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productInformation on multi-boiler installationsOptimising multi-boiler plantWeishaupt multi-boiler control system
Many multi-boiler installations are able to operate moreefficiently, particularly at partial load, if the boiler outputcan be optimised to suit the heat demand. This is wherethe Weishaupt multi-boiler control system can provide anadvanced and practical solution.The principleWeishaupt facilitates the modern, hydraulically optimised controlof multi-boiler installations by measuring and regulating boilerflow rates. Variable-speed boiler pumps and modulating burnerscombine with the innovative control concept to form the idealsolution for multi-boiler plant.The technologyFlow rate is measured in the consumer pipeline and at everyheat generator. Variable-speed pumps at every boiler provide abalanced water flow rate and correct any deviations before theyhave an effect on temperature. The ground-breaking propertiesof this patented system enable an outstanding degree of control,and the efficient and reliable operation of any size of plant.The resultMeasurable benefits compared to typical installations even withcondensing boilers and combined heat and power plant, both interms of control precision and energy consumption.Products and efficiency technologies, such asthe Weishaupt multi-boiler control system, aredeveloped and tested at the Weishaupt Researchand Development Centre.2
Responsive control of multi-boiler plant:environmentally friendly and efficientBolier flow rates controlled by variable speed pumpsVariable speed pumps control boilerflow rateWhen a reduction in load leads to areduction of the circulation flow in theconsumer circuit, the boiler pumps varytheir speed to adapt the rate of flow tothe heat exchanger. This reduces thenumber of burner starts to a minimum.Therefore the Weishaupt system offersthe same benefits to heat generation ashave for so long been available to heatdistribution: speed-controlled circulationpumps whose power consumption isconsiderably reduced by varying volumeflow rate.Condensing boilers with a low lossheader operate without any loss ofefficiencyAcross the whole of the control range,flow-rate control prevents a rise in thereturn temperature to the boiler circuitat the low loss header. The Weishauptsystem thus capitalises on all of thecontrol benefits of the low loss header,without impairing the efficiency of thecondensing technology or comparableapplications.4Control / visualisationFurthermore, balanced volume flowrates prevent overheating of the boileror flow-rate-linked instabilities (e.g. allboilers on or all boilers off).All of the installed boiler capacity isavailable to the consumerWith the Weishaupt system, the watercircuit and the control strategy aretailored to one another.The intelligent volume-flow-rate controlsets the water flow rate so that a boilercan really transport its nominal capacityto the consumer circuit. This supportsthe optimal utilisation of an ecologicallyadvantageous lead boiler, e.g. biomassor combined heat and power; the nextboiler in sequence is only started whenthe lead boiler has reached full capacity.Disruptions during boiler switchingprocedures are compensated forimmediatelyOutstanding control characteristics areachieved because changes in flow ratecaused by boiler switch-on or switch-offprocedures are detected and compensated for immediately, before they havean effect on temperature.Gas demand peaks are levelledThe demand peaks in the gas supplythat often occur with temperature-ledcontrols are effectively reduced oroften even avoided.Alternative heat generators can beintegratedAs well as boiler/burner sequencingwith low and high-temperature hotwater plant, the Weishaupt system isalso ideally suited to sequencing withalternative heat generators (e.g. biomass or CHP plant).The well-thought-out volume flow ratemanagement system can ensure thegreatest possible utilisation of ecologically advantageous heat generatorsin both individual and sequencedoperation. This considerably increasesthe ecological and economical valueadded.Condensing boilers or DHW chargingsystems can be incorporated parallel tothe low loss header without impairingtheir efficiency.
The Weishaupt multi-boiler control system has been proving itself in numerous installations5
The Weishaupt service package:a one-stop solutionBespoke control panels have been designed and built at the main works in Schwendi for more than 50 yearsWith more than 50 years’ experiencein the design and manufacture ofcontrol panels, primarily for burnerand boiler controls, Weishaupt offerscustomers tailored, one-stop controlsolutions.ConsultationGood hydraulic design underlies optimaloperation characteristics. Alongsidecompetent assistance, Weishaupt isalso able to provide a comprehensiveconsultation service.On-site analysis of the current stateBefore design comes the analysis ofthe situation on site. It is possible todetermine right at this initial stagewhether a conversion to the Weishauptsystem will be possible.6As individual as a finger printThe modular structure of the Weishauptmulti-boiler control system offersnumerous options for meetingcustomer-specific requirements.The open bus communications systemsimplifies integration with existingbuilding management systems. Thetext and graphics of the user interfaceare individually tailored.Forecasted energy savingsThe efficiency calculator MKRdeveloped by Weishaupt providesreliable data on the potential energysavings for a plant after conversion.That enables you to consider theamortisation of the intended investmentand plan with a high degree of certainty.Round-the-clock serviceAs well as supplying and assembling allof the necessary components, thecontrols and software are tailored toyour individual requirements. Comprehensive operator orientation/trainingtakes place after commissioning.To ensure your equipment remainsproblem-free in the future, Weishauptprovides round-the-clock service 365days per year.
