Weg weg-motors-success-cases-50035068-case-study-english

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Weg weg-motors-success-cases-50035068-case-study-english

  1. 1. WEG Motors Success Cases
  2. 2. Our essence2
  3. 3. 50 WEG Motors Success CasesWEG, that began in 1961 as a small factory of electric motors, has become a leading global supplierof electronic products for the segments of Oil & Gas, Sugar and Ethanol, Mining, Food & Beverages,Construction, Pulp and Paper, Sanitation, and the Steel Industry, among others.The search for excellence has resulted in the diversification of the business, adding products to theelectric motors which provide from power generation to using energy more efficiently.This diversification has been a solid foundation for the growth of the company that, for offering morecomplete solutions, currently serves its customers in a dedicated manner.Even after more than 50 years of history and continued growth, electric motors remain one of WEG’smain products. Aligned with the market, WEG develops its portfolio of products always thinkingabout the special features of each application.A collection of 50 cases has been put together to recall some of the main supplies of WEG electricmotors in order to show the successful partnerships between WEG Motors with its customersformed over 50 years of experience and to demonstrate the wide range of products, applicationsand segments where WEG is present.The 50 cases celebrate WEG’s fiftieth anniversary and attest to the company’s experience andpresence in several applications.Enjoy your reading. 3
  4. 4. Steel Industry4
  5. 5. CST - Companhia Siderúrgica de TubarãoRecord supply of motorsWEG registered one of its largest individual Sumitomo, and another 57 motors to thesupplies comprising 703 low voltage motors for Brazilian company Inepar. All the motors whichthe hot strip rolling mills at CST - Companhia were installed in the optimization of industrialSiderúrgica de Tubarão, located in Serra, in the processes and installation of a new productionstate of Espírito Santo. The package supplied line of hot strip rolling mills at CST were340 motors to Toshiba Corporation and 306 developed with specific features for use inmotors to the also Japanese multinational, projects in the steel industry. July, 2001UsiminasA wish come trueThe steel segment, an important segment of the Many wishes become needs, both for those whoBrazilian industry on the global scenario, wished have the wish, and for those who help the wishto obtain electric motors able to withstand the come true. And sometimes there are innovationsmaximum possible time without the need of and discoveries and not only improvements in themaintenance and operate in the harsh conditions solutions already known and applied.found in the hot strip rolling mills. In this step of A good example of this is Usiminas who usedthe production process of steel mills, a steel plate imported motors that were not adequate for theapproximately 250 mm thick is reduced to a plate line. To meet this market need, WEG created aof around 2 mm. A total of 3.52 million metric tons national solution, the Roller Table. “Now we haveof plates are processed per year. A number of a motor which is really able to withstand theelectric motors operate on this line. When a motor conditions of the mill,” said Pedro Fioravante,stops running it seriously affects the process. At Maintenance Engineer at Usiminas. “WEG,the end of the line, the winding machine gives the besides solving our problem, also met a need ofproduct the form of coils which will be processed the steel market as a whole,” adds Bras Augustoin the cold strip rolling step until they reach the de Oliveira, Electrical Maintenance Engineer atthickness required by consumers. Usiminas. July, 2005 5
  6. 6. Oil & Gas6
  7. 7. PetrobrasSynergy between WEG and PetrobrasIt is to provide the best service and offer the Netzsch, Weir Pumps, Omel, Mark and others,best products that everyone who works at and is an expert when it comes to products forWEG spends their energy every day. The goal Petrobras. WEG understands the requirementsis to attend to needs and contribute with and characteristics of equipment anddifferent partners in the development of large technology developed in accordance with theprojects in different areas. Petrobras standards. This enables quickAn example is WEG’s specialty in providing quotes for the manufacturers contracted by thefor the constantly evolving oil industry. company, whether domestic or foreign. InAmong the major end customers in this 2002, the motors supplied by the companysector is Petróleo Brasileiro S.A. - Petrobras, having Petrobras as the end customer totaleda leading distributor of oil derivatives in Brazil 34,500 hp. And the goal is to continueand that, in March 2003, reached a record investing in research and development of newvolume of 2.043 million barrels of oil products to suit the evolution of the companyequivalent per day (boe/d), joining the group and offer the best solutions.of oil companies that produce more than 2 Daily, Ex-d explosion proof and Ex-n nonmillion boe/d. sparking motors leave the plant to the endWEG is a partner of the leading customer, Petrobras. All these motors aremanufacturers of pumps and compressors Cepel/Inmetro certified and carry a standardthat supply to Petrobras such as KSB, Sulzer, Petrobras plate. May, 2003 7
  8. 8. Petroquímica União, IBT Moldes and Motobombas Schneider Specific solutions Petroquímica União from São Paulo and IBT US IEEE841 standard, a reference in the Moldes and Motobombas Schneider (Franklin petrochemical industry. The partnership with Electric Group) of Santa Catarina solved PQU, plus the attributes based on WEG know- problems in their applications by developing how, make WELL a top product in electric their own specific solutions from investments motors. PQU invested in the replacement of 40 in WELL (WEG Extra Long Life) motors. motors, submitting them to tests of durability. In The challenge that Petroquímica União - PQU, July 2005, the tests were completed a petrochemical company located in the ABC successfully and the company decided to region of São Paulo between Santo André and replace another 80 motors. “Our policy is to Mauá, had to face was to increase plant seek improvement in efficiency and reduction of availability and reduce the failure rate and failures and downtime for maintenance of downtime. In 1999, the company extended its equipment,” says Nelson Baldi, PQU challenge to WEG that has been a partner Maintenance Manager. “Fortunately, our since the 70s. The two companies then began partnership with WEG worked because we have to develop a more resilient motor that would equipment in operation since 2001 which has offer a better performance at the production not yet broken down. The good results are due line by reducing the failure rate. The new motor to common values and principles of both model is now applied to drive loads in general: companies. In solving our problem, WEG ended pumps, fans, compressors etc. up creating a new product, a competitive “Since 1999, there has been an evolution in advantage for them and for PQU.” the project that culminated in the launch of the Thanks to the good results of the investment, WELL line, with the participation of the PQU is among the five first companies in the Engineering Maintenance of PQU and Sales, world with the lowest downtime. The world Engineering and Technical Services average downtime per year is 130 hours. At departments of WEG,” explains Fernando PQU, in 2004, this total did not exceed 54 Fontes, WEG representative for the region. The hours. In 2005, the company won the PNQ WELL motor was inspired on the demanding 2005 - National Quality Award. November, 20058
  9. 9. PetrobrasHistorical Opportunity“Historical opportunity” were the two words that of all systems and final testing of the unit weresynthesized the new moment of suppliers of completed.goods and services of the oil industry since the According to Petrobras, the inauguration of thediscovery of huge oil reserves in the pre-salt layer P-57, which occurred in October 2010, markedoff the Brazilian coast. And it could be no differ- a new generation of platforms designed andent. Petrobras estimates the acquisition of 200 built from the engineering concept that focusesplatforms, enough to trigger a wave of investment on simplification of projects and standardizationand expansion throughout the chain. of equipment. Based on maximum efficiency,And this is only part of the demand. If it has to technological innovations directed the whole P-57go almost seven kilometers deep to reach the project.pre-salt layer, it still means a great challenge for During the construction of the vessel, the level ofthe domestic industry and one that needs to be national content was approximately 68%, show-met in a short time. It is also true that the first ing Petrobras’ preference for Brazilian suppliersstep towards the new technologies got off on and their competence to overcome engineeringa right foot: the P-57 platform, which went into challenges. In the long-standing partnership withoperation in late 2010 in the Jubarte field in the the company, WEG is one of the national giantsEspírito Santo portion of the Campos Basin, will present in the P-57. Participating in an interna-serve as a model for the units that will operate in tional price-taking made by Single Buoy Mooringsthe pre-salt of the Santos basin. The complexity (SBM), the company that signed the contract forof the platform can be exemplified by the script of engineering, procurement and construction withits construction. The hull of this unit resulted from Petrobras, WEG was chosen to supply motors,the conversion of the “Island Accord” tanker at transformers and panels because it offered thethe Keppel FELS shipyard in Singapore between best technical and commercial solution. “The col- October, 2010October 2008 and March 2010. laboration between SBM and WEG was not justAt the same time, the oil and gas processing a simple partnership, it was an alliance to reach a Scope of solution supplied to P-57:modules were built at the UTC Engenharia build- common goal. The P-57 was a large and complex 39 Medium Voltage Panelsing site, in Niterói, in the state of Rio de Janeiro, project with a tight schedule and the two com- 136 Low Voltage Panelsand at the Brasfels shipyard, in Angra dos Reis, panies stood side by side, keeping good com- 22 Low Voltage Explosion Proof Panels (Ex-de)also in that state, in April 2010. The hull arrived at munication between them and with Petrobras,” 8 Medium Voltage Dry Transformersthe Brasfels yard in April of that year, and then the said Jean-Francois Labrunie, Package Manager 9 Low Voltage Transformersinstallation of the modules, the interconnection at SBM. 10 Medium Voltage Motors for Pumps 4 Medium Voltage Motors for Compressors 150 Motors in General / OEMs (LV) 1 PMS - Power Management System 1 UPS - Uninterruptible Power Supply 9
