Siemens Aeration Competence Center

For internal use only / Copyright © Siemens AG 2010. All rights reserved.
Siemens
Efficient turbocompressor technology for
waste water treatment
Short introduction
Helsingør History
Siemens Turbomachinery Solutions (then HV-Turbo A/S) was acquired in beginning 2007 by
Siemens together with the KK&K Group (Kuehnle, Kopp & Kausch).
The KK&K Group was renamed to “Pre-defined Compressors and Fans” (abbreviated to “PCF”)
and integrated with the Oil & Gas Division of Siemens.
The HV-Turbo Group was renamed to “Municipal and Industrial Application” (abbreviated to
“MIA”) and included in the PCF Group as E O C&S PCF MIA.
First and only gas The first s-type KK&K acquires HV-
turbine is produced aeration turbo Turbo from NTR
compressor is Holding
launched
A series of
turbo-chargers Closing of
is launched shipyard
KK&K group incl.
The first WWTP HV-Turbo acquired
installations in by Siemens AG
Helsingør Ship Germany & USA
Yard founded
1882 1947 1954 1973 1978-81 2000 2007
© Siemens AG 2007. Alle Rechte vorbehalten.

Page 2
ACC Site Information
Location: Helsingør
Business area and products
Applications within Waste Water Aeration (Biochemical), Flue Gas
Desulphurization, Sulphur Recovery, Fermentation and other industrial
applications.
Product Portfolio:
9 Basic compressor types with various customization possibilities
New product development: Direct Drive and Compact versions
Reference list of more than 7,500 units installed
Services, e. g. spare parts, maintenance and repair, installations,
modernization and upgrades
Numbers
Units delivered in 2012: 210

Office area: Approx. 2.500 sqm
Employees in 2013: 70 hereof 22 in Service

Page 3
ACC is a Service Provider to
Manufacturing Site Frankenthal
Business area and products
Steam turbines used as generator drives for power
generation up to 10 MW and as mechanical drives for
e. g. pumps and compressors
Single stage turbo compressors and blowers for
industrial applications and processes
Services, e. g. spare parts, maintenance and repair,
installations, modernization and upgrades
Extended workbench for Power Fans
Management
Volker Neumann (CEO)
Dr. Klaus Jacoby (CEO)
Frank Langner (CFO)
Employees
600 (2011) Thereof approx. 300 in manufacturing

Page 4
Siemens Turbomachinery Solutions
A suitable product portfolio to cover the main aeration applications
Siemens Applications
Aeration-Processes
Biological Waste Water Treatment and floatation
Flue gas Desulphurization (FGD)
Fermentation (e.g. Enzymes for Bio fuel production,
Yeast)
Marine applications
Siemens Solutions
Single stage centrifugal turbo compressors

Flow range 1.500 m3/h – 125.000 m3/h
Pressure range from 0.5 – 2.4 barg
Power range 50 KW – 3.300 KW
Air Supply Systems (automation)

Consultancy (energy optimization studies)
Service/ Upgrades and Revamps
Financing (energy saving motivated)
Page 5
Market leader in supply of aeration turbocompressors
3.500
1.000 1.300
500
Market leader with < 7.000 references

Established regional coverage (CN, US,
EU) and constantly expanding
Only supplier which can offer all
technologies (geared & direct driven)
1978 1983 1988 1993 1998 2003 2007
Number of references Installed units status 2007

