Technical guide
System solution
4-draught steam boiler and CHP with MEC system
6 720 885 509 (2018/03) GB
Page 1: ...Technical guide System solution 4 draught steam boiler and CHP with MEC system 6 720 885 509 2018 03 GB ...
Page 2: ...em extension with peak load boiler 15 3 Engineering information and sizing 16 3 1 Basic principles 16 3 1 1 Economic viability 16 3 1 2 Economic general conditions 16 3 1 3 Technical system data 17 3 2 Pre dimensioning 18 3 2 1 Estimate design of key components 18 3 2 2 Investment costs 18 3 2 3 Evaluation of economic viability 19 3 2 4 Integration of 4 draught steam boiler 20 3 3 Sizing of key co...
Page 3: ...ncerning planning calculation economic viability and quotation 1 2 System solution For commercial and industrial applications the use of a CHP system in conjunction with a steam boiler with integrated waste heat use can be an efficient alternative Here the CHP unit design as CHP module for external flue gas use creates electrical current A downstream boiler system uses the hot flue gases of the CH...
Page 4: ...tion concerning supply reliability efficiency and current cost reduction at simultaneously reduced complexity Benefits for planners engineers Safe planning Boiler and CHP module all from one source Functional system hydraulics and standardised schematic diagrams Complete list of components defined limits of delivery Integration of higher level control Bosch MEC system System safety Tuned and certi...
Page 5: ...m production In addition during operation of the CHP module engine coolant with a temperature of up to 85 C is created Depending on the loss of condensate in the steam network this can be used for make up water preheating in the steam boiler or for space heating or DHW heating The system control MEC system controls the combination of CHP module and 4 draught steam boiler and optimally integrates i...
Page 6: ...temperature level for external use The catalytic converter is installed outside the closed module frame for easy accessibility The flue gas silencers are designed for high temperatures and a mounted downstream the catalytic converter and upstream the external heat sink Electrical output 600 kWel 2000 kWel Modular designed CHP modules are available in the following output ranges 600 kWel 800 kWel 8...
Page 7: ...00 6950 6670 7550 10000 11730 Generation of electricity Generator manufacturer Leroy Somer Leroy Somer Marelli Marelli Stamford Marelli Generator type LSA 47 2 M7 4P LSA 47 2 M7 4P LSA 49 1 S4 4P MJB 400 LC4 MJB 450 MB4 PE734C MJB 500 MB4 Voltage Frequency V Hz 400 50 400 50 400 50 400 50 400 50 400 50 Speed 1 min 1500 1500 1500 1500 1500 1500 Efficiency of generator 96 1 96 2 96 8 97 1 95 9 97 3 ...
Page 8: ...ion Design external flue gas heat utilisation Design external flue gas heat utilisation Design external flue gas heat utilisation Engine manufacturer MTU MWM MTU MTU MWM Engine model 12V4000 L33 TCG 2020 V16 16V4000 L33 20V4000 L33 TCG 2020 V20 Dimensions Length mm 4800 6300 5500 5900 7820 Width mm 2000 1800 2000 2000 1800 Height mm 2300 2500 2300 2400 2680 Weight empty kg 12000 13400 15000 19000 ...
Page 9: ...units required for a 4 draught steam boiler such as e g water treatment feed water degassing system fuel supply pumps etc will not be treated further in this document because their requirements concerning sizing and installation do not differ from a conventional boiler system Especially it has to be observed that the installation location of the feed water control valve is between the two economis...
Page 10: ...3 Outlet shut off valve 24 Reversing chamber door 25 Flame inspection hole 26 Connection for flue gas condensate drainage system 27 Desalination control valve 28 Base frame 29 Level indicator 1 Level indicator 2 optional 30 Burner 31 Flue gas chamber 32 Inspection aperture on the flue gas side 33 Inspection aperture water side 2 3 2 Technical data 6 720 819 535 04 1T 1 2 3 8 7 10 9 12 11 14 13 17 ...
Page 11: ...4 4 The dimension H1 varies depending on the valve manufacturer mm 2262 2512 2557 2642 2947 3177 3222 3312 3562 H22 5 6 5 Dimension depending on selected flue gas temperature influenced by number of tubes in height of economiser 6 For boiler type UL S 28000 there are 2 desalination connections mm 2150 2232 2210 2210 2575 2765 2975 2958 3178 Flue gas connection L11 mm 233 303 373 373 303 303 373 37...