  10. 10. Sulzer Pumps Increased Safety Sulzer Pumps (one of the largest pump manufacturers in the world) hired WEG Brazil to supply four PTB certified HGF315 motors - Ex-e, to couple to their pumps. The motors were sent to the Sulzer plant in India and then shipped to Taiwan where they were installed at the CPC Corporation (Chinese Petroleum Co.) refinery. 2003 Ecopetrol Pumpjack WEG’s branch in Colombia provided a package of 55 motors, 5 to 7.5 hp, for Ecopetrol, a state company in the country. The motors operate with pumpjacks in oil wells. Two 250 hp motors for pumping stations were also provided in the same package. This package is important because it highlights WEG’s experience in providing for the Oil & Gas segment also in foreign markets. 200610
  11. 11. 11
  12. 12. Mining12
  13. 13. Collahuasi Mining CompanyLargest frames in the worldIn May 2003, WEG produced the largest cast iron have an efficiency of 97.5% and operate at 4,700 mframes of the world until then. They were delivered above sea level.to the Collahuasi mining company in Chile in August The diameter of the frames is 1.4 m and they are2003 to move a conveyor belt to transport rocks. 2.1 m long. Twenty tons of sand were used toThe final weight of each motor is 15,000 kg, power make the mold which required the labor of 422,788 kW and voltage, 2,300 volts. The machines workers for the casting process.CBMM July, 2003Foolproof MotorThe only Brazilian producer of niobium and test,” says CBMM Control and Maintenancepresent in all market segments, CBMM - Supervisor, Marcio Teixeira. In contacts withCompanhia Brasileira de Metalurgia e Mineração, Teixeira, WEG’s engineers began working on theuses WMining motors for use in the mining sector specification of the motor that would better suitin its plant in Araxá, in the state of Minas Gerais. It that case. “CBMM needed a motor that couldall started in October 2005 when CBMM drive a water pump of the boiler in a warmcontacted WEG, a long time partner, for what environment (60°C), with the presence of steam,”seemed like a normal purchase to replace a says Formento. That is, the critical environmentmotor. “However, the analysis made by the referred to by Márcio Teixeira. WEG and CBMMengineers of the WEG Sales department showed worked together to define the best solution. Andthat the simple replacement of a normal motor it came in the WMining motor launched in 2005.would no longer meet CBMM’s needs,” explains “We bought one of these motors to try it out. TheSales Analyst Ricardo Formento. It was product withstood the severe conditions ofnecessary, therefore, to provide a specific operation and is running without downtime orproduct for that application. “We have a critical, production losses,” says Teixeira, concludingaggressive and extremely humid environment that the trend now is to use only WMiningwhich puts all the resistance of a motor to the motors. July, 2006 13
  14. 14. Votorantim In most severe applications The first complete cement factory belonging to products, added to the comprehensive service Votorantim in Santa Catarina is already in network in the country also grants the customer Scope of supply: operation. Equipped with WEG technology in the necessary tranquility.” continued the engineer. 07 medium voltage motors (several powers of motors and drives, the unit in Vidal Ramos, in the Among the highlights of supply for the plant in 8 to 3,500 hp) Vale do Itajaí, 180 kilometers from Florianópolis, Ramos Vidal are the slip ring motors with 31 low voltage motors with squirrel cage rotors, cost about US$198 million and will boost the automatic raising of the brushes (to drive the HGF WMining and W22 WMining models (different production of cement, supplying the markets of mills), Master line motors in frames 500 and 560 powers, ranging from 2 to 350 hp) Santa Catarina and Rio Grande do Sul and (more robust thanks to the improvement of More than 300 low voltage motors driving relieving the other factories in the region. The technology at WEG’s foundry ) and, W22 HGF equipment from sub suppliers (prerequisite plant is part of a major investment made by and WMining motors. for delivery) Votorantim which foresees the construction of Interchangeability of medium voltage motors with 01 complete substation including transformers, other units in the country until 2014. other WEG motors already installed at Votorantim panels, protection, cables (25 MVA) Business partners since 2005, this is the first time units in Brazil reduces the amount of reserve 14 dry transformers (several powers from 300 WEG provides the entire distribution system of motors required for the reliable operation of the to 2000 kVA) high and low voltage drives to a Votorantim unit considerably. “The medium and low voltage Low voltage distribution panels, low and medium cement manufacturing unit. It is an integrated motors are all closed and robust enough to voltage cubicles, soft starters and low and medium supply with the usual synergy between the withstand the operating conditions required in voltage frequency inverters companies of the WEG group in developing an cement plants due to the kind of environment integrated package to meet customer needs. The where they are installed and the efforts required package includes transformers for the power for severe applications,” explains engineer Rafael substation, medium and high voltage drive Almeida. The project coordinator of the work in panels, low and medium voltage drives and Vidal Ramos, engineer Clovis Antonio Santana, motors to drive crushers, mills, fans and the says that WEG is currently one of the largest furnace. The last machine was delivered in partners of Votorantim Cimentos. January 2011. According to WEG engineer, Rafael “And that tends to remain like this given the good Fabro de Almeida, the company worked in performance of products and services,” he synergy with the customer from the specification announces. According to Santana, the unit built in of the equipment required for the operation of Santa Catarina is part of the second wave of each application individually to the delivery, investments made by Votorantim Cimentos in installation and start-up. “Besides contributing in Brazil. The company already has new projects for achieving the planned schedules, we worked so the years 2011, 2012 and 2013 for the so-called that the customer’s return on investment may third wave, and prospects for new investments in occur as quickly as possible,” he says. “The sequence, aligned with the evolution of the quality in the service and performance of WEG domestic and international markets.14
  15. 15. Aggmin Equipment VSI Crusher Aggmin is one of the leading Canadian manufacturers and distributors of crushers. WEG motors for this particular application are manufactured to operate in harsh environments and are suitable for projects in the mining and cement sectors. 1997July, 2011 15
  16. 16. Woerner Cost x benefit Prominent in the national lubrication WMining motors, the most outstanding segment, Woerner, a German company are the resistance against high impact that has been in Brazil for nearly 35 shock, more power savings, efficiency years, in partnership with WEG offered levels higher than those of NBR 7094, one of its customers in the gold mining and the motors are also prepared to segment, a complete solution with 16 operate in harsh environments, WMining motors. WEG exclusivity for the providing a longer life to applications. segment, the motors can be used from WMining motors allow Woerner to the extraction to the processing of provide their customers better the ore. performance in the operation of Applied in lubricating systems, which lubrication systems. Located in aim to reduce the friction between the Garuva, in the state of Santa Catarina, bearings and shafts of mills that process in addition to the mining sector, ore to obtain gold, WMining motors Woener also supplies the steel, drive the pumps that are responsible for cement, pulp and paper, sugar and the displacement of the lubricant in the alcohol, and automotive sectors, lubrication system, under controlled among others, and uses WMining flow, pressure and temperature motors in most of the lubrication conditions. systems supplied to their customers. During the project, the mining company can compare the WMining motors with Scope of supply: traditional motors because WEG 2 Motors - 4 hp equipment will share space with 4 Motors – 7.5 hp traditional equipment in two of the four 3 Motors - 20 hp mills of the company. 2 Motors - 25 hp “Our customer was very pleased to 2 Motors - 50 hp know the WMining line which should 3 Motors - 125 hp provide a better cost x benefit than traditional motors,” said Axel van den Kerkhoff, director at Woerner. The mining company expects there to be a reduction of downtime for maintenance of motors and costs of spare parts. Among the main characteristics of the February, 201116