Page 6
Siemens Turbomachinery Equipment

Page 7
Selection of Municipal Wastewater treatment references
Largest in Largest in Largest in S.
world Europe America
Changi WRP (SIN) Tillmann WRP (US) Seine Aval WWTP (FR) Xiaoshan Dong Pian (CN) La Farfana Santiago (CI) Shaoxing WRP (CN)
2.4 mio m3/day 5 x KA100SV, 2006 1.7 mio m3/day 9 x KA44SV, 2005 760.000 m3/day; 50% of 700.000 m3/day
10 x KA80SV, 2002 15 x KA22SV, 2004 population of Santiago 8 x KA44SV, 2003
6 x KA66SV, 2001
Largest in
China
Sulaibiya WRP (KU) Nashville Central (US) Southside WWTP, Dallas (US) Baix Llobrigat, Barcelona (ES) As Samra WWTP (JO) Pudong Bailonggong (CN)
375.000 m3/day 7x KA66SV, 1992 4x KA66SV, 2003 420.000 m3/day 267.000 m3/day 2.0 mill m3/day
5 x KA66SV, 2003 5 x KA66S, 2002 10x KA22SV, 2005 12 x KA22SV, 2007
Largest in
Italy
Milano South WWT (IT) Orange Country, CA (US) Al Ansab WWTP (OM) Berlin-Ruhrleben (DE) Manukau (NZ) Ulun Pandan (SI)
1.050.000 P.E. capacity 4x KA66SV, 1995 220.000 m3/day; 900.000 247.500 m3/day 300.000 m3/day 6x KA44SV, 2003
50% population of Milano P.E. 2x KA100SV, 2005 5 x KA44SV, 1999
4x KA66SV, 2003 3x KA80SV, 2005

Page 8
Aeration Product Portfolio
Short introduction
A comprehensive product portfolio for your aeration needs
Siemens Turbocompressors (STC) for Aeration
3,0
Integrally geared
Differential Pressure [barg]
dual-one stage STC-GO
30 50 kW 100 150 200 300 400

2,25 KW kW kW kW kW kW
1.000
kW 2.000
kW
20 kW
1,75 Integrally geared, one stage
GO(100)
GO(10)
GO(22)
GO(44)
GO(66)
GO(80)
GO(2)
GO(5)
1,25
10 kW
1,0
Direct drive, GO(5-c)
GO(2-c) one stage GO(10-c)
0,75
DO(1) DO(2) DO(5) DO(10)
0,5
0,25
1.000 10.000 100.000
kW figures are showing shaft power at 30 Air flow [m3/h]

degC, 60% RH and 1,013 bar

Page 10
How can Siemens Turbomachinery Solutions support your project?
Your challenges Our answers
Design Support:
Mechanical, Civil, Electrical Plans, 3D Modeling,
Technical Specifications, Design Solutions, On-
Design time documentation
Civil Savings; Mechanical Savings;

Electrical Savings:
Construction
Optimal number of aeration compressors/ High
voltage motors; Correct sizing of pipes, valves
Energy Savings
By most efficient Dual-Point-Control and correct
Operation selection of compressor technology
Other operational savings:
Maintenance Savings. Extended lifetime

Page 11
Siemens
Turbocompressors (STC)
Integrally geared Direct drive

(STC-GO) (STC-DO)
STC-GO STC-GO(GK) Air-foil-bearings

(GL/GB/GC) STC-GO(GK-c)
Level of customizing
Hard- Base frame Console Full enclosure

ware configuration configuration configuration
Sales & Pre-engineered

Execution Fully customizable Pre-engineered
concept Fully customizable
Waste Water Waste Water Waste Water

Appli-
Oil & Gas & FGD Fermentation Fermentation
cations
Fermentation
Frame GO(2)-GO(100) GO(2)-GO(10) DO(1)-DO(10)

