Bosch CHP CE 240 NE Quick start guide

Technical guide
System solution
4-draught steam boiler and CHP
with MEC system
6 720 885 509 (2018/03) GB

Contents
Systemlösung – 6 720 885 509 (2018/03)
2
Contents
1 System solution: 4-draught steam boiler with
combined heat and power (CHP) . . . . . . . . . . . . 3
1.1 Notice on technical guide . . . . . . . . . . . . . 3
1.2 System solution . . . . . . . . . . . . . . . . . . . . . 3
1.3 Features and benefits . . . . . . . . . . . . . . . . 4
2 System components . . . . . . . . . . . . . . . . . . . . . . 5
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Bosch CHP for external waste heat use . . 6
2.2.1 Description CHP CE ... NE . . . . . . . . . . . . . 6
2.2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . 7
2.2.3 Operation conditions CHP . . . . . . . . . . . . 8
2.3 4-draught boiler system . . . . . . . . . . . . . . 9
2.3.1 Description of 4-draught boiler system . . . 9
2.3.2 Technical data . . . . . . . . . . . . . . . . . . . . . 10
2.3.3 Dimensions and connections . . . . . . . . . 11
2.4 MEC System – overview . . . . . . . . . . . . . 13
2.5 Further options for waste heat use/peak
load boiler . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.1 Waste heat boiler HRSB . . . . . . . . . . . . . 14
2.5.2 3-draught waste heat boiler for use
of waste heat only . . . . . . . . . . . . . . . . . . 15
2.5.3 System 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 components . . . . . . . . . . . . 23
3.3.1 Sizing of 4-draught steam boiler . . . . . . . 23
3.3.2 Sizing of CHP module . . . . . . . . . . . . . . . 24
3.3.3 Steam amount/waste heat output
and CHP/boiler combinations . . . . . . . . . 24
3.3.4 Demand for useful energy for
make-up water preheating, heating
energy and DHW . . . . . . . . . . . . . . . . . . . 28
3.3.5 Safety equipment . . . . . . . . . . . . . . . . . . 30
3.3.6 System control . . . . . . . . . . . . . . . . . . . . 30
3.3.7 Flue system . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 System design . . . . . . . . . . . . . . . . . . . . . 34
3.4.1 Hydraulics with bypass . . . . . . . . . . . . . 34
3.4.2 Hydraulics without bypass . . . . . . . . . . . 36
3.4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . 38
4 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 List of components . . . . . . . . . . . . . . . . . 40
4.2 Further technical documents . . . . . . . . . . 41
Keyword index . . . . . . . . . . . . . . . . . . . . . . . . . . 42

System solution: 4-draught steam boiler with combined heat and power (CHP)
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Systemlösung – 6 720 885 509 (2018/03)
1 System solution: 4-draught steam boiler with combined heat and power (CHP)
On the background of increasingly scarce natural
resources, sharp increases in energy prices over the last
few years and a turnaround in energy policy, it has
become indispensable, not only from an ecological, but
also from an economic point of view, to review and
reduce one's own energy consumption.
The industrial sector, the most energy-demanding of the
economic sectors, provides a large savings potential.
Often industrial applications require a steam supply
system. Such a system can be optimised concerning
energy consumption and economic viability by using
combined heat and power (CHP) in combination with a
CHP module. In the context of a turnaround in energy
policy, CHP plays a very important role. Its part in the
power generation mix in Germany will increase until
2020 to 25 %.
1.1 Notice on technical guide
The existing technical guide “4-draught boiler and CHP
with MEC system” can be used as information to simplify
the planning and sizing of 4-draught steam boiler system
in combination with combined heat and power unit by
Bosch.
The technical guide shall help you to understand the
basics for using flue gas heat for creating steam in 4-
draught steam boilers and for designing the components
of a boiler system in conjunction with a combined heat
and power unit (CHP).
The existing technical guide will show possible ways of
execution and respond to open questions concerning
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 CHP for
efficient creation of process vapour. The motor heat of
the CHP module can be used for make-up water
preheating, for heating or for DHW heating.
The steam boiler with waste heat utilisation is a
conventionally fired 3-draught steam boiler with
integrated additional fourth draught (4-draught steam
boiler). The hot flue gas of the CHP module is led
through the boiler to support steam production. Thanks
to the integrated combustion in 4-draught steam boilers,
steam peak load boilers are not necessary here that are
usually required with pure waste heat boilers.
Investment costs, space requirements and equipment
effort can be reduced significantly.
The use of a CHP in combination with a 4-draught steam
boiler is gently on the environment in more than one
respect.
The most important aspect is the considerably lower
consumption of primary energy compared to
conventional, separated production of current, steam
and heat. With a CHP, natural resources are saved and
the environment is protected from pollutants from other
combustion processes.
For the combination of a 4-draught steam boiler series
UL-S by Bosch Industriekessel GmbH and a CHP system
by Bosch KWK Systeme GmbH, different system
hydraulics are proposed in this document and their
planning and execution is described (Æchapter 3.4,
page 34). These are suggestions that allow a simple
realisation.