The efficiency calculator:Reliable projections of anticipated savingsBurner selectionPlant schematicPay-back calculationsThe Weishaupt efficiency calculator can calculate the likely savings of the multi-boiler control system in advance7
Some convincing examples:making visible savingsProduction plant in Wahlstedt (picture courtesy of Grundfos)Deutsche Energie-Agentur GmbH(DENA)’s Energy Efficiency Initiativehas presented two Weishauptprojects as examples of efficientenergy utilisation by trade andindustry. These very impressiveexamples demonstrate the potentialsavings that can be made.Example installation: GrundfossAn extensive energy analysis at theproduction plant in Wahlstedt concludedthat a modernisation of the heatingsystem could realise potential energyconsumption and cost savings. As partof the modernisation, older burnerswere replaced by new models. A newWeishaupt multi-boiler control systemwas also implemented, which ensuresthat only those boilers needed to meetdemand are run. Now precisely therequired volume flow rate is transported,so that the boilers are always operatingat an optimal load point and with themaximum possible efficiency.Results * Reduction in fuel consumption:1,806,000 kWh/year Reduction in electrical consumption:60,000 kWh/year Annual energy saving of 22 % Reduction in CO2 emissions:479 t/year Investment: 265,000 Reduction in costs: 66,500 per year Return of investment: 25 %* Full details can be found in DENA’s “InitiativeEnergieeffizienz Industrie und Gewerbe” seriesof publications.8
Production plant in Rittershausen (picture courtesy of Rittal)Example installation: RittalThe main source of heat in the factoryare two boilers, each of which are fittedwith efficient burners. Both burners areequipped with O2 trim and VSD. Thecombined output of the two boilersamounts to 4.76 MW. Heat is alsoprovided by a biodiesel-fired CHP plantrated at 420 kW, and two catalytic fluegas scrubbers. The main consumer ofthe heat produced is the paint shop,whose pretreatment tanks have to bekept at a constant temperature insummer and in winter. In winter, heatingof the buildings consumes the largestamount of energy. The followingmeasures were taken in order tooptimise the plant:Results * Installation of a multi-boiler controlsystem and an efficient burner Installation of another burner, commissioning of the biodiesel-fired CHPplant. Conversion from thermal fluegas purification to catalytic flue-gaspurification with heat recovery Installation of flue gas heatexchangers in the existing boilers Reduction in gas consumption:8,056,000 kWh/year Reduction in bio-oil consumption forheating: 6,720,000 kWh/year Reduction in energy consumption1,337,000 kWh/year Saving of 9 % CO2 reduction 1,095 t/year Investment: 620,000 Cost reduction: 270,670 per year Return of investment: 44 %* Full details can be found in DENA’s “InitiativeEnergieeffizienz Industrie und Gewerbe” seriesof publications.9
That’s reliabilityBoiler production in Sennwald, SwitzerlandNeuberger building automation in RothenburgThe Weishaupt Group has over 3,000employees and is a market leader forburners, condensing boilers, heatpumps, solar energy, and buildingautomation.administrative headquarters, and hometo the group’s own Research andDevelopment Institute.Since 2009 the business, which wasfounded in 1932, has been structuredas a holding for three companiesoperating in the fields of energytechnology, energy extraction andenergy management.The core division is Max WeishauptGmbH, which is located in the southwest German town of Schwendi, andwhich is where all burners aremanufactured. It is also the group’sHeating systems are manufactured byWeishaupt’s sister company Pyropac,which is located in the Swiss town ofSennwald.Neuberger building automation, sited inRothenburg ob der Tauber in Germany,has been a group subsidiary since1995.Bad Wurzach is home to thegeothermal engineering company,BauGrund Süd, which has been partof the Weishaupt Group since 2009.Borehole drilling by BauGrund Süd
Max Weishaupt GmbH88475 SchwendiTel 49 7353 830,Fax 49 7353 83358www.weishaupt.dePrint No. 83150202, February 2013Printed in Germany. All rights reserved.Neachells Lane, Willenhall, WV13 3RGTel (01902) 609841,Fax (01902) 633343Weishaupt Service worldwide:Weishaupt worldwide:The branch offices inGermany, and the varioussubsidiary companies,representatives andagents abroad, providelocal iumBosniaBrazilCanadaCroatiaCzech enSwitzerland (E.)SerbiaSlovakiaSloveniaSouth AfricaUnited lJapanJordanKorea ysiaMoldavaMoroccoNetherlandsNew siaSingaporeSpainSwitzerland nam
of multi-boiler installations by measuring and regulating boiler flow rates. Variable-speed boiler pumps and modulating burners combine with the innovative control concept to form the ideal solution for multi-boiler plant. The technology Flow rate is measured in the consumer pipeline and at every heat generator.