  17. 17. AlcoaReliability in Amazon RainforestIn the heart of the Amazon, west of the state of field, in addition to stored asset optimization customer problems,” says Sydney Volpi, from TechnicalPará, Juruti has one of the largest deposits of high eliminating unnecessary costs,” explains Stuchi. Sales. Rafael Stuchi also indicates the benefits for thequality bauxite in the world. This is where Alcoa, a team. “This delivery demonstrates all the know-howmultinational aluminum industry, has a company Return on Investment that WEG has for this type of application in the miningthat annually produces millions of tons of ore. “For Alcoa, this was a customized solution which area, in which cost reduction, operational availabilityBecause of this high volume, one of the biggest ensured the optimization of stock and elimination of and reliability are the focus of the projects developedchallenges of the Bauxite Mine in Juruti is to balance costs due to a detailed study of the motors installed by the service area ,” he says.the production process of storage, without at the mine in Juruti carried out together with WEG,” cliente cuja atuação é marcada por um histórico degenerating unnecessary costs. It was essential to said Carlos Nelo, Supervisor of Engineering and parceria e compras de produtos da WEG.invest in developing a strategic and sustainable Reliability at the Alcoa Bauxite Mine in Juruti. “A WEG possui uma metodologia de dimensionamentoproject and for that the company relied on WEG’s específico e tem um corpo técnico disponível paraexpertise in the mining segment. Mine of opportunities solucionar os problemas do cliente”, afirma SidneiWith a specialized work carried out by the company, Mining is one of the main segments in which WEG Volpi, da área de Vendas Técnicas da WEG. Rafaelit was possible to dimension exactly what the operates, always developing expansion projects Stuchi também indica os benefícios para a equipe.customer needed at the plant. WEG developed the and major investments for the sector. “Este fornecimento demonstra todo o know-how que ainterchangeability project and dimensioning of the In this context, Alcoa is an important customer WEG possui para este tipo de aplicação na área destock of electric motors for quick replacement, whose performance is marked by a history of Mineração, na qual redução dos custos,ensuring the continued maintenance and operation partnership and purchases of WEG products. disponibilidade operacional e confiabilidade são osof the plant. “WEG has a specific dimensioning methodology focos dos projetos desenvolvidos pela área daFor an installed plant of more than 700 motors, and has a technical staff available to resolve Service”, afirma.WEG defined a supply of 146 motors to ensureoperation. The scope involved low and high voltagemotors as well as interchangeable gearboxes. Theproject was conceived using the WMining line whichis specific for the mining area.According to Rafael Fonseca Stuchi and Dany deMoraes Venero of the WEG Service Area, thisequipment was developed to ensure the availabilityof the plant through a stock of well sized motors,according to criteria based maintenance (MTBF -Mean Time Between Failures) production (criticality)and logistics. “With a stock of correctly sizedmotors, we offer the customer increased reliabilityand operational availability of immediatereplacement in the event of equipment failure in the November, 2010 17
  18. 18. Food and Beverage18
  19. 19. CargillEnergy savingsIn early 2009, Cargill installed two WEGfrequency inverters in the motors of the boilerat the unit in Ponta Grossa in the state of Energy savings results withParaná, part of the Complexo Soja (that buys, 60 hp motor:sells and processes soybeans and other Savings of 37 kWhoilseeds). According to Gilmar Weidner from Estimated savings of 144,607 kWhWEG Service, the energy efficiency jobs of electricity per yearcarried out are bringing the expected results: Return on investment: 11 months“The customer has reached his goal which is Energy savings with motor + frequencyto save energy monthly, producing with the inverter: US$ 12,840.00/yearsame quality.” Investment with motor + frequencyIn partnership with Cargill, last year WEG inverter: US$ 10,830.00carried out studies and tests to determine thebest way to save energy, streamline operations Result of application engineeringand upgrade the manufacturing facilities with 200 hp motor:through the assessment of energy Savings of 48 kWhconsumption and application engineering of Estimated savings of 509,416 kWh/yearnew products. With in loco verification, Return on investment after replacementopportunities for improvement such as the with W22 Premium 150 hp: 7 monthsrepowering of the fan motor, installation of a Energy savings with motor + frequencyvariable frequency drive on the 200 HP and 60 inverter: US$ 37,620.00/yearHP fan motors and automation of the system Investment with motor + frequencywere found. With the inverters, it was possible inverter: US$ 20,680.00to eliminate the mechanical damper and alsogain in the production process of theequipment. October, 2009 19
  20. 20. Nestlé Prompt solution and sure results As energy consumption grows in the country, that works 24 hours with a high performance the operation, the greater the difference in the increase in generation capacity requires motor is paid in two years,” he says. To kick energy saved over the months and the faster high long term investments. The result is the off the project, Nestlé had the support of CMS the investment pays for itself. Tonim says that increased cost of electricity and threats of Energy, a utility company. CMS funded the the company chose WEG as a supplier shortages which worry the government, purchase of the first 141 motors through an because it is present in all Brazil. For Nestlé, consumers and businesses. To encourage ANEEL resolution that determines that a this presence in Brazil is a very serious matter: economy with reduced production would bring percentage of the annual operating revenues “We have factories scattered all over and with more loss than gain. of a utility companies must be destined to WEG, we have an agent always nearby. The answer is to adopt solutions that save projects and actions for energy saving or Furthermore, they are also present worldwide. energy without interfering with the production. energy efficiency. WEG supplied Nestlé with When I was in Thailand, I came across some Motors, which account for almost 70% of the high performance motors and gave full support equipment imported from Europe using a WEG annual energy consumption in industries, are in the initial survey to define which motors motor.” the main focus in successful energy saving would be replaced and the specification of projects. Among several projects to reduce those which would replace them. Motors, energy consumption, Nestlé is replacing old compressors, cooling towers, boilers, pumps, electric motors with energy efficient motors. fans and exhaust fans were replaced. The replacement project was concentrated on According to a survey in European industries, September, 2003 motors which run 20-24 hours/day. The mentor the compressor consumes 25% of the total of the project was Gilberto Tonim, manager of power, followed by pumps (22%) and fans Electrical Engineering and Automation at (16%). Nestlé Brazil, who counted also on electric According to Roberto Carlos Contini, WEG projects engineer, Edson Zutin, and specialists Applications and Sales engineer who assisted in electricity in each unit. “Our goal is to save Nestlé on the occasion, the main advantage of energy, so we decided to replace obsolete the replacement is energy saving, but there motors, which use more electricity, with are other advantages. “You replace old motors energy efficient motors. Energy costs are (about 20 years) with motors with a new rising at a level above the price of the motor,” design, a service factor 15% higher than the says Tonim. “It’s not worth buying a standard rated power, improved efficiency and motor. The difference in the cost of a high- environmentally friendly because WEG performance motor is small compared to the recycles the old motors and, they still have two energy savings generated,” he explains. years warranty,” he summarizes. After the According to Tonim, the project focused on motors are replaced, the next step to save motors that run 90 to 100% of the time even more is to use frequency inverters. because they allow a faster return on The return on the replacement is proportional investment. “The replacement of an old motor to the use of the motor. The more continuous20
  21. 21. Buaiz Alimentos Suggested action x R$ Invested and Annual ReturnIdentifying needs Current Suggested R$ Invested (x thousand) PowerWith the application of the Energy Efficiency methodology R$ Annual Return (x thousand)by the WEG Service team at Buaiz Alimentos, based in CurrentVitória, in the state of Espírito Santo, the company Suggestedestimated a savings of US$ 80 thousand a year on Powerelectricity. The work consisted in the diagnostic study of193 motors of several departments in the company. With Directthis, WEG identified the need to replace 156 motors with ReplacementHigh Efficiency models and repower, to a lesser or greaterpower than the current, another 23.The results were so good that the evaluation on a test-group on 26 motors showed a savings of energy in kWh/ Totalyear 7.2% higher than the initial estimate. October, 2007 21
