)and simulation possibilities

qHomogeneous APL “Look and Feel”, ergonomic design and structure

qExtended set of blocks with corresponding block icons and faceplate

qEasy integration into existing or future APL and Industry Library projects

qOnly one engineering environment for application and safety program

SIPAPER Drives / Winder APL –The benefits at a glance



• Automation standardbased on SIMATIC PCS 7

• Several views in operatingwindows

• Visualization of sequences• Services & diagnostic

functions• Online help

• Highest availability• User friendly-simple

operation• Minimized interface• Simple migration on later

versions


SIPAPER DCS APL –The automation standard for the fiber industry



qLong-term investment security by guaranteed PCS7 compatibility –Use of APL-conform blocks and faceplates and F-Systems

qEasy upgrade from previous SIPAPER versions with migration tool

qAdvanced library for pulp & paper industry specific requirements

qExtended diagnostic functions (signal quality, block jump etc.)and simulation possibilities

qHomogeneous APL “Look and Feel”, ergonomic design and structure

qExtended set of blocks with new and improved functionality –Function blocks for power plants

qEasy integration into existing or future APL and Industry Library projects

SIPAPER DCS APL –The benefits at a glance



• Integrated quality control• Cross directional control• Machine direction control• Report manager & archive• Grade archive• Automated grade change

• Mill wide uniform solution• Integrated control strategy• Open scanner interface


SIPAPER QCS APL –The quality detection and control solution



SIPAPER IT MIS –The gateway between automation and management

• MIS solution based onSIMATIC IT

• Identification of long termtrends

• Best monitoring of equipmentbehavior

• Visualization of performance• KPI for better decision

making• Flexible and Scalable




• Network design• Turbo Generators• HV/LV Switchgear/Control

gear• Transformers• SCADA

• Stable network design• High power factors

• Good voltage control• Low harmonic distortion

level• Low losses

• Highest availability


SIPAPER Power –the solution for intelligent energy management



SIPAPER APC –The effective solution of intelligent automation

• Intelligent automation• Model Predictive

Controller• Online adaption• Integration into DCS

system

• Better quality• Reduction of chemicals• Reduction of energy

consumption• Less impact on the

environment




• Technical Consulting &Engineering Support

• Energy & EnvironmentalServices

• Plant Maintenance &Condition Monitoring

• Service Contracts,Repair & Field Services

• Modernization &Optimization Services

• Technical & Online Support• Spare Parts• Training

• Energy Efficiency• Higher transparency• Reduced operating costs• Highest availability


SIPAPER Services –Technology based services for more competitiveness



Drive TechnologySINAMICS, SIMOTICS, …

Industrial AutomationSIMATIC, SIPLUS, …

Energy ManagementSIMOCODE, SIVACON, SIPROTEC, ...

Industry ServicesLife Cycle Services, Plant Data Services,

…

Increase efficiency, improve quality, reduce energy consumption.With SIPAPER – tailored products and solutions for Fiber Industry

World-class products + perfectly matching, industry-specific modules

The SIPAPER Portfolio

SIPAPERDrive Systems

SIPAPER Drives APLSIPAPER Winder APL

SIPAPER Gears

SIPAPEROperations

SIPAPER Services

SIPAPERProcess Automation

SIPAPER DCS APLSIPAPER QCS APL

SIPAPER APCSIPAPER IT MIS

SIPAPERPower Distribution

SIPAPER Power

Integrated SIPAPER Solutions



Innovation for Drives High Torque & Attached Synchron

Topics

Advanced Low Speed Design

Attached Synchron - 1FW3

High Torque - 1FW4

Attached Asynchron - 1RN6

A Direct drive system is a system that takesthe power coming from a motor without anyreductions

In the drive technology the number of directdrives increase.They replace the conventional solution ofasynchron motor and gear.

If a high torque at low speed is required, thetorque drive, as a special kind of the directdrive, could be used.

Motor Cooling Solutions

Economical Aspects

Conclusion



Drive solution for a requirement of high torque at low speed

Traditional alignment shaft, gear,motor and foundation

MotorGear

CylinderFoundation

Cylinder

Integrated solution Attached Driveon cylinder pivot

MotorShaft

CylinderFoundation

Direct drive without gear

Traditional alignment: Shaft,cover, gear, motor and foundation

Integrated solution:Attached Drive on cylinder pivot


1FW3/1RN6 Motor 1FW4 Motor


AC asynchronous standard frame motor

1. high pole pair number n = f/p

2. a star connectioninstead of delta

à Advanced Low Speed Design

Reduction of speed & increase oftorque:

Disadvantage1. Oversizing

2. Heating at low speed



AC permanent magnet synchronous standard frame motor – 1FW4

1. Same frame design concept like standardasynchronous motor.

2. No gearbox

Differences to Standard motor

1. Glued magnets on the rotor

2. Mainly watercooled



High efficiency (up to 97%)

Rated speed (200 - 800rpm)

Range of Torque (7500 - 42000Nm)

Rated voltage (400V, 460V und 690V)

Air cooling (70% torque @equal frame size)

The 1FW4 motor is also named High-Torque motor (HT-direct-motor).This kind of solid shaft motor is produced in frame size FS400, FS450 and FS500.Air and water cooled versions are available.

