Plant Construction, Engineering & Components
Powerful addition introduced
WEG has extended its W60 motor series, which now covers a power range of 500-16,000 kW at frequencies of 50 or 60 Hz. The three-phase induction motors are designed for the 2,300-13,800 V voltage range and are available with frame sizes from IEC 450 to IEC 1000 (NEMA 7000 to 1600). Designed for industrial applications such as compressors, pumps and fans, the W60 line provides high performance and reliability even under the most difficult operating conditions. The W60 is used mainly in the oil and gas sector, in mining, for electrical generation in power plants, in cement production, as well as in water and waste water applications.
“The W60 motors have been very well received by the market since being introduced in 2014,” says Andreas Schulte Mesum, Director European High Voltage Solutions at WEG in Germany. “WEG has designed all the motors in the expanded W60 line with the help of the latest software in order to achieve the highest reliability combined with long service life. The result is a compact, robust design which permits operation even in the toughest environments. It also boasts very low noise and vibration levels whilst also being suitable for high-speed applications. With the powerful standard W60 series motors WEG supplies comprehensive and competitive solutions in the medium and high voltage range.”
Robust, light, space-saving and efficient
Due to its optimised design, the W60 series motors are not only more compact, but also lighter than their predecessors. The compact dimensions offer a significant advantage: the W60 motors take up to 50 % less installation space than comparable motors. This makes them one of the most compact modular motors of this type on the market. The rugged design with high-quality housing and end shield are made of grey cast iron up to the IEC 560 standard. Sizes above IEC 560 feature a steel housing. A specially designed motor shaft prevents critical flexural vibrations at rated speeds – as well as below the rated speed in the case of two-pole motors – and ensures particularly low vibration levels. As a result, the W60 motors are also suitable for applications with frequency converters or heavy vibration loads. Thanks to the high-quality rotor and stator lamination, low-loss fans and optimised heat exchangers, the W60 series motors achieve unusually high efficiency and power density (output power relative to the weight). As a result, standard W60 series industrial motors are among the most efficient of their type on the market. What’s more theW60 motors are engineered for continuous use, horizontal mounting configuration and are easy to install and commission. They are also ideal for use with medium-voltage frequency inverters as standard, with no speed restrictions due to critical vibration speeds. The three-phase induction motors are designed for protection classes IP24W to IP55 and are suitable for safe or hazardous areas (Safe or Hazardous: Ex-n, Ex-t, Class I Div. 2, Class II Div. 2).
Flexible and modular
The W60 series benefits users in the form of maximum flexibility, as the 2 to 12-pole motors are available in three configurations: open and self-ventilated (IC01, WP-II), closed with air/air heat exchanger (IC611, TEAAC) and with air/water heat exchanger (IC81, TEWAC). The two-pole motors up to size IEC 560 are equipped with ball bearings, and are optionally available with sleeve bearings. Sleeve bearings are available as standard for larger two- and four-pole motors, but also for the complete W60 series if required. Thanks to the modular design, users can customise the motor to suit their specific application by means of optional expansion components such as differential pressure switches (air-cooled), leak detector (water-cooled), automatic lubrication system (anti-friction bearings) or rotary encoder.
News Plant Construction, Engineering & Components Processing Technologies
“Green” building for meeting needs of customers and employees
Endress+Hauser Canada has built one of the “greenest” company buildings in the country for 20 million euros. The newly opened customer and training center in Burlington/Ontario, located around 50 kilometers southwest of Toronto, is energy self-sufficient and CO2-neutral. A process engineering training facility, a large calibration laboratory, a workshop, a training center and around 120 modern workstations have been accommodated on 4,400 square meters of floor space – double the previous location.
The company has had its own sales company in Canada since 1990, serving customers from Manitoba to the Atlantic provinces. The employees at the headquarters in Burlington and in branches in Montreal, Calgary and Edmonton are supported by various representatives. Whether basic materials, metals & mining, oil & gas, food, chemicals, life sciences, water & wastewater, energy & power plants – virtually all industries are at home in this resource-rich country.
New building stands for brand values
“The customer and training center is an impressive example of Endress+Hauser’s global strategy of building and maintaining customer partnerships. This is how we grow, in Canada and around the world. It shows our commitment to customers and our dedication to sustainability.”
– Matthias Altendorf, CEO
Statement to the public
“The new building should express our aspirations as a company – to our customers, but also to the public as a whole,” emphasizes CEO Anthony Varga. During the planning process, the focus was on the needs of the customers. “We can support customers here in the best possible way throughout the entire life cycle of their facilities. We offer a welcoming environment and set standards with the ecological building design.”
At the heart of the new building is a process training unit; the second facility of its kind in Canada. Such Process Training Units (PTU) exist at Endress+Hauser sites around the world. At these pilot plants, customers can practice using a wide range of measuring instruments. They benefit from the long-standing partnership with Rockwell Automation and other manufacturers. Customers can thus simulate conditions on the plant that are similar to their own operations.