System solution: 4-draught steam boiler with combined heat and power (CHP)
Systemlösung – 6 720 885 509 (2018/03)
4
1.3 Features and benefits
A CHP module provides several benefits, besides saving
resources and reducing the environmental impact,
significant revenues can be achieved using the current
produced by the CHP module.
The revenue is composed of credits for created current
and credits for created heat. Here is must be
differentiated whether the current is produced for own
use of whether it is completely fed in the upstream
mains.
Benefits for end-customers/investors/plant users
• Low consumption of primary energy compared to
conventional, separated production of current, steam
and heat
• Is gentle on the environment: Saves CO2and
resources
• Remuneration for self-produced current in
accordance with corresponding national regulations,
e. g. Germany EEG/KWKG
• Amortisation time/ROI of less than 3 years possible
• Sustainable due to decentral energy generation
• Space-saving, no installation of additional peak load
boilers
• Modular system with all benefits of CHP operation
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 certified safety equipment
– All flue gas temperatures from the Bosch CHP
module are securely attained, also in partial load
operation
– Optimised flue gas sound insulation – smoothed
flue gas pulsation, solutions for use in industry,
mixed and residential areas
– Tuned control with bypass dampers with safety
function
– Matched flue system, optimised to admissible flue
gas back pressure of CHP module with regard to
wear of system, maintenance and contamination
– Matched material pairs in flue gas path
• Excellent price/performance ratio/fast ROI/low TCO
– Meaningful, sustainable calculation of economic
viability
– Overall efficiency of CHP module > 70 % by using
waste heat in steam boiler and limiting the flue gas
temperature downstream of the fourth draught/
economiser and use of MEC system
– By using the MEC system, the runtime of the CHP
module is optimised by tuned control strategy.