1FW4 High-Torque motor (HT-direct-motor)


1FW4 MotorExample of use – Press

Conventional: 1PQ8 with gear New ! : 1FW4without gear

The motor is designed for dynamical applications as well as for applications with a constant torquerequirement, like the press section in the paper machine.



1FW4Advantages (Characteristics / Customer benefits)

Quick compactdesign

No gear

Applicatoryadvantages

§ Reduced weight up to 50% (compared to ASM)

§ better efficiency compared to ASM with gear§ Maintenance friendly (no gear oil)§ Reduced risk of mechanical failure§ Low noise for the entire system

§ High constancy of torque§ High torque in compact design



1FW4Example



Motor

Attached Motor

Gear

Cylinder

Cylinder

Foundation

Traditional alignment shaft, cover, gear,Traditional alignment shaft, cover, gear,motor and foundation

Attached Motors


Hollowshaft motor on the shaft journal


1RN6AC asynchronous attached (hollow shaft) motor

1RN6-motors are asynchronous squirrel cage motors and be delivered as compact unit in hollowshaft design. They are available in framesize FS300 and FS380.

Water cooling

Rated speed up to 1000rpm

Range of torque (166 - 774Nm)

Rated voltage (400V and 690V)

Spectrum of power (13 - 83 kW)



The 1RN6-motors are recommended for use with guiderolls.

Compact - disk structure

Lightweight construction of aluminum

Simple / quick integration into the machine

Ambient temperature of 40°C

Source: Voith

1RN6Example of use – Guiderolls



1RN6Advantages (Characteristics / Customer benefits)

Quick compactdesign

No gear andshaft


§ Less space required§ No motor foundation§ Simple / quick integration into the machine§ No protection cover required§ Lightweight construction of aluminum

§ Maintenance friendly (no gear oil)§ Reduced risk of mechanical failure§ Mounting and logistic advantages§ Low noise for the entire system

§ Less speed fluctuations of the cylinders, caused by clearanceless transmission§ Encoderless operation possible



Source: Voith

Source: Voith

1RN6Hollow shaft motor


© Siemens SA 2016 All rights reserved.Source: Voith

1RN6Hollow shaft motor



1FW3AC permanent magnet synchronous attached (hollow shaft) motor

1. Combination of the attached motor and high torquemotor concepts

2. High dynamic capabilitiesà torque/mass ratio 1.1 to 6.4 [Nm/kg]à torque/inertia ratio 800 to 1800 [Nm/kgm2]).



High efficiency (up to 96%)

Rated speed (150 to 600rpm)

Up to 4800 Nm torque at 65°C cooling water

Rated voltage (400V and 690V)

Water cooling

1FW3-motors are delivered as compact unit in hollow shaft design.They are available in framesize FS150, FS200 and FS280.

1FW3Torque motor – special design for P&P


1FW3Example of use – Dryer section

The 1FW3-motors achieve the extended requirements of the paper industry. They are designed forapplications within high environmental temperatures and humidity, like dryer hoods.

The motors are designed for the following environmentalconditions:

Ambient temperature of 90°C

Temperature of the cooling water - 65°C

Pivot temperature of 80°C

High humidity - 90°C (155g H2O/kg air) Source: Voith



Tooth Coils Distributed Winding

¤Ä¤ Ä¤¤Ä Ä ¤ Ä¤¤Ä Ä ¤ Ä¤Ä Ä ¤ Ä¤¤ Ä

Advantages:§ Simple and economic design§ Compact active parts

Disadvantages:§ small power factor (0,6 to 0,7)§ limitations for higher speed levels

Advantages:§ Good power factor (0,85 to 0,95)§ Higher speed applications are possible

Disadvantages:§ Decrease of rated torque ( around 5%)§ increased production costs

1FW3Winding Systems



Example for efficiency factors of two motor types used at Smurfit Kappa Nettingsdorf, Austria,

inside dryer hood at nominal speed of 300 1/min and four different loads (100%, 75%, 50%, 25%)

Load 1FW3288-1.Y N06(690V)

1FW3283-1.Y N03(690V)

100% 93,0 92,0

75% 94,2 93,0

50% 94,7 93,6

25% 94,7 93,6

1FW3Higher efficiency at partial load


1FW3Engineering drawing



1FW3Advantages (Characteristics / Customer benefits)

Quick compactdesign

No gear andshaft


§ Simple / quick integration into the machine§ No motor foundation, reduced load§ No protection cover required