Page 12: ... 10000 UL S 12000 UL S 13000 UL S 14000 UL S 16000 UL S 17000 UL S 18000 UL S 22000 UL S 28000 Dimensions L11 1 The dimension L1 is a recommended dimension and is subject to the burner manufacturer type and the actual steam output mm 8369 9007 9008 8674 9854 9920 9944 9610 9868 L22 3 2 Minimum transport dimensions when valves burner and terminal box have been removed without cable conduit with cab...
Page 13: ...s and devices are available on request System access The MEC system gives humans and machines access to the entire system Via an integrated local web server the user can access the system using any terminal device such as PC notebook or tablet in the network with a standard web browser With the modern and intuitive user interface the user can access the complete system and each individual plant Ha...
Page 14: ...s variant should be preferred in case of retrofitting existing boiler system A bypass already exists in the waste heat boiler Fig 6 Bosch waste heat boiler HRSB Fig 7 Simplified function diagram Bosch waste heat boiler HRSB and CHP simplified depiction 1 Flue CHP module 2 Flue bypass 3 Chimney 4 Economiser 5 Peak load steam boiler 6 Make up water 7 Water service module WSM V 8 Manifold 9 Consumer ...
Page 15: ...ad boiler If the motor waste heat provided by the CHP module is not sufficient for the heating water supply or if it shall be supply also redundantly to the CHP module the system can be extended by a boiler for covering these loads Fig 9 Function diagram System extension via peak load boiler strongly simplified depiction 1 4 draught steam boiler 2 Economiser 3 Chimney 4 Flue gas heat exchanger 5 W...
Page 16: ...P system can be used for internal power consumption or can be supplied to the public power network The infeed of current to the public network can be promoted depending on CHP size in acc with KWKG CHP Act Germany For the economic viability of a CHP module it is crucial to clearly define the currently valid subsidy conditions If the created power is used internally the economic efficiency of the C...
Page 17: ...d Medium System parameters Unit Within system limits Yes No Steam Performance Min 1250 kg h Max 28000 kg h 4 draught steam boiler Part of fourth draught waste heat Max 20 Positive pressure Max 30 bar Steam temperature Max 235 C Current Performance Min 240 kWel Max 2000 kWel Voltage Min 230 V Max 400 V Heating water Performance Min 230 kWth CHP Max 1100 kWth Pressure rating Max 6 bar Temperature Fl...
Page 18: ...ts As a sound basis for an investment decision and for evaluation of the investment costs and preliminary consideration of economic efficiency the system with 4 draught steam boiler and CHP module with MEC has to be compared with the construction of a 3 draught boiler system The shown cost estimate is based on the following framework conditions Output steam boiler 2000 kg h each Output BHKW 400 kW...
Page 19: ...h 5800 MWh 203 000 Fuel demand steam boiler 4 draught steam design 35 MWh 5000 MWh 175 000 Fuel demand CHP module 35 MWh 5300 MWh 186 900 Fuel demand floor standing condensing boiler 35 MWh 2700 MWh 94 500 700 MWh 25 700 Power drawn 150 MWh 1600 MWh 246 900 3500 MWh 525 000 Cost allocation internal power consumption 45 300 Reduction peak load 90 kW 400 kW 36 000 Reimbursement of petroleum tax 29 4...
Page 20: ...of the CHP module to prevent reverse flow of fuel Fig 10 4 draught steam boiler with bypass Changing from normal to bypass operation is effected via pneumatically controlled flaps in the flue gas line of the CHP module Here one of the bypass flaps is opened and subsequently the flue gas line leading to the fourth draught of the boiler is closed The flue flows unused directly to the chimney and pas...
Page 21: ...the CHP module is led via the fourth draught of the steam boiler In consequence when the boiler target pressure is achieved not only the boiler but also the CHP module have to be shut down to prevent further increase of the boiler pressure Due to this fact at times of low steam consumption pulsing of the CHP module can occur Fig 11 4 draught steam boiler without bypass 6 720 819 535 07 1T ...
Page 22: ... and in rows on the water side whereby ECO of the fourth draught in flow direction is always passed through first Due to the feed water control valve with pump freewheel function between both economisers part of the feed water can be led back to the feed water container and the container can be used as heat reservoir In consequence runtimes of the CHP module as well as the efficiency of the system...