  22. 22. Garoto Reliability of plant During the assessment phase of the motors at The adoption of the proposed solution for the Chocolates Garoto, 182 motors were identified blenders led to a number of benefits and gains, not with potential to be replaced. After the only with the reduction of energy consumption by instantaneous measurements of current in improving motor efficiency of the standard motor continuous-duty rating, the loads of the motors for a high performance motor, but also: were evaluated and the company decided that the Reduction of routine and maintenance costs actions should occur as follows: Reduced inventory of parts 7 motors were identified for repowering with Increased reliability of plant high efficiency motors Reduction of man-hour to change and 28 motors of refineries in Lines 1 and 2 were restart motors identified for replacement with 14 high efficiency Reduction of amount of motors motors with higher power Reduction of installed demand (kW) 02 motors of cooling towers of cold water Lower cost for acquisition central were evaluated for possibility of being Availability of manpower replaced by motors of 12 poles, 8 poles and Reduction of operation cycle in 1 hour frequency inverter New motor in same frame as previous 85 motors were identified for replacement with high efficiency motors of same power 20 motors were high efficiency. Most of them were purchased with equipment and would be maintained July, 200922
  23. 23. SadiaConstant cleaningThe replacement of standard electric motors with Scope of supply:high efficiency motors of the WWash line with WWash Line High Efficiency Motor, 2 hp, 1770return on investment through gains in energy RPM, DOL starter, 380 V, Pulley/belt coupling.efficiency and reduction of maintenance andoperation costs represents one of the most more The replacement of the standard motor with therepresentative actions of Application Engineering high efficiency WWash motor provided a 42%and Energy Efficiency for application in industries. reduction in energy consumption, thereby obtaining a return on investment in 1.5 years,The methodology used by WEG follows these steps: besides the gains shown below proving the real Analysis of data and definition of potentially feasibility of the application. inefficient motors Overview of processes Increase of MTBF (from 20 days now it Diagnosis of operating conditions is already in about 01 year) Study of Application Engineering of Reduction of maintenance costs Measurements for evaluation of results and demands Replacement of motors and measurements Availability of maintenance personnel to for evaluation of results perform other activities Increase of process reliabilityThe project was applied on the cutting disc of the Increase of product qualitymeat cutting machine, replacing the standard motor Increase of availability and efficiencywith a high efficiency WWash motor. This motor is of processsuitable for applications where hygiene and cleanlinessare essential, having the most complete sealing Electric motors play a fundamental role in thesystem, perfectly meeting this application that needs continuity of processes. Therefore, an adequateconstant cleaning. The motor also has the exclusive study of application engineering and energyWEG NOBAC coating that prevents bacterial efficiency can provide a substantial reduction inproliferation ensuring the quality of the process. overall costs. November, 2010 23
  24. 24. Sadia Energy Efficiency In pursuit of actions that contribute to energy saving, Sadia, in Dois Vizinhos, in the state of Methodology Paraná, replaced the standard type motor of the To select the motors which represent potential savings in the exhaust system of the Kopper turbine at its poultry replacement, it is necessary to know the operating food manufacturing plant with a High Efficiency characteristics and technical specifications of the equipment, motor. but also implies knowledge of the process in which the The economy generated in this application alone equipment will be used. The methodology used by WEG was resulted in a reduction of 9.4% in power ordered in five steps to find solutions and opportunities for consumption, which represents US$ 2,360.00 less energy savings: in Sadia’s annual budget (return on investment in Analysis of data and definition of potentially inefficient motors 10 months). The replacements in these cases Overview of processes represent one of the most representative actions Diagnosis of operating conditions for use in the industry because the investment is Replacement of motors quickly recovered through energy efficiency gains. Measurements for evaluation of results December, 2009 Cocari Efficiency in storing grains The demand for grain in Brazil is growing more and Both Silo 01 and Silo 02 were filled with corn and the Measurements were taken with the IMS energy more each day and WEG, together with energy efficiency solution was applied only in Silo 02. analyzer to compare the energy consumption between Agroindustrial Rezende, is following this process of Both silos maintained the same level, aeration time, the two silos. evolution. The company is the first to innovate and motor power, specification of ventilators, that is, all The application of the solution gave Silo 02 a 90% develop an energy efficiency solution for aeration of the general characteristics, thus enabling a reduction in energy consumption thereby, a return on grain storage silos. comparison of real earnings between the two silos. investment in 03 months. The solution was implemented at COCARI - Aeration Control Cooperativa Agrícola do Norte do Paraná, in the EF-ENERGY state of Paraná, showing potential energy savings as well as the effects on product quality and functionality of the system. The solution consists in the application of the W22 Premium motor driven by a frequency inverter connected to the ENERGY EF-Aeration controller. The solution does not require the replacement of the thermometry system already present in the silos. CFW-11 Frequency Inverter W22 Premium Motor24 February, 2011
  25. 25. Doux FrangosulEasy cleaningThe food processing industry requires very reduced burns due to overloads. The motors arespecial care with hygiene. That’s why the WEG also easy to clean”, says Junior Biazi,WWash line of electric motors stands out in this Maintenance Coordinator at Doux Frangosul.market for it meets the requirements of the food Because the solution solved the problem ofindustry as to the need for constant cleaning. constant burning (average of four faults in motorsDoux Frangosul – part of the Franco-Brazilian per month) mainly because of the seals, 24group Doux and one of the three largest motors were purchased and installed in 2008,exporters of poultry in the country - is one of the replacing an entire line with WWash. “This supplycompanies that now relies on this solution at their is part of a Doux Frangosul project that seeks toPoultry Slaughter Unit in Passo Fundo, in the reduce maintenance costs and downtime of thestate of Rio Grande do Sul. A total of 24 WWash Stork lines, due to the low reliability ofmotors work about 21 hours a day on the conventional motors. Before, it was common toautomated cutting lines of poultry of the brand stop the module completely because one motorStork. that burned automatically canceled the process.The solution has fitted perfectly to theenvironment that, for being extremely wet, needshigh pressure cleaning water jets three times aday. The WWash has the most complete sealingsystem, the W3Seal ® and protection, IP66W inelectric motors, preventing water and dirt fromentering the motor and ensuring the durability thatthe application needs. And the coating is donewith the exclusive WEG NOBAC ® which hasantimicrobial properties. To complete the anti-corrosion package, the shaft and the bolts arestainless steel.Doux Frangosul celebrates for having chosenWWash motors. “There was an immediatereduction in maintenance costs, with increasedmotor service life and productivity in the line.Other benefits are energy savings due to the highefficiency motors operating 21h/day, the servicefactor of 1.15 and special insulation which March, 2010 25
  26. 26. Civil Construction26
  27. 27. National Theatre of HungaryModern sceneryThe National Theatre of Hungary in Budapest has The electric drive is composed of tubes mountedWEG equipment in the machinery above and with integrated guides, a positioning measurementbelow the main stage. The work is the result of system and a drive and braking unit using WEGcombining multiple technologies. On the outside, brake motors certified by VDE in Germany. Thethe Hungarian National Theatre impresses with its machine is fitted with 48 individual winches fullybold architecture and perfect integration into the equipped with WEG motors with a tractionlandscape. But it is inside that its most unique capacity of 300 kg and a driving output power offeatures can be seen. It is fully equipped with 5.5 kW, and 33 winches to move the scenery withcomputer-controlled drives that allow the many a traction capacity of 400 kg and a driving outputdifferent changes in the scenery. power of 7.5 kW. September, 2003Gotthard Base TunnelLargest railroad tunnel in the worldWEG motors power the ventilation system of theGotthard Base Tunnel, the biggest railroad tunnelin the world in Switzerland. With 57 kilometers, thetunnel is located between Erstfeld and Biasca,joining to another tunnel in Zurich which connectsto Lugano. By 2025, there will be a network of6,000 km of high speed train lines in Europe.The Alp Transit Project is responsible for bringingthe high speed train system to Switzerland. March, 2004 27