size Up to 2 bar diff. up to 1.0 bar diff. up to 0.9 bar diff.
range

Page 12
STC-GO(GL) STC-GO(GK) STC-GO(GK-c) STC-DO
Design Custom Engineered Custom Engineered Pre-Engineered w/options Pre-Engineered w/options
Package Assembly Customizable Customizable Limited Customization Limited Customization
Core Air-end/gearbox Air-end/gearbox Air-end/gearbox Air-end/motor
Drive System Geared Geared Geared Direct-Drive w/VFD
Bearings/Lubrication Sleeve, Forced Lube/Oil Ceramic Ball/Oil Ceramic Ball/Oil Air foil/none
Impeller Design Job Specific & Optimized Job Specific & Optimized Job Specific & Optimized Standard 13 types available
Standard;
Cooling Water or Air Water or Air Air Closed Loop Coolant
Capacity Control IGV or VD Inlet Guide Vanes IGV or VD Inlet Guide Vanes IGV or VD Variable diffuser (VD)
Dual-Point Control Optional w/ VD & IGV Optional w/ VD & IGV Optional w/ VD & IGV Standard w/ VD & VFD
Controller Specifiable (PLC) Specifiable (PLC) Limited Selection (PLC) Limited Selection (PLC)
Lead Time 30-40 weeks 30-40 weeks 16-20 weeks 12-16 weeks
Instrumentation Specifiable Specifiable Limited Selection Limited Selection
Process Control MCP or DCS MCP or DCS MCP or DCS MCP or DCS
Motor/Voltage Specifiable/Specifiable Limited Selection/Low Limited Selection/Low Standard/Low
Motor kW (Max) 3,000 315 315 315
Starter SSRVS/VFD (stand alone) Optional VFD Optional VFD VFD included
Turndown (mass flow) 45% 45% 45% 35%
Enclosure Design Optional & Specifiable Optional Standard Upgrade Optional Standard Upgrade Standard IGV Inlet guide vanes
VD Variable diffuser
Ambient temperature Not limited Not limited <45 degree C <45 degree C VFD Variable frequency drive
Optional Material None MCP Master control panel
SS impeller & guide vanes None None
SS Stainless steel
Page 13
Dual Point Control

Philosophy
Short introduction
“Energy efficiency is not just low-
hanging fruits – it is fruits that is lying
on the ground” US Secretary of Energy, Steven Chu
How can we pick up this fruit in

municipal sewage treatment?

Page 15
Possibilities to reduce energy consumption in WWT process
More extensive process changes
with structural changes to plant
Upgrade and increase level of air

distribution automation
Exchange aeration equipment with higher

efficiency equipment (dual point control)
Change process to reduce DO-set point to reduce
required air-volume

Page 16
Fruits on the ground: Where is the biggest fruit to be pick up?
In the secondary treatment phase Electricity consumption for waste water treatment plant
waste water is treated by means of (activated sludge)
bacterial breakdown of the dissolved
biological waste. Lighting & Building
Chlorination 8% Wastewater pumping
0,3% 14%
In order to foster this bacterial break- Belt Press
Screens, Grid
4%
down, the oxygen level of the water 1.4%
needs to be increased. Aeration is the Anaerobic Clarifier
digesting 3%
process by which the area of contact 14 %
between water and air is increased,
either by natural or mechanical
means, resulting in air being suspended Return sludge
in water. pumping & Gravity
thickening
1% Aeration
54.3 %
Source: Water Environment Federation Energy Conservation Task Force.

Energy Conservation in Wastewater Treatment Facilities. 1997
Scope of evaluation without distribution
pumping stations

Page 17
What sources of aeration are possible? And what is the efficiency?
Retention time
Technology Type OTE kgO2/kW.hr 10,000 m3 water Limitations
Facultative 7-50 days Space
Lagoon Aerobic 3-6 days Retention time
Aerated 2-3 days
Rotors 1,52 – 2,13 4-12 hours Water depth

Mechanical Aeration Low speed 4-12 hours Life cycle costs
1,82 – 2,13
Possibly inhomogeneous quality
High Speed 1,52 – 1,98 4-12 hours
Moving parts
Combination Systems Turbine 0,91 – 1,52 4-12 hours Possibly inhomogeneous quality
Jet 1,22 – 2,13 4-12 hours Moving parts
Diffused aeration Course 1,22 – 2,13 4-12 hours Capital costs
Fine 2,43 – 4,36 4-12 hours Increasing maintenance of system

Most efficient choice Generally more complex system

Page 18
Short Introduction in Dual Point vs. Single Point control
Turbo compressor control methodology differences
Dual point control
Decision criteria's:
e f f i c i e n c y - %
• Design point
single–stage efficiency
• Turndown capability
Speed controlled
(VFD) for maximum
flexibility
direct drive • Efficiency over
Speed controlled
whole turndown
(VFD) range
i s e n t ro p i c
multi- stage
Speed controlled (VFD)
Usual operating
range of WWTP
positive disp
% c a p a c i t y