The Group places great emphasis on sustainability and energy efficiency in construction projects all over the world. The new building in Canada covers its electricity needs via 800 solar modules on the roof. These can generate around 408,000 kilowatt hours of electrical energy per year. This exceeds the building’s needs, so electricity can be fed into the grid. A geothermal system extracts heat via 50 wells from a depth of 180 meters and distributes it throughout the building via 63 heat pumps.
South-facing windows on the upper floor capture sunlight, and the triple-glazed facade prevents heat loss. A four-meter-high ficus tree in the atrium improves air quality and symbolizes the “green” idea. Thanks to all these measures, the building is one of the greenest structures in the country. It is the first private company to seek all three certifications from the Canada Green Building Council: the Net Zero Energy and Zero Carbon Building Standards, and Leadership in Energy and Environmental Design (LEED) Gold.
News Plant Construction, Engineering & Components Safety & Security Water & Waste Water
Significant underestimation of flood risks
In order to better assess flood hazards, hazard maps should include historical data. This is what researchers at the CEDIM – Center for Disaster Management and Risk Reduction Technology at the Karlsruhe Institute of Technology (KIT) are advocating. CEDIM has presented a first report on the flood disaster in Rhineland-Palatinate and North Rhine-Westphalia. Regarding the role of climate change, the combination of more available water in the atmosphere and increasing persistence of large-scale weather patterns holds an increasing potential for extreme precipitation events.
Last week’s flood disaster claimed more than 170 lives in Germany (as of July 21, 2021). People are still missing. The damage to buildings and infrastructure can only be roughly determined and is in the double-digit billions – of which at least two billion euros alone for transport infrastructure. In the meantime, the German Insurance Association (GDV) has calculated the insured damage to buildings and infrastructure. (GDV) has estimated the insured damage at four to five billion euros in Rhineland-Palatinate and North Rhine-Westphalia alone. How did the floods, which mainly affected Rhineland-Palatinate and North Rhine-Westphalia, come about? How can flood hazards – especially rare, extreme events – be better estimated in advance? These are the questions that CEDIM’s Forensic Disaster Analysis (FDA) Group has been addressing, and it has produced its first report.
As the researchers explain, enormous amounts of precipitation led, for example, to the water level at the Ahr (Altenahr) significantly exceeding its previous record of 2016 (3.71 meters, discharge: 236 m³/s). However, due to flooding, the gauging station failed at a value of 5.05 meters (discharge: 332 m³/s). The Rhineland-Palatinate State Office for the Environment used model calculations to calculate a level of up to seven meters for the night of the catastrophe; based on this, the experts estimated a discharge of between 400 and 700 m³/s.
Several factors led to the extremely high precipitation totals
From a meteorological perspective, several factors led to the extremely high precipitation totals. In addition, the highly indented terrain of the affected regions, especially in the district of Ahrweiler, with partly deeply incised river valleys, increased the surface runoff. The already nearly saturated soil due to partly heavy precipitation in the preceding days further aggravated the situation.
“Within 48 hours, more rain fell in parts of North Rhine-Westphalia and Rhineland-Palatinate than usually falls there in the entire month of July; the majority even fell within only about ten hours.”
– Professor Michael Kunz, CEDIM Spokesperson
To estimate the flooded areas in the hardest-hit areas of Kreis Ahrweiler and Rhein-Erft-Kreis, the research team combined satellite data with aerial photos from (amateur) drones and helicopters, as well as photos from social media. According to these estimated flooded areas, there are just over 19,000 buildings in the affected areas with a value of around nine billion euros. Combined with empirical data from past flood disasters (infrastructure damage, natural hazards, and other damage), the researchers estimated total damage between eleven and 24 billion euros (first CEDIM estimate: July 21, 2021). It should be noted, however, that flooded areas represent only a portion of the total affected area.
More available water in the atmosphere and increasing persistence of large-scale weather patterns increase risk
According to the Karlsruhe disaster researchers, whether a single extreme event or the sequence of several extremes can already be attributed to climate change can neither be precisely proven nor completely denied, especially when it comes to events on short time and spatial scales that are strongly influenced by local factors. However, for the large-scale processes in the atmosphere that lead to the development of extreme events, the following is true: The combination of more available water in the atmosphere as a result of temperature increase and an increasing persistence of large-scale weather patterns with a tending northward shift of the jet stream, the strong wind band in the upper troposphere, has a high hazard potential. “As a positive trend is expected for these three factors, the potential for extreme precipitation events will also increase in the future,” Kunz explains.