  28. 28. Middlesbrough Transporter Bridge Renewal of iconic bridge Middlesbrough’s iconic Transporter Bridge has helping to reduce the operating costs of the Commenting upon the successful completion of been given a new lease of life, following bridge. the project, Councilor Paul Thompson, replacement of its original electric motor and drive “This project was perfectly suited to Deritend’s Middlesbrough Council’s Executive Member for system, which had given nearly 100-years of multi faceted electro-mechanical approach, Streetscene Services and Transport, said: “The service, with WEG motors and inverter drives incorporating everything from design and Transporter is an iconic landmark that is recognized supplied and installed by WEG distributor, commissioning to manufacture and site around the world, and of which we are truly proud. Deritend RMB. The replacement system will installation.” said Deritend Operations Manager “It’s fantastic that, nearly 100- years after it first ensure that the renowned landmark is in tip-top Mark Westwood. carried people across the river, it is in full working condition for its centenary celebrations next year “One of the main criteria within the tender order and looks as good as the day it was opened. (2011). document was for the original drive system to “That is in no small part due to the efforts of “We are obviously delighted that WEG motors remain in place and recognize the heritage status companies like Deritend whose expertise will have been chosen for such a high profile project,” of the site and treat it accordingly. We achieved ensure it’s still up and running in another 100 years. commented Marek Lukaszczyk, European this by designing a bespoke solution which is built The only working bridge of its kind in England, the Marketing Manager for WEG. “Our motors have a around the existing equipment and the ‘old to Transporter connects Middlesbrough to Port deserved reputation for quality and reliability, new’ concept is clearly visible.” Clarence on the bank of the Tees. It was originally evidenced by their use in some of the most high The mechanical drive solution provided by built in 1910 by Sir William Arrol and Co of Glasgow profile applications worldwide, including the new Deritend has enabled the existing, listed drive to to replace an earlier steam ferry. A Transporter 818 m (2,684 ft) high Burj Tower in Dubai – the remain in its entirety with only the need to bridge was chosen because the Parliament of the tallest building in the world, and new road tunnels disconnect the coupling bolts on both motor time ruled that the new method of crossing the river in Sydney, Madrid and Hong Kong.” couplings. had to avoid affecting shipping on the waterway. The transporter bridge was shut in May 2010 to allow for the replacement of the original electric motors and drive system. The work was undertaken to enhance the bridge’s reliability and safety, while ensuring a reduction in the time it is closed for routine maintenance. As an added benefit, the new motor/drive system will enable the bridge to be operated safely in higher wind speeds than previously possible. The motors supplied and installed by Deritend are 3- off 45 kW 4- pole machines (2 operational, 1 spare) from WEG’s W22 high efficiency range. They are equipped with 1024 PPR encoders and are controlled by two WEG CFW-11 inverters. Overall, this package provides fast, precise control with high levels of energy efficiency, December, 201028
  29. 29. 29
  30. 30. HADERA Project Drinking water Ensure drinking water for human consumption in the of about 1.5 million people. WEG participated of this next 22 years. This was the objective of the Hadera challenge by providing the whole package of Project in Israel, one of the largest desalination electric motors. The package of more than 70 plants in the world and located in a strategic region induction motors with powers ranging from 160 to where water is worth gold. Between 2007 and 6000 kW, was supplied to a private high-tech Israeli 2008, the country had a period of scarce rain that company focused on desalination plants who has reinforced the need for investments in the been a WEG customer since 2005. production of drinking water. The region in Israel is The motors worked in a large combined-cycle arid and the country has developed advanced thermoelectric power station which optimizes and technologies for water reuse and permanent reuses energy in the desalination process of the irrigation through pipeline systems. In the Hadera electricity generation cycle. One of the differentials Project, 100 million m³/year of water will be of these motors is the operation with frequency withdrawn from the Mediterranean to be desalted inverters varying in rotation according to the and then destined mainly for the daily consumption requirements of the application and load. May, 2008 Delhi Metro Safety in subways WEG was involved in the Delhi Metro project in India, equipping the ventilation system of the subway stations in the city of Delhi. WEG supplied 44 motors, 29 with power of 37 kW and 15 with power of 200 kW of the Smoke Extraction line to the subway stations through Flakt-Woods UK (supplier of fans and exhaust fans). The Smoke Extraction line was developed for exhaustion of smoke in case of fire, ensuring the motor will operate for a certain period in an environment with temperatures up to 400 degrees Celsius. March, 200430
  31. 31. Sidnei Opera HouseWEG present in SydneyWEG made an important supplyamong the thousands of productsapplied in the theater: 11 electricmotors of 200 kW, 6 poles, frame355. The motors drive the exhaustsystem and air conditioning of theSydney Opera House. The theaterwas built in 1973 and is one of themain attractions of the city. Thetheater is also regarded as amasterpiece of engineering due to itsinnovative architecture with giantwhite concrete shells. 1993 31
  32. 32. Ponte of Leixões Flow of sea traffic The Port Administration of Douro and Leixões inaugurated a new movable bridge. WEG participated of the project providing equipment to the now fourth largest bascule bridge in the world. Located in northern Portugal, in Matosinhos, near Porto, the Port of Leixões is one of the most important in Portugal, accounting for 25% of exports and the movement of 15 million tons of goods per year. The new bridge was inaugurated in April 2008 as part of the Strategic Development Plan of Port of Leixões, a project that aims at improvements in port infrastructure. The new bridge replaced the old structure allowing the widening of navigable space in more than 20 meters. The innovative hydraulic system powered by WEG products facilitates the opening and closing of the bridge, which implies a significant reduction in waiting time at the margins. The bridge has a 92 meter span and enables the navigation channel to widen from 59 to 77.5 meters. This measure represents a major improvement in the flow of traffic by sea, allowing the entry of larger ships in the port. Another advantage of the new bridge is the April 2008 widening of land routes because, unlike the old structure, the movable bridge allows passage of larger vehicles. WEG participated of the project providing eight Designed by Gustavo Cudell Ltda., a company in The project was completed and delivered to the W21 electric motors, 280 and 125 hp. Besides the field of industrial automation, the new bridge Port Administration of Douro and Leixões in the equipment, the company also developed a was part of a larger project that aims to reshape 2007. The WEG equipment ensures the quality special coating for marine environments which and modernize the structure of the Port of and success of the installation in the structure of was applied to the motors. Leixões. Leixões.32
  33. 33. 33
  34. 34. WEG Motores Sugar and Ethanol34
  35. 35. YpiócaModernization of plantWEG was ahead of the automation project of one of automated, the new unit was the result of an collection and irrigation pumps, for example) to thethe most modern ethanol plants in the country. investment of around US$ 39.5 million. It is among mills and factories. The motor which drives the millFamous throughout the country and abroad for its the most modern in the world and is strategic to the is an HGF line motor, 500 hp, 690 V.traditional aguardente (alcoholic liquor distilled from company. The goal is to supply a third of the market The defiber, blades 1 and 2, are run by 1,100, 900fermented sugar cane), the Ypióca Group is of Ceará with ethanol over the next three to four and 500HP, 690 V motors. José Paulo dos Santos,investing in a new market: ethanol. years and increase the group’s revenues by about Engineering manager of Ypióca says that theThe company opened a plant in Jaguaruana, in the 20%. Today, Ceará imports 160 million liters/year of competition to choose the supplier was fierce.state of Ceará, on 23 October, 2009, with capacity ethanol, practically all that is found in fuel pumps in However, due to the 100% Brazilian technology andto produce between 40 and 60 million liters/year of the state. For this new challenge, Ypióca sought after-sales that Ypióca has known for a long time,ethanol, about 90 million liters/year of cachaça solutions from WEG, a partner for more than three the decision was to extend the partnership. “WEG(another name for aguardente), as well as the decades, with products operating from the planting has a very good customer service. There is nonepossibility of manufacturing neutral alcohol. Fully of the sugar cane (controlling panels of the water better in the country,” adds dos Santos. January, 2010 35