Page 19
Dual Point Control with STC-GO series
Air flow = f(n)
Diff. pressure = f(n²)
Impeller speed = n
Single Point speed control
limits the turndown range as the
pressure drops much faster than the
flow by reduced speed. In order to
reach a decent turndown, it is necessary
to design the compressor for a much
higher value with the result of overall
lower efficiency.
Dual Point control

Independent regulation of
capacity and head:
Capacity regulation via variable diffuser
vanes: diffuser vanes are gradually
closed, reducing the nozzle area,
whereby a continuous turndown to
45% by keeping the maximum
efficiency is achieved.
Head regulation: Inlet guide vanes
(IGV) are adjusting the performance
map acc. to fluctuations in temperature/
humidity and pressure changes
Page 20
Integrally geared: Dual-Point vs. Single Point Control
Page 21
Direct drive: Dual-Point vs. Single Point Control
Page 22
Qualified Performance test, based on ISO and ASME-PTC-10
Performance test Based on Performance Data Sheet (PDS)
Every compressor will go through an 8 - 16 hours

full load performance test including measuring of
vibrations and noise emission and a performance
certificate will be issued for every compressor unit
leaving the factory
A small 75 kW unit and a large 2000 kW unit during test run

Page 23
Short introduction
STC-GO series
The fully customizable integrally geared STC-GO-series
Integrally geared STC-GO
Well proven design with over 7.000

installed references in over 2.300
WWT and Power plants
Fully customizable to fit the plants

and project requirements
Each unit undergoes a performance

test before delivery, in accordance to
ISO and PTC-10
This series covers the full flow and

pressure requirements
1.500 m3/hr to 125.000 m3/hr

0.5 – 2.4 barg
50 to 3.300 kW

Page 25
The fully customizable integrally geared STC-GO-series
Integrally geared STC-GO
Cone diffuser
Well proven design with over 7.000
installed references in over 2.300
Inlet filter and WWT and Power plants
silencer
Fully customizable to fit the plants

and project requirements
Each unit undergoes a performance

test before delivery, in accordance to
ISO and PTC-10
This series covers the full flow and

pressure requirements
1.500 m3/hr to 125.000 m3/hr

Compressor Speed Base plate Local control 0.5 – 2.4 barg
air end increasing with panel with
gearbox auxiliaries Dual point 50 to 3.300 kW
control
Silencer hood for noise reduction and several upgrade and customization options available
depending on project and plant requirement

Page 26
Siemens A/S Turbomachinery Solutions
Pre-engineered geared compact units
Page 27
Air Bio Control (ABC)

Automation solution
Short introduction
Air Bio Control (ABC): Automation solutions for WWTP
Page 29
ABC solution for two aeration lines with 12 zones
Page 30
Pay-as-you benefit
Financial Solutions
Short introduction
“Pay as you benefit” solution
“Pay as you benefit” shows our confidence in
the achievable energy savings for your plant
With our partner Siemens Financial Services
(SFS) we take over the initial investments in
our products, allowing you to:
save liquidity in turbulent times
free investments for other purposes
put energy savings back into your facility
increase effluent quality & stability
save the environment w.o. putting pressure
on your credit line
Payback via the agreed energy savings over
the payback time

Page 32
Siemens “Pay as you benefit” solution
Where is it possible with Siemens Financial
Services

Page 33
Siemens “Pay as you benefit” solution
The “Pay as you benefit” concept
Additional savings due to

energy price increase
Customer
Energy & Operational costs

Savings used for initial savings
investment repay
Baseline
Reduced operational costs after
installation of Siemens blowers
Duration of program Time (years)

Page 34
Thank You
Thank you for

your attention
Evolution of Automation Solutions for WWTP
Manual Control
manual aeration control