System components
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Systemlösung – 6 720 885 509 (2018/03)
2 System components
2.1 General
The CHP system with waste heat use for steam
generation consists of 2 key components plus required
accessories.
The key components are:
• A CHP module, designed for flue gas heat utilisation
(without flue gas heat exchanger), consisting of
combustion engine and generator
• A steam boiler with combustion and integrated fourth
draught for waste heat use
• The superordinate control of the combination CHP
and 4-draught steam boiler should be effected by the
Bosch control system MEC system.
The combustion motor is intended for activating the
generator. The hot flue gas, that is created during the
combustion process, with temperatures above 400 °C is
used in the 4-draught steam boiler for steam 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 is in the compete energy
production system on site.
Fig. 1 Simplified function diagram 4-draught steam boiler and CHP module and CHP (simplified depiction)
[1] 4-draught steam boiler
[2] Economiser
[3] Chimney
[4] Flue gas heat exchanger
[5] Water service module
[6] Mains power supply
[7] Consumer
[8] Manifold
[9] Memory
[10] CHP
[11] Flue with bypass
Current
Water/condensate
Steam
Flue gas
If a replacement power supply is necessary, e.g. as in
hospitals or other safety-relevant facilities, a CHP
module can also be used as standby power generator.
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2.2 Bosch CHP for external waste heat use
2.2.1 Description CHP CE ... NE
The modular construction system of CHP modules for
external waste heat use in the output range
240 kWel ... 2000 kWel ensures an operation that
simplifies maintenance, commissioning and planning.
Bosch CHP modules care supplied for external waste
heat use in 2 different types and sizes:
•CHP CE ... NE with an output range to 400 kWel.
based on the approved Bosch CHP modules CHP CE
•CHP CE ... NE in the output range 600 ... 2000 kWel
is a modular CHP module in the output range of
600 ... 2000 kWel.
The CHP module consists of a system module, that
can be extended in function via corresponding
accessory modules.
Fig. 2 Decoupling of heat of flue gas and cooling water
in a CHP module, example CHP module with
600 kWel performance
[1] Natural gas
[2] Waste heat performance (depending on
temperature change in steam boiler)
Electrical output 240 kWel and 400 kWel
Both CHP modules with electrical output of 240 kWel
and 400 kWel are delivered as compact modules, ready
for connection. The components are integrated in the
soundproof cabinet. As ready-for-connection units, the
compact modules are equipped with an integrated
control cabinet. They further comprise a spark-ignited
gas engine (only for CHP CE 400 NE with flue gas
turbocharger) and a synchronous generator for
producing three-phase current (400 V, 50 Hz) and
heating energy. They are suitable for connection,
electrically and for control purposes, to the German low-
voltage network in accordance with VDE-AR-N 4105 or
the regulations of the Federal Association of the German
Energy and Water Industry (Bundesverband der
deutschen Energie- und Wasserwirtschaft, BDEW).
The variant described here spares the internal flue gas
heat exchanger, in consequence the flue gas heat is
available at a high 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
• 854 kWel
• 1200 kWel
• 1287 kWel
• 1560 kWel
• 1718 kWel
• 1999 kWel
• 2000 kWel
The core of the CHP consists of a perfectly tuned unit
with components such as a spark-ignited gas engine
with flue gas turbocharger and a synchronous generator
for producing three-phase current (400 V or 10.5 kV,
50 Hz).
The individual components, such as pumps, heat
exchangers or sensors are combined in modules, wired
and integrated electrotechnically in a terminal box. The
spatial arrangement of the modules can be adapted to
the existing spatial conditions. The options are
constructed in a way that they can be integrated in
existing modules without too much technical effort.
Independently of the ordered options, Bosch CHP
systems provide as standard a comprehensive safety
and fire prevention concept.
The 4-draught CHP modules fulfil, electrically and for
control purposes, the German grid connection
conditions in accordance with
VDE-AR-N 4105 low-voltage or the medium-voltage
regulation by the Federal Association of the German
Energy and Water Industry (Bundesverband der
deutschen Energie- und Wasserwirtschaft, BDEW).
In the variant described here, the CHP module is
designed for external heat utilisation and therefore
provides the flue gas heat for another system. The flue
system is designed for flue gas temperatures up to
550 °C.
Achievable performance of waste heat utilisation in
the steam boiler
The output of the utilised waste heat depends on the
cooling degree of the flue gases in the flue gas boiler. As
an estimate, this is at approx. 20 ... 25 % of natural gas
use in kW.
Bosch BHKW
CHP 600 NE
6 720 819 535-02.1T
1
2453 °C
75 °C85 °C
333 kWth
360 kWth
600 kWel
1438 kW
~
~

