Energy efficiency thanks to data transparency

The electrical engineering company Klebs+Hartmann is at the forefront of technical trends. To tap energy efficiency potentials, existing switchboards and power monitoring systems are expanded by communication-capable components that seamlessly fit into digitalization.

The commercial use of electricity was still in its infancy when in 1904, a "special business for the implementation of electrical light and power systems" started up operations in Ludwigshafen, Germany. The company still exists – and it has remained true to its roots: Today, Klebs+Hartmann GmbH & Co. KG, a large, yet still a family-operated trade business, with some 100 highly-competent employees, covers a wide spectrum of electrical engineering: the portfolio of deliverables ranges from low to medium voltage switchgear, through installation and repair of electrical machines, right down to servo and frequency converter technology, process automation and backup network systems. A special emphasis is placed on planning, configuration and manufacturing of low-voltage main distribution boards according to the requirements of IEC 61439 up to 4000 amps (A) current intensity.

 

As a long-standing technology partner of Siemens, the electrical engineering specialist also relies on the manufacturer's switchboard and power monitoring solutions in its own operations. Regular updates ensure that the systems are always up to date – and ever new areas of potential can be opened up, especially in terms of energy efficiency and digitalization. For this purpose, the systems have now been enhanced with communication-capable components.

Pioneer for innovations

The electrical engineering professionals from Klebs+Hartmann are always at the forefront of technical trends – and that is why they rely on the latest technical solutions also in their own operations. Thus they can gather practical experience with new systems and also benefit from them in very tangible ways. And not least, the systems serve as demonstration objects for interested customers. At Klebs+Hartmann, as well as on the customer side, the major focus is on sustainability and energy efficiency. A current example is the company's own electrical car, which is also used as an energy store for the photovoltaic system.

 

Klebs+Hartmann has a long-standing competence partnership with Siemens. Thus, among other things, the company is a certified "SIVACON Technology Partner" for Sivacon S8 low-voltage switchboards and cooperation partner for the power monitoring system with the powermanager power monitoring software from the Sentron portfolio. And in this manner, relevant systems and solutions have been successfully deployed and undergone continuous further development for several years at Klebs+Hartmann.

Power monitoring with profits

The company already implemented power monitoring according to ISO 50001 in 2012. For this purpose, the existing Sivacon S8 main power distribution was supplemented by relevant measuring devices as part of an enhancement designed to make electrical and other energy flows transparent. 

 

The data are recorded by the measuring devices either directly via the current and voltage input or indirectly via additional sensors such as flow meters with pulse output (e.g. compressed air) and fed into the computer network through digital inputs (S0 impulses) from the measuring device via Modbus TCP. The first step was to deploy a total of 18 7KM PAC series measuring devices from the Sentron portfolio from Siemens: 17 measuring devices as well as one especially high-performance that supplies additional data and logically links values. Further data are delivered by a 3WL air circuit breaker in a withdrawable unit design, which is integrated into the power monitoring solution by means of a COM16 interface.

Based on the data that the powermanager power monitoring software delivered, we at Klebs + Hartmann were able to save 10 to 15 percent of our energy costs in terms of electrical power.
Friedrich Schöffel, Head of Electrical Engineering at Klebs+Hartmann

At Klebs+Hartmann, the results of power monitoring were compelling right from the start, and were reflected above all in enormous savings in electrical power, as well as in compressed air. Another advantage resulted for the use of IEC motors of various efficiency classes. The possible savings can be checked and illustrated using the powermanager power monitoring software for an immediate comparison during a customer consultation. Thus, Klebs+Hartmann, as a Siemens motor partner, can deliver strong arguments in recommending the 1LE1 motor type in the highest efficiency class IE4.

Exploiting digitalization opportunities

Newly developed components now offer additional options, especially in terms of digitalization and networked environments. Firstly, this pertains to the latest 3VA molded case circuit breaker generation.

The communication- capable models from the 3VA2 series come with an integrated metering function for the detection of current, voltage, and power values. Dr. Rudolf Maleri, Managing Director of Klebs+Hartmann, points out further advantages: “Digital solutions provide substantial gains in efficiency for switchgear engineers, too. Through software-assisted planning and configuration, for example, the entire value-added process in control cabinet and plant engineering can be streamlined”. 

 

Commissioning and maintenance of the molded case circuit breakers are possible via the powerconfig commissioning software. The software facilitates parameterization of all communication-capable measuring devices and circuit breakers from the Sentron product family by control cabinet builders, installers and automation technicians. Especially for multiple devices, this adds up to substantial time savings. To check the functionality of the molded case circuit breakers, the software is made complete by a test device.

With an increasing automation level where everything is interlinked, system and component availability have become more important than ever.
Dr. Rudolf Maleri, Managing Director of Klebs+Hartmann

Options for improved power quality

Today, increasing automation on the one hand and ever more flexible power generation on the other hand result in much more complex requirements in terms of power quality: The feed-in occurs through diverse power producers, which can lead to higher voltage and frequency fluctuations. At the same time, modern automation systems depend on constant power quality. Thus, improved power quality boosts and guarantees system availability, as malfunctions and damage can be prevented in production or in terminal equipment. The technical answer to this is found in the new 7KM PAC5200 measuring device: it can record and analyze mains variations or interruptions with an integrated Power Quality Recorder.

2018-03-02

Picture credits: Siemens AG

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