Modernization of forming fan drive systems for a mineral wool and insulation materials manufacturer
We support companies in the construction and manufacturing sectors by modernizing drive systems, improving process efficiency, and reducing the risk of unplanned downtime. One example of such a project was the modernization of forming fan drive systems for a manufacturer of insulation materials and mineral wool products.
As part of the project, we implemented modern Siemens G120X variable frequency drives rated at 500 kW, carried out the fabrication and installation of power and control panels, and completed the parameterization and commissioning of the drive system.
Goals
- Minimizing the risk of production downtime
- Improved control of the forming process
- Enhanced operational efficiency
- Improved motor control performance for forming fans
Challenges
- Modernization of the forming fan drive system
- Removal of existing drives and installation of new drive units
- Integration of the drives with the supervisory control system
- Ensuring reliable operation of the installation under high-power drive loads
Solutions
- Siemens G120X variable frequency drives rated at 500 kW
- Fabrication and installation of power and control panels
- Electrical and I&C (Instrumentation & Control) engineering design
- Drive parameterization and commissioning
- Communication with the control system via the Profibus network
- Integration with a Siemens S7 PLC
Benefits
- Improved drive system efficiency
- Simplified operation of the forming fans
- Enhanced motor control performance through Siemens G120X drives
- Reduced risk of production downtime
- Improved reliability and operational safety of the installation
Scope of modernization
As part of the project, we modernized the forming fan drive systems. The scope of work included the removal of the existing equipment and the installation of new drive assemblies. We supplied four drive packages equipped with Siemens G120X variable frequency drives rated at 500 kW with a supply voltage of 3 × 400 VAC.
Each of the four drive packages consisted of three separate cabinets:
- Power supply cabinet
- Drive cabinet
- Control cabinet
In total, we supplied, installed, wired, and commissioned 12 power and control cabinets.
 Drive cabinets No. 110 and 120 before modernization |
 2 × 500 kW drive cabinets No. 110 and 120 after modernization |
Drive parameterization and commissioning
Drive parameterization and commissioning
As part of the project, we carried out the parameterization of the variable frequency drives using the manufacturer’s software, Wi-Fi connectivity, and a web-based configuration interface. The drives were configured to communicate with the supervisory control system via the Profibus network and a Siemens S7 PLC.
During commissioning, we verified motor rotation direction and performed the AMA (Automatic Motor Adaptation) procedure. We also enabled the flying start function, which allows the drive to seamlessly regain control of a rotating motor after a temporary power interruption.
The implemented drives were additionally equipped with a Safety function and safety relay. This solution enables fast and reliable motor shutdown in the event of a fault, significantly enhancing the operational safety of the drive system.
Summary
The modernization of the forming fan drive systems improved overall efficiency, enhanced motor control quality, and reduced the risk of production downtime. By implementing Siemens G120X variable frequency drives rated at 500 kW, we delivered a modern, efficient, and safe drive system tailored to the requirements of mineral wool and insulation material production processes.