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Systemlösung – 6 720 885 509 (2018/03)
2.2.2 Technical data
Unit CHP CE 240
NE
CHP CE 400
NE
CHP CE 600
NE
CHP CE 800
NE
CHP CE 854
NE
CHP CE 1200
NE
GenSet
Gas category – Natural gas Natural gas Natural gas Natural gas Natural gas Natural gas
Power
consumption
kW 668 1034 1438 1898 1993 2750
Electrical output kW 240 400 600 800 854 1200
Thermal output kW 236 288 333 431 443 625
Electrical
efficiency
% 35.9 38.7 41.7 42.1 42.8 43.6
Type – Design
external flue
gas heat
utilisation
Design
external flue gas
heat utilisation
Design
external flue gas
heat utilisation
Design
external flue gas
heat utilisation
Design
external flue
gas heat
utilisation
Design
external flue
gas heat
utilisation
Engine
manufacturer
– MAN MAN MWM MWM MTU MWM
Engine model – E2842 E 312 E2842 LE 322 TCG 2016 V12 C TCG 2016 V16 C 8V4000 L33 TCG 2020 V12
Dimensions
Length mm 4380 5300 3900 4057 4200 3900
Width mm 1510 1660 2400 1467 2000 2400
Height mm 1980 2472 2260 2190 2300 2260
Weight (empty) kg 4400 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
Temperature levels
LT mixture circuit °C – 47.5/45 44/40 46/40 42/40 43/40
Heating water
without flue gas
heat exchanger
°C 83/70 82/72 85/75 85/75 85/75 85/75
Flue gas
temperature
without flue gas
heat exchanger
°C 570 440 453 452 443 414
Maximum flue gas
temperature
°C 650 650 550 550 550 550
Flue gas tube
dimension (KAT)
– DN 200/PN 10 DN 200/PN 10 DN 250/PN 10 DN 300/PN 10 DN 300/PN 10 DN 350/PN 10
Flue gas mass flow
rate (wet)
kg/h 877 2102 3343 4418 4524 6551
Available flue gas
back pressure
mbar 15 17 25 25 25 25
Flue gas back
pressure boiler
mbar 10 10 15 15 15 15
Flue gas limit values
CO mg/m3i.N. d300 d300 d300 d300 d300 d300
NOx mg/m3i.N. d250 d500 d250 d250 d250 d250
NMHC mg/m3i.N. d150 d150 d150 d150 d150 d150
Table 1 Specifications CHP CE 240 NE ... CHP CE 1200 NE

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2.2.3 Operation conditions CHP
The following operating conditions are required to
maintain the warranty:
• Ensure dust and halogen-free cooling and
combustion air
• Ensure that the exhaust air and exhaust gas lines are
correctly dimensioned, and run them separately
• Maximum setup height without a drop in
performance: depending on model used 100 ... 500
meters above zero
• Ratio of starting/operating hours: 1 start to 6
operating hours averaged over the year
• Methane count: 80
• Natural gas Hi = 10 kWh/m3
• Maximum exhaust gas counterpressure depending on
GenSet motor manufacturer 40 ... 60 mbar
• Module only suitable for setup within a building
• The condensate and flue gas line are pressurized and
must be appropriately designed, and the operating
pressure must be demonstrated in a pressure test.
Unit CHP CE 1287 NE CHP CE 1560 NE CHP CE 1718 NE CHP CE 1999 NE CHP CE 2000 NE
GenSet
Gas category – Natural gas Natural gas Natural gas Natural gas Natural gas
Power consumption kW 2974 3629 3991 4666 4588
Electrical output kW 1287 1560 1718 1999 2000
Thermal output kW 664 819 974 1076 1053
Electrical efficiency % 43.3 43 43 42.8 43.6
Type – Design
external flue gas
heat utilisation
Design
external flue gas
heat utilisation
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 18100
Generation of electricity
Generator
manufacturer
– Stamford Marelli Leroy-Somer Stamford Marelli
Generator type – PE734F MJB 500 LA4 LSA 51.2
VL95 C6S/4P
LV804T MJB 560 LB4
Voltage/Frequency V/Hz 400/50 400/50 400/50 400/50 400/50
Speed 1/min 1500 1500 1500 1500 1500
Efficiency
generator
% 96.5 97.1 96.5 96.3 97.4
Temperature levels
LT mixture circuit °C 43/40 44/40 43/40 43/40 45/38
Heating water
without flue gas heat
exchanger
°C 85/75 85/75 85/75 85/75 85/75
Flue gas temperature
without flue gas heat
exchanger
°C 440 426 426 449 410
Maximum flue gas
temperature
°C 550 550 550 550 550
Flue gas tube
dimension (KAT)
– DN 350/PN 10 DN 400/PN 10 DN 400/PN 10 DN 450/PN 10 DN 450/PN 10
Flue gas mass flow
rate (wet)
kg/h 6700 8665 8940 10458 10983
Available flue gas
back pressure
mbar 25 25 25 25 25
Flue gas back
pressure boiler
mbar 15 15 15 15 15
Flue gas limit values
CO mg/m3i.N. d300 d300 d300 d300 d300
NOx mg/m3i.N. d250 d250 d250 d250 d250
NMHC mg/m3i.N. d150 d150 d150 d150 d150
Table 2 Specifications CHP CE 1287 NE ... CHP CE 2000 NE