Page 36
Constant Pressure Aeration Control
fixed pressure aeration control

Page 37
Semi-Automatic Aeration Control
semi–automatic aeration control

Page 38
Fully-Automatic Aeration Control
fully automatic aeration control

Page 39
ABC solution: Working principal
6800 m3h
sp
627 mBar
pv PID 8500 m3h PID 2 ppm sp
cv
Valve position
1.85 ppm
pv
cv pv
cv
Vane Position PID 634 mBar sp
PID Automatic Set Point Control…

Set point NH4
PID
Set point O2
O2 NH4
PID
FT

Page 40
The ABC solution
Page 41

Siemens Aeration Competence Center

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For internal use only / Copyright © Siemens AG 2010. All rights reserved.

Efficient turbocompressor technology for

waste water treatment

1882 1947 1954 1973 1978-81 2000 2007

© Siemens AG 2007. Alle Rechte vorbehalten.

Units delivered in 2012: 210

© Siemens AG 2007. Alle Rechte vorbehalten.

© Siemens AG 2007. Alle Rechte vorbehalten.

Single stage centrifugal turbo compressors

Air Supply Systems (automation)

Market leader with < 7.000 references

1978 1983 1988 1993 1998 2003 2007

Number of references Installed units status 2007

© Siemens AG 2007. Alle Rechte vorbehalten.

© Siemens AG 2007. Alle Rechte vorbehalten.

© Siemens AG 2007. Alle Rechte vorbehalten.

Aeration Product Portfolio

30 50 kW 100 150 200 300 400

kW figures are showing shaft power at 30 Air flow [m3/h]

© Siemens AG 2007. Alle Rechte vorbehalten.

Civil Savings; Mechanical Savings;

© Siemens AG 2007. Alle Rechte vorbehalten.

Integrally geared Direct drive

STC-GO STC-GO(GK) Air-foil-bearings

Hard- Base frame Console Full enclosure

Sales & Pre-engineered

Waste Water Waste Water Waste Water

Frame GO(2)-GO(100) GO(2)-GO(10) DO(1)-DO(10)

© Siemens AG 2007. Alle Rechte vorbehalten.

Design Custom Engineered Custom Engineered Pre-Engineered w/options Pre-Engineered w/options

Package Assembly Customizable Customizable Limited Customization Limited Customization

Core Air-end/gearbox Air-end/gearbox Air-end/gearbox Air-end/motor

Drive System Geared Geared Geared Direct-Drive w/VFD

Cooling Water or Air Water or Air Air Closed Loop Coolant

Instrumentation Specifiable Specifiable Limited Selection Limited Selection

Motor/Voltage Specifiable/Specifiable Limited Selection/Low Limited Selection/Low Standard/Low

Motor kW (Max) 3,000 315 315 315

Turndown (mass flow) 45% 45% 45% 35%

Dual Point Control

How can we pick up this fruit in

© Siemens AG 2007. Alle Rechte vorbehalten.

Upgrade and increase level of air

Exchange aeration equipment with higher

© Siemens AG 2007. Alle Rechte vorbehalten.

Source: Water Environment Federation Energy Conservation Task Force.

© Siemens AG 2007. Alle Rechte vorbehalten.

Rotors 1,52 – 2,13 4-12 hours Water depth

Jet 1,22 – 2,13 4-12 hours Moving parts

Diffused aeration Course 1,22 – 2,13 4-12 hours Capital costs

Fine 2,43 – 4,36 4-12 hours Increasing maintenance of system

© Siemens AG 2007. Alle Rechte vorbehalten.

Speed controlled (VFD)

© Siemens AG 2007. Alle Rechte vorbehalten.

Dual Point control

Every compressor will go through an 8 - 16 hours

A small 75 kW unit and a large 2000 kW unit during test run

© Siemens AG 2007. Alle Rechte vorbehalten.

Well proven design with over 7.000

Fully customizable to fit the plants

Each unit undergoes a performance

This series covers the full flow and

1.500 m3/hr to 125.000 m3/hr

© Siemens AG 2007. Alle Rechte vorbehalten.

Fully customizable to fit the plants