Integrated Drive Systems. What Is an Integrated Drive System? The Siemens Integrated Drive Systems... 6

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1 ARC WHITE PAPER By ARC Advisory Group APRIL 2013 Integrated Drive Systems What Is an Integrated Drive System?... 3 The Siemens Integrated Drive Systems... 6 Siemens Legacy as an Electrical Equipment Supplier... 9 Business Issues Faced in Absence of an Integrated Drive System Offering Mining Industry Benefits of Integrated Drive Systems Oil & Gas Industry Benefits of Integrated Drive Systems Cement Industry Benefits of Integrated Drive Systems Last Word VISION, EXPERIENCE, ANSWERS FOR INDUSTRY

2 VSD Motor: 6000HP, 1800RPM, 6kV, TEWAC Gear: Rated speed /6761 RPM Coupling Base Plate Integrated Drive Systems Single purchase order for entire drive system; streamlined processes Coordinated delivery times across multiple products Custom service contracts and extended warranty options Technologically innovative products and processes from a single source Matched engineered components Time to market, development and implementation efficiency Highly flexible, complete process and customer-oriented solutions Optimized design efficiencies Engineered systems built from a comprehensive range of components Systems responsibility Streamlined Business Process Benefits of Integrated Drive Systems for EPCs, OEMs and End Users 2 Copyright ARC Advisory Group ARCweb.com

3 What Is an Integrated Drive System? Drive train is a term widely used referring to a combination of electric drive, motor, gearbox, and coupling which transfers electrical energy to a rotating part of machinery. This paper will focus on drive trains in the mining, cement, and oil and gas markets. Copyright ARC Advisory Group ARCweb.com 3

4 Drive Trains Are Engineered Solutions Often Posing Huge Challenges Reducing Risk and Cost of a Drive Train Implementation 4 Copyright ARC Advisory Group ARCweb.com

5 Siemens Integrated Drive System Components Maximize ability to customize products/solutions to meet my specs (operational effectiveness) Optimized components designed to work together (operational effectiveness) Maximize speed of implementation (simplification of the process) Minimize installation downtime (efficiency) Copyright ARC Advisory Group ARCweb.com 5

6 The Siemens Integrated Drive Systems Integrated Drive System Team Approach Expert Consultation Pre-tested Installation Maintenance Customization Optimal Design Configuration Purchase Order Process Streamlined Warranty administration Single point of contact Logistics management Operation and Engineering Center (OEC) 6 Copyright ARC Advisory Group ARCweb.com

7 Operations and Engineering Center Support of Integrated Drive System Project Project Management Adjustable Frequency Drives (low voltage, medium voltage, DC) SIMOTIC Motors (AC Induction, DC) Gearbox Units Mechanical Couplings Siemens Integrated Drive Systems Offering Copyright ARC Advisory Group ARCweb.com 7

8 Siemens Provides Critical Technical Overview Necessary for IDS Evaluating direct online vs. VSD starting for energy efficiency, cost, and performance Optimizing economic, efficiency, and reliability for specific application Provide comprehensive diagnostic tools for entire drive train Optimization with what if scenario Modeling analysis Thermal analysis of a system Torsional analysis Resonance points Load dynamic analysis Appropriate method of cooling gear units to prevent overheating Flexibility requirement in coupling to avoid vibration Value Derived from a Global Base of Proven Products 8 Copyright ARC Advisory Group ARCweb.com

9 Siemens Legacy as an Electrical Equipment Supplier Electric Drives Technology Product Family Max Power Range Low Voltage AC Drives SINAMICS S120, S150, G130, G150, G MW Medium Voltage AC Drives SINAMICS GM150, SM150, GL150, SL150 GH MW DC Drives SINAMICS DCM 2.5MW Siemens Variable Speed Drive Portfolio Copyright ARC Advisory Group ARCweb.com 9

10 Electric Motors Technology General Purpose AC Product Family SIMOTICS GP Max Power Range 200 HP Severe Duty AC SIMOTICS SD 1,650 HP Trans-standard for harsh conditions SIMOTICS TN 1,650 HP Definite Purpose AC Explosion Protected AC SIMOTICS DP SIMOTICS XP 1,650 HP 1,350 HP DC Motors SIMOTICS DC 2,150 HP Large Custom Motors & Generators High HP Multiple Product Families Engineered Motors 100,000 HP 2, ,000 HP Geared Motors SIMOGEAR 260 HP The Siemens Global Motor Portfolio Note: Engineered solutions available in higher power rating 10 Copyright ARC Advisory Group ARCweb.com