§ Maintenance friendly, less components§ Improved degree of efficiency§ Reduced risk of mechanical failure§ Mounting and logistic advantages§ Low noise for the entire system

§ High constancy of torque§ Improved control behaviour§ Use within 90°C ambient temperature and high humidity§ Less speed fluctuations of the cylinders, caused by clearanceless transmission§ High dynamic




Source: Voith

Source: Voith




Source: Voith Source: Voith



Mounting of an attached motor

1. Simple designAdvantage

Disadvantages1. Motor foundation or support flange required

2. Elastic coupling

3. Reduced stiffness

Solution using a coupling

Requirements on the Mounting

1. Possibility of movement in axial and radial direction(thermal expansion, misalignments)

2. stiffness of the connection



Mounting of an attached motor

Solution with torque arms

1. Balance of axial tolerances and missalignment

2. No foundation required

3. Rotational stiffness

4. Motor aligned automatically

Advantages

Disadvantage1. Play in radial direction

DirectConnection to

the shaft

Connected withClampingSystems



Mounting – Examples

Source: Voith



Material BHmax in[MGsOe]

Price per Weight in [US$/lb] /[US$/kg]

Price per BHmax in[US$/MGsOe]

*Max. Temp.[°C] / [°F]

AlNiCo5 5 20 / 44 4.3 540 / 1004

SmCo20 (26*) 20 100 / 220 6.0 300 / 572

NdFeB40 (41*) 40 50 / 110 1.4 140 / 284

1. High-carbon steel - weak, easy lost of magnetic field (temp, mech. shock)

2. AlNiCo5 (since 1930’s) - little corrosion, very brittle

3. SmCo20 (since 1970’s) - strong magnets, expensive

4. NdFeB (since 1990’s) - very strong magnets, cheap, affinity to oxygen

Characteristics + history

Maximum energy product BH(max) 1000 [GsOS]=7.9577[J/m³]

Magnetic materials for motors


Electrical operation

Attached motors offer redundancy in the case of drive fault

Stop of machineà stop of production

Depending on the motor sizing themachine can continue run with100% speed.Only an increased ramp up time isneeded.


DRIVEFault



Cooling

Motor

Advantages of Forced Water Cooling

Self air cooling

Cyl

inde

r

Narrow space,Hot environment(e.g. inside dryer hood),Dust and scraps

Forced air cooling

1. Reduced amount of volume2. No contamination (closed loop)3. Increased availability4. Control of temperature

Cooling System1. Cooling media - demineralized and clean water (antifreeze)2. Minimum number of materials

(stainless steel, copper/brass materials)

Less airflow at low speed

PumpsHeat Exchanger

Forced WaterCooling



Cooling / Heating System for watercooled motors

Compact system for watercooled motors

Dimensions (cm)L x W x H: 300 x 230 x 260

Weight: 2 t

Power:Cooling up to 250 kW*Heating up to 160 kW**26 motors (8,5 kW/motor )

CHP – Cooling Heating PlantApllication for 26 motors 1FW3285 (90°C)



Cooling / Heating System for watercooled motors

Operation and visualization:§ Stand-alone with operator panel

§ Integrated in SIPAPER Drives / DCSSoftware



Inverter Motor Gear Total

Direct drive 97% 93% - 90.2%

Asynchronousmotor 97% 94% 96% 87%

Example: 73KW required powerà Direct Drive saves 18000KWh per year compared to Asynchronous motor

3. Synchronous motors are a little less efficient at full load.

2. Permanent magnet motors are more efficient in partial load areacompared to asynchronous motors.

1. Losses of the gear box are eliminated. (Efficiency increase by 2 per cent ormore, depending on the type and design of the gear box.)

Direct drivesInstallation costs



Direct drivesInnovation for Value added

§ Elimination of gear and shaft

§ Recommended for revamping projects

§ Compact high torque motors for cylinders and leading rolls

§ Water cooled concept

§ Optimized for applications in paper and coating machines

§ Higher efficiency for complete drive train especially at partial load



Fiber Industry –Ingenuity for Pulp and Paper Industry

Instruments Quality Control Sectional Drives Process Motors & Drives

siemens.com/sipaper

Industrial ETHERNET

Converting,Packaging, Shipping

SheetCutter

Reel CutterRewinderPaper MachineHeadboxStock PreparationGrinding

Profibus DP

Calander

TMPWoodWastepaper

Pulp

LV Power Distribution

Process Control SystemPower Generation HV/MV Power Distribution Engineering Financing

Gears

M MM MM M MM MM M



Thank you for your attention!

Angel CillerueloPulp & Paper Manager

Siemens SA

Process Industries and DrivesProcess SolutionsFiber Industry

Ronda de Europa, 528760 Tres Cantos, MadridSpainMobile: +34 607078400

E-mail: [email protected]

siemens.com/sipaper


ingenuity for pulp and paper industry - siemens 2 angel cilleruelo / pulp & paper ... qadvanced...

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