Bosch steam boiler at bottling plant with predictive monitoring feature

Condition Monitoring basic ensures efficiency

At the Altmühltaler Mineralbrunnen GmbH bottling plant in Treuchtlingen, Germany, a new steam boiler system from Bosch Industriekessel has been in operation for several months now. It is one of the first systems to be equipped with the new Condition Monitoring basic boiler management function. This ensures consistently high efficiency and availability of the system, and has been available as a new standard functionality within the Bosch boiler control BCO since March this year.

A very wide range of plant data such as flue gas temperature, desalination volume and boiler load are analysed and evaluated by the innovative software and displayed for the operating personnel via the traffic light model: green means everything is perfect, while orange and red indicate progressive deviations in the boiler's operating mode, or inefficient operation. The calculation algorithms work out diagnostic forecasts, allowing operating parameters that could lead to a drop in efficiency, increased wear or unplanned stoppages to be identified and corrected at an early stage.

Condition Monitoring basic detects, for example, unfavourable start-ups, incipient water and flue gas side soiling or corrosion risk due to flue gas condensation. Efficient and predictive maintenance messages help prevent unplanned down times.

The high data transparency also facilitates energy-optimised boiler operation. Optimisation potentials are highlighted by determining and displaying meaningful plant data, including the boiler load profile, the number of burner cycles or the thermal losses caused by desalting and blow-down.

The operator also receives swift and cost-effective solutions to malfunctions via the teleservice function in the BCO boiler control. Other system equipment includes an integrated economizer and dual firing for economical and environmentally-friendly operation. The boilers are fired with either natural gas or light fuel oil.

With a capacity of 4,000 kilograms per hour, the Bosch boiler reliably provides the process steam required by the bottling plant. The steam is used in production processes such as cleaning, pasteurisation and sterilisation. The steam boiler system was moved into position and installed by plant construction company Dankl Dampfsysteme GmbH & Co. KG from Freilassing, Germany. The customer service team at Bosch Industriekessel was responsible for commissioning the system.

Bosch Industriekessel GmbH, part of the Bosch Thermotechnik GmbH, has stood for innovation in industrial boiler technology for more than 145 years. Boiler systems for steam, hot water and heating, manufactured to customers' specification, provide efficient heating and process heat for all applications. Boiler house components, which are modular in design and perfectly coordinated, together with intelligent regulation and control technology, significantly simplify the planning, installation and commissioning of the complete system. Comprehensive service support from one source rounds off the innovative product portfolio.

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The Bosch Group is a leading global supplier of technology and services. In fiscal 2012, its roughly 306,000 associates generated sales of 52.5 billion euros. Since the beginning of 2013, its operations have been divided into four business sectors: Automotive Technology, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 360 subsidiaries and regional companies in some 50 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. Bosch spent some 4.8 billion euros for research and development in 2012, and applied for nearly 4,800 patents worldwide. The Bosch Group’s products and services are designed to fascinate, and to improve the quality of life by providing solutions which are both innovative and beneficial. In this way, the company offers technology worldwide that is “Invented for life.”

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Tags: Plant, Steam, Boiler, Monitoring

Bosch Thermotechnology is a leading European manufacturer of energy-efficient heating products and hot water solutions. In fiscal 2018, the company generated sales of about 3.5 billion euros (66 percent outside Germany) and employed approx. 14,200 people. Bosch Thermotechnology has strong international and regional brands and manufactures a diversified product range in Europe, America and Asia.

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The Bosch Group is a leading global supplier of technology and services. It employs roughly 410,000 associates worldwide (as of December 31, 2018). The company generated sales of 78.5 billion euros in 2018. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. As a leading IoT company, Bosch offers innovative solutions for smart homes, smart cities, connected mobility, and connected manufacturing. It uses its expertise in sensor technology, software, and services, as well as its own IoT cloud, to offer its customers connected, cross-domain solutions from a single source. The Bosch Group’s strategic objective is to deliver innovations for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.” The Bosch Group comprises Robert Bosch GmbH and its roughly 460 subsidiary and regional companies in over 60 countries. Including sales and service partners, Bosch’s global manufacturing, engineering, and sales network covers nearly every country in the world. The basis for the company’s future growth is its innovative strength. At nearly 130 locations across the globe, Bosch employs some 68,700 associates in research and development.

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