11 Flender Acquisition Complements the Core Business Helical / Bevel Helical Gear Units Vertical Gear Units Planetary Gear Units Geared Motors The Siemens Flender Brand Mechanical Drive Types Mechanical Drives and Coupling Flexible Highly Flexible Hydrodynamic Torsionally Rigid Types of Coupling Copyright ARC Advisory Group ARCweb.com 11

12 Business Issues Faced in Absence of an Integrated Drive System Offering High Power Drive Trains Are Custom Engineered 12 Copyright ARC Advisory Group ARCweb.com

13 Unifying Order Management across the Drive Train Opportunities to Optimize the Design Copyright ARC Advisory Group ARCweb.com 13

14 Integration Challenges Faced Service and Repair 14 Copyright ARC Advisory Group ARCweb.com

15 Mining Industry Benefits of Integrated Drive Systems Revenue and Capital Expenditure Index of the Mining and Metals Industry; Source: ARC CapEX Index Copyright ARC Advisory Group ARCweb.com 15

16 Conveyors Gearless Conveyors Horizontal mills Vertical mills Crushers Grinding rollers Water/slurry pumps Draglines Mining trucks Mining Shovels Mining Industry Applications Combustible Corrosive High temperature High degree of condensation High elevation IDS Designed for Mining Industry Environment 16 Copyright ARC Advisory Group ARCweb.com

17 Oil & Gas Industry Benefits of Integrated Drive Systems Offshore/Onshore Drilling and Production Gas/Liquid Pipeline LNG Gas Storage Refining Petrochemicals Oil & Gas Industry Applications Examples Copyright ARC Advisory Group ARCweb.com 17

18 Cement Industry Benefits of Integrated Drive Systems Industry Energy Cost Variable Cost Automotive 2% 5% Cement & Glass 9% 21% Chemical & Petrochemicals 5% 11% Food & Beverage 2% 5% Mining & Metals 22% 50% Oil & Gas 6% 14% Pharmaceutical 4% 9% Pulp & Paper 4% 9% 18 Copyright ARC Advisory Group ARCweb.com

19 Crushers Roller presses Vertical mills Tube mills Rotary kilns Separators Bucket elevators Conveyor belt Fans Cement Industry Applications Copyright ARC Advisory Group ARCweb.com 19

20 20 Copyright ARC Advisory Group ARCweb.com

21 Last Word Copyright ARC Advisory Group ARCweb.com 21

22 22 Copyright ARC Advisory Group ARCweb.com

23 Analysts: Himanshu Shah, Salvatore Spada Acronym Reference: For a complete list of industry acronyms, please refer to AC Alternating Current ASD Adjustable Speed Drive DC Direct Current EMPP Electrical Motor and Two Planetary Gears EPC Engineering, Procurement and Construction HP Horse Power HVAC Heating, Ventilation, Air Conditioning IDS Integrated Drive System LC-I Load Commutated Inverter LNG Liquid Natural Gas MMDC Main Motor and Drive Contractor MV Medium Voltage MW Mega Watt OEC Operations & Engineering Center OEM Original Equipment Manufacturer PLM Product Lifecycle Management ROI Return on Investment RPM Revolutions per Minute SITRAIN Training for Industry TCO Total Cost of Ownership VFD Variable Frequency Drive VSD Variable Speed Drive Founded in 1986, ARC Advisory Group is the leading research and advisory firm for industry. Our coverage of technology from business systems to product and asset lifecycle management, supply chain management, operations management, and automation systems makes us the go-to firm for business and IT executives around the world. For the complex business issues facing organizations today, our analysts have the industry knowledge and first-hand experience to help our clients find the best answers. All information in this report is proprietary to and copyrighted by ARC. No part of it may be reproduced without prior permission from ARC. This research has been sponsored in part by Siemens. However, the opinions expressed by ARC in this paper are based on ARC's independent analysis. You can take advantage of ARC's extensive ongoing research plus experience of our staff members through our Advisory Services. ARC s Advisory Services are specifically designed for executives responsible for developing strategies and directions for their organizations. For membership information, please call, fax, or write to: ARC Advisory Group, Three Allied Drive, Dedham, MA USA Tel: , Fax: Visit our web pages at Copyright ARC Advisory Group ARCweb.com 23

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