  36. 36. Usina Miriri Electrification of process Most sugar and ethanol mills work with steam the boiler. “Then, this steam is sent to the new Detailed scope: turbines. However, this technology does not generator, producing more energy for Miriri that Generator 7500 kVA / 13.8 kV ensure total control of what is being produced. can also sell this product,” explains Marcos Generator Output Cubicle Therefore, plants are electrifying processes, Hubner, WEG engineer and analyst for the Sugar Generator Surge and Excitation Cubicle acquiring motors with inverters to drive the mills, and Ethanol segment. Generator Neutral Conductor Cubicle increasing power generation and improving the The acquisition of the new drives with variable Control and Protection Panel of Generator operation as a whole. With the electrification speed provides more control and monitoring Motors HGF355 Line, 500 hp, 6 poles, 480 V process, the plant consumes less and sells more. which, with the High Efficiency motors, minimizes Oil Transformers 750 kVA An example is Usina Miriri, in the state of Paraíba, operating costs by reducing the levels of Oil Transformers 1,500 kVA which produces sugar and ethanol. The mill had a maintenance and consumption. According to Oil Transformers 1,000 kVA steam turbine and acquired WEG products to Melo, WEG was chosen for the supply because it MV Distribution Cubicle change this system by means of electrification. is a national company and because they were LV Distribution Panels WEG provided protection cubicles, control panels already known for the quality of their products. Motor Control Centers and automation, generator, transformers, motor “As we have been partners for a long time, we Frequency Inverters Model CFW11 control centers, frequency inverters and three- have observed WEG’s level of technology grow Frequency Inverters Model CFW09 phase high performance electric motors. The every day,” he says. Approximately 2,300 hp of WEG High equipment is used to generate, distribute and The industrial manager at Miriri also praises the Efficiency Motors control processes. “We are modernizing the plant, technical assistance and after- sales. “Whenever starting to work with a new line that had not been we need to, we can easily contact with previously explored, which is sugar, and representatives in the region and our doubts are increasing power generation. All this with WEG clarified.” To reach the optimal solution, the WEG solutions,” says Emanuel Pinheiro de Melo, team made several technical visits and many Industrial Manager of Miriri. Through the business units coordinated by the Energy electrification of the mill, the customer minimized Business Center were directly involved. The visits excessive costs with maintenance. Now, the generated technical proposals and the whole reduction in steam consumption is redirected to negotiation took about six months. August, 201036
  37. 37. Usina Costa BioenergiaOptimization of plant“WEG developed all the instrumentation and of interlocks and safety. The goal is to meet the of the 25 motors of the mills and other motorelectrical project, installed the software system and need of the plant by combining high performance pumps is made by WEG software. Interlocks andautomation management. Communication and efficiency. Through the Energy unit, WEG can advance and stopping strategies were developedsystems, motors, pressure transmitters, radars, decrease the volume of machines in stock at the to ensure the best form of control in thepower generators, everything works on the WEG plant because it designs motors mechanically preparation and extraction. The synchronism ofplatform,” says Valmir Costa, CEO of Costa interchangeable with existing motors. The these steps allows the continuous and repetitiveBioenergia. With the complete solutions, except for sugarcane follows on the rubber conveyor and extraction in the displacement and speedthe mechanical part, the plant was delivered ready reaches the twin mills, starting the grinding parameters.for operation. The electrical package, sold in process. At this point, there are vertical boxes “All this technology allows us to be more efficient,turnkey mode, allows the customer a differential called Donnelly chutes where the sugarcane forms providing a much higher return on investment,”negotiation with the company. In this supply a compressed mass to ensure a constant weight says Valmir Costa, CEO of Costa Bioenergy. “Insystem, WEG defines the criteria of the project on at the entrance of the juice separation rollers. examining the proposals, it was very easy to worka single base, optimizing the plant. On entering the The level of sugarcane inside the chute is used to with WEG’s because it was one of the mostplant, the sugarcane is raw or burnt and is placed control the speed of the rubber conveyor and, complete. Sometimes doubts arose and ouron a metal conveyor belt where it is cleaned by consequently, feed the mill. Complex adjustments contact with WEG’s engineering area was alwaysfans using WEG high-powered motors. Then, the of rotation between the drive motors are made to very direct and easy. We already knew about thesugarcane passes through the chipper which ensure perfect synchronization between them. If performance of the products and this supplyreduces the size of the sugar cane sticks. On the the rotation is low, the fibers may pile and the exceeded our expectations,” said Cícero Furtado,same conveyor, the cane goes through a shredder process is interrupted. If the rotation is high, there person in charge of Maintenance at Costathat opens the plant fibers and ensures the may be losses in the extraction of the juice from Bioenergia.process index called “open cell”. The chopped and the fiber. In Brazil, a plant usually begins with fourshredded cane is removed from the metal mills with the possibility of expanding to two more.conveyor and placed on a rubber conveyor of the This constitutes the so-called six grindingsame width, but greater speed. tandems. The juice separated in the four mills isAfter this shredding, the sugarcane passes returned to the previous mill in a process calledbeneath an electromagnetic device called imbibition.electromagnet which is used to remove metal The need for washing occurs because the fiberimpurities which may damage the mills (next step). has little sucrose (less than 3%). After separatingA WEG motor also drives the spill drum which the juice and the pulp, the liquid is sent to a tankevenly distributes the sugarcane on the conveyor. which feeds the processes of producing sugar andAt this stage of preparation, WEG developed ethanol, while the fiber goes on conveyors to thesoftware that makes the complete control of the boiler or the biomass yard to be burned,progress of the conveyors, rotation of the motors, generating the steam required for thelevels of the Donnelly chutes, downtimes, system manufacturing process of the plant. All the control July, 2010 37
  38. 38. Usina Trapiche Increase in productivity Located in Sirinhaém, in the state of Pernambuco, disbursements only when we have enough raw the Trapiche plant has its own auxiliary power materials.” generation and also constantly seeks the The industrial manager of Trapiche explains that it development and modernization of processes. For is not necessary to replace all the equipment at this reason, WEG developed a project that once since the change is significant and involves a foresees the electrification of three mills and also new concept of plant operation. “We are preparing allows the use of a single motor as a spare in two Trapiche for the future and WEG allows us to do positions in the preparation of sugarcane. “We this gradually, while having a financial return,” he chose WEG for what it represents in Brazil and concludes. worldwide, for the quality of the equipment and It is also important to point out that the differential compliance in delivery,” says Eduardo Mota of this supply was the customization of a 2000 kW Valença, Industrial Manager of Trapiche. motor for the sugarcane shredder. The space for One of the advantages of this supply is the the equipment is small and for the replacement it possibility of the customer changing the installation was necessary to develop it in the required of the motor cooling system. In one position, the measurements and with a special heat exchanger. heat exchanger is installed on top of the motor, The WEG Engineering team produced the perfect and in another, because of space limitations, it is solution for the space available. on the side. The WEG motors used at Trapiche, for processes in general, are of the W22 Plus line. The Detailed scope: replacement of the machines is part of a plan to Motors HGF355 Line, 550 hp, 6 poles, 690 V expand the plant that lasts three years. Motors W22 Line, 100 hp, 6 poles, 690 V “This first step increased the grinding of the Drive with Frequency Inverter AFW11M sugarcane without overloading the other Dry Transformers 2,000 kVA, 13,8/0,69 kV equipment. So, we got more capacity while MV Cubicles - CWMT / Class 15 kV maintaining safety,” says Valença. According to Input and Output Cubicle and Cables him, the partnership with WEG allows the Cubicles for mills 1, 2 and 5 investment to be made quickly. “Over three years Motor for Shredder MAI560 Line, 2,000 kW, we will buy the equipment to reach the goal of 6 poles, 6.600 V development we want. We make the Motors W22 Line, 50 hp, 4 poles, 380 V August, 201038
