usa.siemens.

com/ids

Integrated Drive Systems (IDS)

Optimized for Minimum Vibration
Siemens IDS ensure motor/drive compatibility for all types
of service and environmental conditions

Electric motors with variable frequency drives (VFDs) that

are driving pumps and compressors, with or without
gearboxes, are applied in various industrial applications
for the production of oil, natural gas, cement and other
products. These electric motors, driving pumps and
compressors, often require a wide range of operating
speeds in order to meet the process requirements and to
increase the overall process efficiency by reducing electrical
energy consumption. For higher reliability and longer life of
rotating mechanical equipment, the vibration of individual
components, and of the entire drive train, should be as low
as possible throughout all operating speeds. One common
method of designing low vibration equipment is to have a

separation margin between the critical natural frequencies

and operating speed range, as required by API 541.
Many times, the components of the rotating equipment
(i.e. motors, drives, or gearboxes) and driven equipment
(i.e. pumps, compressors and fans) are manufactured by
different OEMs. Each manufacturer typically applies
their own unique design specifications. Individually,
each component is designed to its own specifications
and meets the low vibration rotor dynamics design criteria
and requirements. However, it commonly happens that a
system with properly designed individual components may
still have high vibration, due to the interactions of these
components.

Answers for industry.

How will the size, location and weight of a coupling effect

motor vibrations and reliability? How will utilizing a
Siemens IDS improve reliability?
The coupling between the various rotating equipment is an
important mechanical component, which can help to reduce
the interaction and vibration in the drive system, if designed
correctly. This is dependent on the proper choice of coupling
type, with optimized dimensions, to separate the interactions
of components. Done properly, this reduces the vibration of
drive train systems.
It is important to note that coupling mass, inertia, and location
of the center of gravity has an influence on the vibration and
rotordynamic behavior of the shaft. Heavier couplings reduce
the critical speed of the rotor design, and must be included in
the rotor dynamics design. If special couplings, such as fluid
couplings and oversized couplings, are being used, then it is
important to include and integrate the coupling design into
the product design in order to avoid vibration problems.

Qualification
If nothing is specified by the customer related to external
loading or misalignment capabilities, the vibration and rotor
dynamics design of drive train will be based on Usual Service
Conditions, as defined in NEMA MG1.
Case Scenario 2: What is the Cause of Vibration?
Description
A customer ordered an 18,000 HP, 2 pole, 710 frame, API
motor with Perfect Harmony VFD for their high speed
compressor application. The motor met APIs vibration criteria
in the test field (both coupled and uncoupled). The motor
also has low vibration at the customers site. However, the
customers overall system has high vibration during the startup
of the process. This results in shutdown of the compressor
system. What is happening?
While there could be many reasons for high vibration of the
system, one of the possible causes is explained here.

Case Scenario 1: Can a Coupling Cause Vibration?

Situation
A motor ran within specifications by itself, but now has high
vibration with a customer-supplied coupling half, mounted on
the rotor shaft.
Description
A customer ordered a 5,000 HP, 4 pole, 630 frame API motor
with a PERFECT HARMONY VFD for their compressor application.
Siemens was not provided the coupling mass and inertia. The
OEM or system integrator needed an oversized coupling to tune
the torsional resonances. The motors rotor is designed per API
541, which requires a 15% separation margin between the
critical speed and maximum continuous speed of operation.
The mass of the coupling would decrease the rotors critical
speed if it is heavier than the coupling used in the design of
the rotor.
Many times the end user or system integrator doesnt
understand how critical this is to system reliability, and
therefore doesnt coordinate between component
manufacturers.
Integrated Drive System Solution
In an Integrated Drives System, Siemens will provide the motor
and coupling. The coupling mass and inertia, which is a critical
piece of this system, will be known by Siemens. This will allow
them to optimize the application and include the coupling in
the design of the drive system from the start. If the customer
wants to use special couplings, such as fluid or oversized
couplings, Siemens will integrate this special requirement into
the design and optimize the rotor dynamics of the motor for
high reliability, while also meeting the API separation margin
criteria. With IDS solutions, customers will have peace of mind
that motor-couplings are designed and integrated correctly to
meet their shaft vibration criteria. If coupling design is not
integrated in the overall system design, then it may cause
installation and commissioning delays resulting in lost
production and revenue.

The Danger of Critical Speeds and Vibration

Usually larger two pole motors and compressor systems run
overcritical, which is defined as an operating speed above
the first bending mode. In order to have a good overall
rotordynamic design of the complete system (i.e. the
compressor, motor, and VFD) the customer or system integrator
should avoid allowing the motor and compressor rotor critical
speeds to be similar. If the critical speeds are close to each
other, then one component could interact with the other.
This results in system resonance and may cause high vibration.
Siemens experience has shown that these system level
vibrations are very sensitive to operating and installation
conditions. Such vibrations fall into the category called
parametric vibration instabilities. This implies that small
changes in the system, such as ambient temperatures, gas
densities, or small misalignment, could excite these kinds of
vibrations.
Integrated Drive System Solution
In an IDS solution, Siemens can work with the Compressor
OEM, or through the system integrator, to ask the right
questions and acquire enough knowledge to design the motor
so its critical speed does not coincide with the compressors
critical speed. With this information known, Siemens can
optimize the rotordynamic design of the motor to avoid
vibration issues which may cause substantial start up delays
leading to lost production and revenue.
Qualification
Siemens must be made aware of any Unusual Service
Conditions or special design considerations at the time of
proposal in order to include any price and delivery impacts.
Otherwise, Siemens responsibility will be limited to product
compatibility, under Usual Service Conditions, excluding the
interaction with the driven equipment. System responsibility for
any Unusual Service Conditions must be specifically accepted by
Siemens in their proposal.