Page 23: ...ate For optimum waste heat use of the CHP flue gases by the steam boiler a base load requirement as continuous as possible is decisive IMPORTANT If the maximum steam amount must be available at any time e g also if the CHP module is idle due to missing LT heat utilisation or maintenance the output of the fourth draught must not be considered for sizing Fig 13 Ratio boiler output required steam amo...
Page 24: ...lisation in the steam boiler up to approx 94 The energy is provided as high quality electrical energy LT and HT energy for steam generation For a planned waste heat utilisation the sizing of the CHP module should be oriented towards the maximum output of the fourth draught of the steam boiler 3 3 3 Steam amount waste heat output and CHP boiler combinations As already described in chapter 3 3 1 pag...
Page 25: ... 7 6 6 6 5 7 4 6 4 2 3 2 CHP CE 1200 NE Waste heat performance kg h 478 478 478 478 508 501 501 462 462 533 459 Waste heat proportional 38 2 23 9 18 4 14 9 12 7 10 0 8 4 6 6 5 8 5 3 3 8 CHP CE 1287 NE Waste heat performance kg h 551 551 551 551 586 598 532 532 532 614 529 Waste heat proportional 44 1 27 6 21 2 17 2 14 7 12 0 8 9 7 6 6 7 6 1 4 4 CHP CE 1560 NE Waste heat performance kg h 670 670 67...
Page 26: ...portional 2 9 2 7 2 5 2 4 2 2 1 9 0 0 CHP CE 1200 NE Waste heat performance kg h 476 456 491 497 499 512 Waste heat proportional 3 7 3 3 3 1 2 9 2 8 2 3 0 0 CHP CE 1287 NE Waste heat performance kg h 548 525 565 572 575 590 Waste heat proportional 4 2 3 8 3 5 3 4 3 2 2 7 0 0 CHP CE 1560 NE Waste heat performance kg h 646 655 704 709 714 736 Waste heat proportional 5 0 4 7 4 4 4 2 4 0 3 3 0 0 CHP C...
Page 27: ...00 8000 10000 12000 CHP CHP CE 1200 NE 1200 NE 1200 NE 1200 NE 1200 NE 1200 NE 1200 NE 1200 NE 1200 NE 1200 NE 1200 NE steam boiler UL S 4000 4000 5000 5000 6000 7000 7000 8000 8000 10000 12000 CHP CHP CE 1287 NE 1287 NE 1287 NE 1287 NE 1287 NE 1287 NE 1287 NE 1287 NE 1287 NE 1287 NE 1287 NE steam boiler UL S 4000 4000 5000 5000 6000 7000 8000 8000 8000 10000 12000 CHP CHP CE 1560 NE 1560 NE 1560 ...
Page 28: ...at performance in kg h 13000 14000 16000 17000 18000 22000 28000 CHP CHP CE 240 NE 240 NE 240 NE 240 NE 240 NE 240 NE 240 NE steam boiler UL S 13000 14000 16000 17000 18000 22000 28000 CHP CHP CE 400 NE 400 NE 400 NE 400 NE 400 NE 400 NE 400 NE steam boiler UL S 13000 14000 16000 17000 18000 22000 28000 CHP CHP CE 600 NE 600 NE 600 NE 600 NE 600 NE 600 NE 600 NE steam boiler UL S 13000 14000 16000...
Page 29: ...ke up water steam amount C Performance steam boiler 1 CHP 240 NE 2 CHP 400 NE 3 CHP 600 NE 4 CHP 800 NE 5 CHP 854 NE 6 CHP 1200 NE 7 CHP 1287 NE 8 CHP 1560 NE 9 CHP 1718 NE 10 CHP 1999 NE CHP 2000 NE 6 720 819 535 17 1T 0 10 20 30 40 50 60 70 80 90 100 0 5 000 5 000 10 000 10 000 15 000 15 000 20 000 20 000 C kg h A l h B 10 9 8 7 6 5 4 3 2 1 ...
Page 30: ...eased for external use exemplary installation drawings in PDF and DXF as well as comprehensive quotation texts 3 3 6 System control The superordinate control of the combination CHP and 4 draught steam boiler should be mainly effected by the Bosch control system MEC system A control with MEC system is possible but the system benefits generated by MEC that are presented in the following chapters can...
Page 31: ... annual efficiency is possible All required sensors and actuators with exception of 2 meters are used for MEC system functionality The 2 meters are the gas flow meter and the current flow meter of the current generated in the CHP For this purpose usually calibrated meters of energy corporations are installed For planning it has to be observed that these meters have an M Bus interface or optionally...