Significant flood events in the Ahr Valley as early as 1804 and 1910
“There have already been two particularly significant flood events in the Ahr Valley in the past, in 1804 and 1910, but a comparison with historical records suggests that this year’s values should be classified lower than those of 1804,” says CEDIM deputy spokesperson Dr. James Daniell. For the 1804 flood event, the discharge was already estimated at about 1,100 m³/s by the University of Bonn. This year’s event may have been hydrologically similar in magnitude to the 1910 event with a discharge of 500 m³/s. “The current flood maps for the Ahr valley are currently based on discharge statistics with data since 1947, as homogeneous measurement series have been available since that time. However, this means that the two historical events have not yet been taken into account in the hazard assessment,” says Dr. Andreas Schäfer, lead author of the report. For example, the current estimate of a hundred-year flood as a design basis for flood protection for the Ahr River is 241 m³/s.
CEDIM’s FDA Group urges the inclusion of historical data in flood hazard maps, including data from before continuous measurement records, to better assess flood hazards. “Admittedly, when analyzing and interpreting the data, we must generally keep in mind that both infrastructures and flood protection measures have changed in recent years. As a result, it’s harder to compare readings directly, and we should focus less on water levels,” Daniell explains. “We can use gauge levels from 1804 and 1910 as indirect indicators to identify flood years. However, measured data on discharge, on trends over time, and on precipitation totals are more important for interpretation. Ultimately, however, both historical variables – gauges and discharge – should be included when developing hazard maps.”
News Plant Construction, Engineering & Components
Delivery of two Biogas Plants to Japan
Currently, WELTEC BIOPOWER is setting up two agricultural 250-kW biogas plants for one of Japan‘s major milk producers. One of the plants is being set up in Urahoro on Japan‘s island of Hokkaido. The second plant is being built in Sakata in the prefecture of Yamagato on Honshu, the largest island. The structural design of the two biogas plants takes the earthquake risk in these regions into consideration. The generated power and heat will be used directly on site in order to enable energy autonomy. The commissioning will take place in summer 2021 in Urahoro and in autumn 2021 in Sakata.
Following the Fukushima nuclear disaster in March 2011 and thanks to the support of renewable energies, biogas enjoys a good reputation in Japan. Among the renewable energies, biogas is considered to be a weather-independent energy source that makes a significant contribution to the required grid stability. Additionally, the preconditions for the development of biogas are favourable, since despite the limited availability of other raw materials, Japan boasts plenty of biomass potential. Efforts to promote biogas projects had already started in 2002. A short while thereafter, WELTEC built its first „Made in Germany“ plant in Japan. However, the pace of development in this area picked up only after the government introduced the feed-in tariff for green energy in July 2012.
The companie’s latest biogas projects in Japan are hybrid dairy farms. This means that the embryos of special beef cattle breeds are transferred to dairy cows, allowing the farm to produce both milk and beef. Every year, the two locations of an agricultural company group yield approximately 30,000 t of liquid cattle manure, which will be used for the energy production in the anaerobic digestion plants. To ensure efficient digestion, WELTEC BIOPOWER is setting up one stainless-steel digester in Urahoro. In Sakata, the concern is building two digesters, as the animal headcount will soon be increased. With a height of 6.3 m and a diameter of 25.34 m, the three bioreactors will each have a capacity of 3,176 m³. The benefits of stainless-steel tanks include compact shipping in just a few containers from Europe to Japan and easy adaptation to the structural requirements in earthquake regions.
At the Urahoro site on Hokkaido, the liquid substrates will be pumped to the digester from three upstream storage tanks. Two of the three pre-storages are already in place, but are being furnished with state-of-the-art technology. WELTEC is building the third pre-storage tank with a capacity of 393 m³ from scratch. Its height is 5.03 m, and its diameter measures 9.98 m. A pre-storage of the same size is also being set up in Sakata. Due to the cold winters with a lot of snow, the prestorage tanks at the two locations will be insulated and furnished with gas-tight double-membrane roofs. Additionally, the company is setting up a digestate storage tank with a capacity of 524 m³ for each location. Following the separation, the digestate will be spread on the company‘s own fields as fertiliser. Apart from the digesters, upstream and digestate storage tanks, separation and pump technology, they are also setting up a 250-kW CHP unit at each of the locations.
Based on the customer’s specification, the plants will run in parallel grid operation. Therefore, both construction projects are viewed as pilot projects in Japan. The fact that the power will not be fed into the grid, but will be used for the rotary milking parlour and other facilities, makes the operator more independent from the power grid.
This makes sense from an economic perspective, as the grid capacity and stability in Japan is endangered especially in the earthquake areas. The fact that the framework conditions for the development of bioenergy are favourable is a great advantage: The yearly biomass potential in Japan amounts to approximately 284.4 million t, enough to produce about 13 billion kWh of electricity and continually supply 2.8 million households. At the bottom line, the efficient utilisation of raw material in biogas plants such as in Urahoro and Sakata contributes to the economic viability, eco-compatibility and security of supply and thus to the success of the energy transition in Japan.