Case Scenario 3:
Should an Application Use a 2-Pole or 4-Pole Motor?
A customer wants to install a high speed drive system to drive
the process compressor in a refinery. The compressor requires
6,000 HP at a top speed of 6,800 RPM. During off-peak loads,
the customer also wants to operate the compressor at lower
speeds to save energy. Hence, the operating speed range of this
application is from 500 6,800 RPM. Reliability and availability
of the drive train are the key requirements for the solution.
IDS Solution Options
There could be several viable solutions for these kinds of
scenarios. The sections below present three potential options.
Option 1 Direct drive, high speed motor, driven by a VFD
Direct coupled high speed motors, driven by variable frequency
drives (VFDs) eliminate the need to have a gearbox in the drive
system. Direct drive systems are usually the most compact
solution, in terms of space requirements, and offer high
availability due to reduced maintenance. High speed motors
at this horsepower and speed range require special design
considerations and engineering efforts, which may result in
a higher initial cost of equipment. Aside from high first costs,
a high speed motor with oil film bearings has a flexible rotor
design. This results in having a critical speed of the motor rotor
within the speed range of the operation. For safe and reliable
operation of the drive system, a 15 percent separation margin
is required between the critical speed and operating speed.
Due to this reason, the customer is losing significant energy
savings in his process. Direct drive high speed motor systems
could be designed with active magnetic bearings, which could
allow the motor rotor to run at its critical speed. This is because
vibration can be virtually eliminated by active damping in the
bearings. High speed motors with Active Magnetic Bearings
(AMBs) could further increase the systems initial cost.
Therefore, if an adequate solution is available with other
standard technologies, then a solution with AMBs is much
more expensive and higher lead time.

Option 2 Standard 2-pole induction motor, driven by a

VFD and a speed increasing gearbox
A standard two pole induction motor with oil film bearings,
along with a speed increasing gearbox, could be a solution if
space is available for the gearbox. A 6,000 HP motor at 3,600
RPM will have a flexible rotor design, due to the bearing span
in the motor design. Flexible rotor design results in having a
bending critical speed of the motors rotor within the operating
speed range. For the safe and reliable operation of the drive
train, a 15 percent separation margin is required between the
critical speed and operating speed. Due to this reason, the
customer is losing significant energy savings in their process.
Option 3 Standard 4-pole induction motor, driven by a
VFD and a speed increasing gearbox
A standard 4-pole induction motor with oil film bearings, along
with a speed increasing gearbox, could be a solution if space is
available for the gearbox. A 6,000 HP motor at 1,800 RPM will
have a rigid rotor design. This rigid rotor results in having a
bending critical speed of the motors rotor above the operating
speed range of the application. Hence, no separation margin is
required. The customer could operate the system at all speeds
from 500 6,400 RPM.
Option 3 Tandem standard 2-pole induction motors,
driven by a VFD and a speed increasing gearbox
Two standard 2-pole 3000 HP induction motor in tandem
arrangement with oil film bearings, along with a speed
increasing gearbox, could be a solution if space is available for
the gearbox and motors . A 3,000 HP motor at 3600 RPM will
have a rigid rotor design. This rigid rotor results in having a
bending critical speed of the motors rotor above the operating
speed range of the application. Hence, no separation margin is
required. The customer could operate the system at all speeds
from 500 6,400 RPM. Since the at two pole speeds gear ration
is smaller than 4 pole speeds results in a cheaper gear box.
IDS Option 3 results in the most cost-effective system with best
total cost of ownership, which is also a reliable solution for this
application.

Lifecycle integration
Integrated software and services
throughout the entire lifecycle.
For better performance
and maximum investment
protection.

Horizontal integration
Integrated drive portfolio:
all variable speed drives, motors,
couplings, and gear units
available from a single source.

Perfectly integrated for all

power and performance classes.
Customized solutions to meet
your exact specifications.

Comprehensive software tools and expert

services for the entire lifecycle, from planning,
engineering, and execution
all the way to
services.
5 Services
4 Production execution
5 Production engineering
2 Production planning
1 Product design

With Integrated Drive

Systems you can reduce
your maintenance
costs by up to

15%

Boost the
availability of
your application
or plant up to

99%

Vertical integration
Integrated into automation: from
the equipment level via controller
level up to MES thanks to Totally
Integrated Automation (TIA).
Whatever the application.

With TIA Portal

you can cut your
engineering time
by up to

30%

*e.g., conveyor application

Siemens Industry, Inc.

3333 Old Milton Parkway
Alpharetta, GA 30005
1-800-241-4453
info.us@siemens.com

usa.siemens.com/ids

Subject to change without prior notice

Order No.: DTAN-00024-0315
Printed in USA
2015 Siemens Industry, Inc.

The information provided in this flyer contains merely

general descriptions or characteristics of performance
which in case of actual use do not always apply as described
or which may change as a result of further development
of the products. An obligation to provide the respective
characteristics shall only exist if expressly agreed in the
terms of contract.
All product designations may be trademarks or product
names of Siemens AG or supplier companies whose use by
third parties for their own purposes could violate the rights
of the owners.