Page 32: ...ldings must be dissipated through suitable airtight pipework above the roof in accordance with the German Firing Installations Order It is only permitted for flue gases to enter chimneys or flues if it can be proven that the flue gases can be dissipated effectively even while combustion equipment is connected This flue can be routed within buildings in ducts and channels that are ventilated from t...
Page 33: ...sidered with respect to the noise emissions These requirements usually make the use of sound isolated installations and secondary or tertiary silencers necessary The following must be provided for every individual flue gas pipe Mating flange for CHP module outlet flange Axial expansion joint to separate structure borne noise and absorb thermal stresses flexible connection accessory construction se...
Page 34: ...quired sensors pumps and valves are already marked A super ordinated building control system is not mandatory for standardised hydraulics 3 4 1 Hydraulics with bypass Fig 17 System hydraulics 4 draught steam boiler and CHP module with bypass 1 CHP module without internal flue gas heat exchanger 2 4 draught boiler system with burner 3 Water service module 4 Buffer cylinder for waste heat of engine ...
Page 35: ...bypass has several functions If designed for this purpose at idle state of the steam boiler the CHP module can continue to be operated via bypass if required For this it has to be assured that the heat can be taken from the low temperature side and that in addition the generated current can be used efficiently via the German Renewable Energies Law In order to bypass the fourth draught the hot flue...
Page 36: ...t FPO Buffer cylinder top temperature sensor FPU Buffer cylinder bottom temperature sensor FTA Temperature sensor flue gas temperature FTR Return temperature sensor FTS Feed water temperature sensor FTV Flow temperature sensor G Natural gas K Expansion joint KAT Catalytic converter for reducing emissions PSD Primary silencer up to 240 kWel installed in the module SSD Secondary silencer always outs...
Page 37: ...th the customer for which process the heat from the buffer cylinder can be used It can be be integrated in the heating network or it can be used for DHW heating or for special processes The commonly in the CHP module integrated flue gas heat exchanger is superfluous because the hot flue gas is used as waste heat for the fourth draught of the steam boiler The flue gas first flues through a catalyti...
Page 38: ... and or in the corresponding Bosch planning documents for CHP and steam boilers For steam boilers read the Technical Information TI 024 Requirements of the boiler installation room Information for the installation of boilers and boiler house components Æ chapter 4 2 page 41 Figure 19 shows a possible installation variant for the components Installation example Fig 19 Installation example combinati...
Page 39: ...Engineering information and sizing 39 Systemlösung 6 720 885 509 2018 03 Fig 20 Installation example floor plan views dimensions in m 6 720 819 535 21 1T 6 00 6 00 5 00 1 35 4 15 4 15 4 15 5 00 ...
Page 40: ... KG 420 2 1 CHP 2 1 10 CHP CE NE x 2 2 Heating pipes 2 2 10 Heating pipe x 2 2 20 Connection assembly with pump and valve return temperature increase x 2 2 30 Expansion joint x 2 2 40 Shut off valves x 2 2 50 Safety equipment x 2 3 Flue gas lines incl insulation suitable for temperatures to 650 C 2 3 10 Catalytic converter x 2 3 20 Primary silencer x 2 3 30 Secondary silencer x 2 3 40 Tertiary sil...
Page 41: ... 40 Extract air fan x opt 2 5 50 Exhaust air duct x 2 5 60 Multi leaf damper x 2 5 70 Weather grille x 3 Electrical installation KG 440 3 1 Electrical installation cable between boiler and CHP control cabinet and electrical 3 1 10 Components x 3 1 20 Cable route x 3 1 30 NS MS infeed x 4 MSR KG 480 4 1 control cabinet 4 1 10 Control cabinet for all components x 4 1 20 Higher level control MEC Cont...
Page 42: ...ension via peak load boiler 15 Waste heat boiler and CHP module 14 H Human Machine Interface HMI 13 31 Hydraulics System hydraulics with bypass 34 System hydraulics without bypass 36 I Installation 38 M MEC System See system control O Operation conditions 8 P Peak load boiler 14 Function diagram 14 15 S Sound insulation 33 System control 30 Control behaviour key components 31 HMI 13 31 Interfaces ...
Page 43: ...43 Systemlösung 6 720 885 509 2018 03 Notes ...
Page 44: ...Subject to technical modifications ...