  39. 39. Companhia Energética Vale do São SimãoQuality in servicesExclusiveness in services is the most important São Simão, located in the city of Santa Vitória, in Detailed scope:reason Companhia Energética Vale do São Simão the state of Minas Gerais. Drive Panelschose WEG as its main supplier of electrical The 1 to 350 hp motors are High Efficiency motors Frequency Inverter MVW-01equipment. “We trust the company for the and present extremely advantageous operating Distribution Cubiclesexcellence in their equipment and services,” says costs. The high efficiency ensures a rapid return on Generator switchboardsAlexandre Bicalho de Andrade, Director of the investment because the motors provide increased High Efficiency Motors of 1 to 350 hpAndrade Group, responsible for Cia Energética power savings. Transformers (dry and oil) of 112.5 to 2,500 kVAVale do São Simão. With an installed capacity of 2,500,000 tons of Turbogenerators: 31,25 and 37.50 MVADrive panels, distribution cubicles, generator sugarcane, the daily production of Companhia Motors HGF 400, 550 kW, 6 poles, 690 Vswitchboards, 1 to 350 hp motors, transformers Energética Vale do São Simão reaches 22,000 Motors HGF 315 C, 230 kW, 6 poles, 690 V(dry and oil) from 112.5 to 2,500 kVA and bags of sugar, 600,000 liters of hydrated ethanol Motors MGI 710, 4000 kW, 6 poles, 13800 Vturbogenerators of 31.25 and 37.50 MVA, were the and generation of 55 MW / h with exportation of 25 Transformer 5,000 kVA (dry)products installed by WEG to modernize Vale do MW / h energy. August, 2010 39
  40. 40. Usina Santo Antônio Pioneering project in northeast The Santo Antônio plant, in the state of Alagoas, for the production process. The revolution came in thousand) and they exported about 6.5 million kW. was the first in the northeast to operate a 2001. In the first harvest which the plant operated So, they ended up generating enough resources completely electrified plant. The investment with new generators, it was not necessary to to, in just one harvest, pay all the investment made allowed it to diversify a new business: the acquire energy (a monthly savings of US$ 62.5 at the time. generation and supply of electricity. WEG has been supporting the evolution of Santo Antônio since 2001, when the plant began the search for energy efficiency. By the end of 2007, the plant had installed three generators (two of 6.25 and another of 18.75 MVA), automated the process and started the electrification of the mill (two 1,600 hp motors, inverters, transformers, another 900 hp motor with inverter and a transformer). At harvest time in 2007, the seven motors with inverters went into operation to drive the boiler exhaust fans with more energy savings, which paid dividends as they also began operating a substation to export electricity with a 25 MVA transformer. WEG provided the necessary solution for this transformation of economy into profits. Today, the steam that once drove the mill is transformed into electric energy which, in addition to moving the plant, has its surplus sold, thus becoming the third product of the company, along with ethanol and sugar. The smart operation of WEG motors with speed variation provided by inverters, reduces power consumption so that there is more energy for sale. For WEG, this supply has become a reference of great importance due to the innovative and pioneering character in the northeast region of the country. Until then, the Santo Antônio plant was very inefficient in terms of energy. They even had to purchase approximately 1,000,000 kWh monthly September, 200740
  41. 41. Grupo Santa TerezinhaWEG Technology in production of sugar and ethanolGrupo Santa Terezinha is among the major sugar andethanol producers in the country. Established in the Scope of supply:early 60s and with eight units in the northwest of the 2 driving machines with frequency inverterstate of Paraná, it sought in WEG the solution for a assembled on panel model AFW09 0600T/major change in its manufacturing process. In this 440 V - Regenerativeincreasingly demanding market, the Group invested in 3 three-phase electric motors, model HGFthe electrification of the exhaust fans of boilers 1 and 2 500 hp, 4 Poles, 440 Vof the plant in Cidade Gaúcha, in the state of Paraná. 1 three-phase dry transformer, 1500 kVA –The turbines of the boilers were replaced with electric 13.8 kV / 0.44 kVmotors driven by frequency inverters where the speed Start-up of equipmentvariation and control of the process enables energyefficiency and reliability, in addition to reduction ofdowntime and corrective maintenance. In the oldmodel, the turbines were powered by the steamgenerated in the process of burning bagasse, with lowefficiency and high maintenance, not reaching thestandards required by today’s sugar and ethanolmarket.For some time now, WEG has presented electrificationprojects and mechanization systems using steamturbines. As Cidade Gaúcha already operated with twosimilar electrified exhaust fans, now it has four of themwith the same characteristics. The plant also acquireda reserve motor that was built to be fullyinterchangeable with the four systems, giving morereliability to the operation.The supply to the Santa Terezinha plant wascoordinated by the WEG Business Center team, whereonly one person is responsible for the manufacturingprocess of all components in the company. This way,the customer profits in terms of safety and moreflexibility especially in the flow of commercialinformation and technical definitions. September, 2011 41
  42. 42. WEG Motores Sanitation42
  43. 43. Tupras Lost City - The Valley of AquasystemsSanitation the Waves Water Park Water purification stationWEG products for the water and sanitation segment Largest theme park in South Africa Weg motors equipped the water purification stationcontinue to open borders and conquer markets. WEG has in Belgium through the company Aquasystems.provided two irrigation projects for the Turkish company The wave driving system of the park, works as WEG provided 36 motors, 110 kW, 6 poles,Tupras through WEG branches in Spain and Japan. follows: the water is dammed up to a certain level manufactured at the plant in Portugal. The motorsIzmit Project: and then about 40 WEG motors with power ratings are used in surface aerators in the water 166 Ex-d and Ex-n motors, 2 and 4 poles, 110 kW from 0.75 kW to 30 kW begin to operate the purification system. These are unique productsKirikkale Project: hydraulic pumps that are responsible for opening because Aquasystem provides its aerators to 6 HGF315C, HGF355 and HGF500 motors – 1,200 kW the flood gate. The water falls by gravity and different parts of the world, requiring flexibility in 29 Ex-n motors, low voltage, powers between 3 and 90 kW produces waves. different voltages and frequencies.2005 1993 2005 43
  44. 44. Pulp and Paper44
  45. 45. FibriaReliability from beginningFibria, company that resulted of the merger ensure that procedures are adequate. “We makebetween Nova Aracruz and VCP (Votorantim several inspections while the motors are not inCelulose e Papel), is currently the largest operation and we also follow the testing phase tocompany of the segment with a production see if they work properly,” said Avila. “With this,capacity of 5.25 million tons of pulp and 179,000 WEG ensures reliability since the beginning of thetons of paper per year. operation,” he adds.The company has three plants in Brazil. The unit WEG supplied Fibria in the state of Espírito Santoin Três Lagoas, in the state of Mato Grosso do with a motor developed specifically to meet theSul, is the largest cellulose mill in the country with entire chemical load involved in the process. “Thea single production line which began operations motors used previously did not last 5.000 hoursin the first half of 2009, and was equipped with without maintenance. The new motor was madethe most advanced technology within the highest to operate 17,000 hours without stopping,”standards of environmental management. explains Avila.Practically 100% of the motors of the industrial Among its features, the equipment has a specialplant are WEG, totaling about 1,250 units, coating, a stainless steel shaft and does notincluding High Efficiency motors, medium voltage require lubrication. The delivery also included theand large motors, and 47 transformers (up to installation verification service to ensure proper80/105 MVA). One of the differentials in this operation. “A scratch in the coating exposing thesupply by WEG for this project was the metal is already the doorway corrosion,” sayscommissioning and monitoring of the start-up. As Avila.explained by Leandro Avila, Service Supervisor ofthe WEG Motors unit, the work is to be “the eyesof the customer” in the process of receiving andinstallation of the equipment at the site. This isbecause WEG motors and transformers aredelivered before the factory is completed.And in the period between delivery and theeffective operation, which takes several months,even years, the products are at risk of beingexposed to rain, mud and other conditions, whichcould jeopardize future performance. Therefore, September, 2008WEG has at least one person in charge at thesite, through its technical assistance in the region.These professionals check the conditions ofinstallation and storage of the equipment to 45
  46. 46. Klabin Dedicated Project In September 2008, the market warmed up with 76 medium and large motors. The partnership the launch of Klabin’s MA-1100 Expansion Project. between Klabin and WEG was established from The project, carried out at the Monte Alegre unit in the outset. the state of Paraná, represented an investment of The motors supplied were manufactured specifically US$ 1.08 billion and increased the production to meet the needs of the customer. As a traditional capacity of the unit of 700 thousand tons of paper partner of Klabin, WEG participated in the MA-1100 per year to 1.1 million tons. The main point of the Project with a significant contribution by supplying expansion was the new paper machine, the MP 9, electric motors for all plants that were part of the considered the most modern in the world for the expansion. This included the supply of motors with production of cardboard. WEG supplied the different technology than that used so far at the project with 593 High Efficiency motors and over Klabin Papéis Monte Alegre industrial unit. September, 2008 Kronospan in Switzerland Expansion plan HS AntriebsSysteme AGO, WEG representative in Switzerland, supplied a package with 30 energy efficient motors with frames 160 to 355 to plan the expansion of Kronospan in Switzerland, one of the largest manufacturers of wood-based products in the world. The motors are used in pumps, fans and worm conveyors and the energy efficient motors ensure a rapid return on investment. 200346
  47. 47. CocelpaFeasibility study ensures energy efficiency July, 2009A feasibility study was carried out on 28 motors Benefits generated by study ofof pumps, fans and filters, with powers 30 to 350 application engineering:hp running almost 24 hours a day. The result Optimization of cost X benefits of motorsshowed that the payback time would be 1 year Improvement of availability and efficiency ofand 9 months for all motors. It was then decided plant by identifying and acting on obsoletethat a group of seven motors would be replaced motors and those of difficult maintenancein the first stage of implementation, at a total Assurance of efficiency in appropriate use1600 hp. All motors maintained the same power. of energyOnly one was replaced with another of lower Identification and adaptation of motors with highpower. maintenance costs due to frequent failuresAmong the motors that were replaced with high because of incorrect specificationefficiency motors, was the pump of the recovery Reduction of maintenance demandsboiler, keeping the power of 250 hp. Dissemination of concept/importance of correctThe other motor that was replaced was the one specification of equipmentthat drives the exhaust fan of the limekiln, with350 hp.The changes suggested included thereplacement of standard electric inductionmotors with high efficiency induction motors. 47
  48. 48. Trombini Extra innovation From a suggestion made by WEG, Trombini former Trombini business partners and deposited in lower power consumption. Embalagens S.A. is investing in a new motor full confidence in their skills. The integration Another advantage of the WMagnet line is that it technology that promises to become a between the supplier of the machine and the works with constant torque without forced benchmark in the pulp and paper market, due to supplier of the drives and automation was very ventilation, thus eliminating one more maintenance the excellent results it brings. The paper plant effective from the design phase, ensuring the full item, releasing an MCC (Motor Control Center) acquired the complete electrical and automation accomplishment of the objectives,” explains drawer and saving energy that would be package for the new paper machine unit of Fernando Volpato, Fraiburgo unit manager at consumed by the ventilation motor. The reduction Fraiburgo, in the state of Santa Catarina, the MP4, Trombini. in energy consumption can reach 150,000 kW per from WEG. And it bet on the idea of replacing According to Hergen general manager, William year on a machine like Trombini’s MP4. traditional induction motors used in such Rodrigues dos Santos, this was the largest There are other advantages related to the CFW11 equipment with modern WMagnet motors which machine ever produced by the company and will frequency inverter that drives the WMagnet, are motors with permanent magnet rotors. be a benchmark in the papermaking market. The especially in applications that require synchronism The MP4 already has a differential because of its general evaluation of this project was the best and speed. As additional benefits, the WMagnet speed of operation: 1,000 meters per minute, a possible because all the quality and productivity generates less noise and has more mechanical feature found in few machines currently operating goals were achieved demonstrating WEG’s power in a smaller frame, which means it takes in the country, and the rewinding machine of technical competence in integrated solutions at up less space (an expensive item in the market 2,500 meters per minute with a regenerative this level of speed (1,000 meters per minute). Dos today). braking system. Santos believes that there are very likely to be “Because it is a high energy efficiency product Using this type of motor is new not only to new projects in the future where it will be possible and considering that it is not necessary to use Trombini, but to the Brazilian market. “Most to offer the customer a proposal in partnership forced ventilation, the return on investment is packaging paper machines work with induction with WEG, using motors with permanent magnet excellent. If we consider the whole drive package, motors. The use of the WMagnet in this rotors. And why invest in what’s new, when most the return takes place in less than two years,” application will be a benchmark for the market,” follow the traditional model? Although the estimates Volpi. The machine has been in explains Sydney Volpi, sales analyst for the WEG permanent magnet motors have a higher cost if operation since February 2011 and the result, Pulp & Paper segment. And all this readiness for compared to induction motors, the benefits of this according to the customer’s assessment, could the new has a catarinense (natural of the state of technology justifies this difference. The first not be better. “We are very satisfied with the Santa Catarina) DNA from beginning to end, since benefit is the absence of Joule losses (IR ²) in the supply, including engineering, equipment, the machine was designed and built by Hergen, rotor, since there is no current therein. Thus, the software, after sales, etc. manufacturer of equipment for the paper industry motor runs at a lower temperature, allowing a In fact, the performance of WEG systems totally of Rio do Sul in Santa Catarina. “Both vendors are considerable improvement in efficiency, resulting exceeded our expectations,” praises Volpato.48
  49. 49. October, 2011Scope of supply: DC Motors W22 Plus Line DC Motors WMagnet Line Drive Panels with Frequency Inverters CFW11Line Soft-starters SSW-06 Panels with PLCs and remote units Command and supervision systems (command and engineering stations) Cubicles type MTW03 Dry Transformers Software engineering services/ supervision Start-up services Training services 49
  50. 50. Veracel Largest wood chipper in the world With 220 companies operating in the country and data is automatically transmitted to WEG, which go to the paper machine at the industry where it 2 million hectares of planted area for industrial allows more flexibility in solving any problems. was extracted or at another. purposes, Brazil currently produces 12.7 million With the commissioning of the new line, Pine, with long fibers, is used for making more tons of pulp per year and is the fourth largest practically all motors used in the Veracel resistant paper, like the one for packaging. The producer of the product, behind only the United production process are WEG, one of the deciding eucalyptus, with short fibers, is used to make States, China and Canada. And it wants to factors in choosing the equipment supplier. The disposable paper or writing paper. continue growing. Data from Bracelpa, the installation of the new line of chippers eliminated Brazilian Association of Pulp and Paper show that a bottleneck in the production of chips for the over the past 10 years investments in the sector pulp and provided environmental and economic totaled US$12 billion, with a trend to rise. gains for the company, with the generation of To achieve these results, the sector bets on surplus energy. It also permitted operational technology and innovation. An example is Veracel availability of the other two lines, which is Celulose, an integrated agro-industrial project, important for maintenance. which covers all stages of pulp production - from The chipper is at the beginning of the pulp planting to the delivery of the final product. production process. That’s where the trunks of In June 2009, the company, based in Eunápolis, eucalyptus and pine, already peeled, will be in the state of Bahia, put the wood chipper from transformed into chips of various sizes. That is, line 3, the largest in operation worldwide, into the entire log enters and exits the machine and operation, with a capacity of 400 cubic meters of comes out chipped. At this stage powerful motors wood per hour. are required to do the trick. In Veracel’s chipper, Supplied by Andritz, a world leader in systems each of the four WEG motors has the power of and services for pulp and paper industries, 400 kW, about 2,200 hp in total. A small car, for among others, the HHQ-Chipper™ has four WEG example, has a motor of about 70 hp. high-voltage motors (400 kW, four poles), working The chips are taken to the digester, where they in heavy duty to ensure the supply of wood chips are cooked at high temperature and pressure with to produce pulp and to generate biomass, which chemicals. From this results the cellulose pulp is used as an energy source. To increase which will follow to the washers and will be reliability, WEG created a commissioning and separated from the black liquor. In this step, the start-up system via smart phone. With this, pulp, which is brown, can go through bleaching, besides the professional in field having immediate depending on what it will be used for. Then, it is access to all the information he needs, the field dried and broken up into bales. And, it is ready to January 201050

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