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Systemlösung – 6 720 885 509 (2018/03)
2.3 4-draught boiler system
2.3.1 Description of 4-draught boiler system
The basis of a 4-draught steam boiler is a 3-draught
boiler from which a part of the smoke tubes is
separated. The hot flue gases of the CHP module
(in the design for external flue gas utilisation) are lead
through this separate smoke tube field, the so-called
fourth draught, and are used for steam generation.
Fig. 3 Positioning of fourth draught in reversing chamber
[1] Second draught
[2] Third draught
[3] Flue gas
[4] Fourth draught
Due to different pressure ratios on burner and waste
heat side, and for avoiding back coupling, both flue gas
paths have to be clearly separated on the flue gas side.
This separation concerns, besides the boiler and
possibly existing economisers, also the flue gas routing
via 2 separate chimneys.
The auxiliary 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 economisers, in order to increase economic viability
and to save steam for heating up the feed water. In
addition, it is recommended to equip the feed water
container with an overflow device.
This ensures that an unwanted activation of the pressure
relief valve at the feed water container is prevented
during waste heat recovery of the CHP module in the flue
gas heat exchanger (ECO2) with at the same time very
low to no steam generation. Both points are shown in
the hydraulics (Æchapter 3.4, page 34).
6 720 819 535-03.1T
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By dividing the third draught, the amount of
steam generated by waste heat is limited for
the total output of the boiler
(Æchapter 3.3.3, page 24).

System components
Systemlösung – 6 720 885 509 (2018/03)
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Fig. 4 Overview UNIVERSAL steam boiler
[1] Inspection aperture on the flue gas side
[2] Flue gas connecting branch
[3] Inspection aperture on the flue gas side
[4] Pressure indicator (with test function)
[5] Pressure transducer
[6] Pressure limiter
[7] Shut-off valve
[8] Vent shut-off valve (optional)
[9] Maintenance platform (optional)
[10] Steam shut-off valve
[11] Desalination shut-off valve1)
[12] Positive pressure safety valve 2 (optional)
[13] Positive pressure safety valve 1
[14] Lifting lug
[15] Connection pipework
[16] Connection economiser
[17] Flue gas heat exchanger
[18] Conductivity transducer
[19] Terminal box
[20] Level measurement transformer
[21] Level limiter
[22] Mud quick action stop valve
[23] 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
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222324
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26272830313233 29
19
16 18
21
20
15
6
5
4
1) For boiler type UL-S 28000 there are 2 desalination
connections.
Unit UNIVERSAL
steam boiler
Type – UL-S
Heat transfer medium – High pressure
saturated steam
Type – 4-draught flue tube
technology
Performance kg/h 1250 ... 28000
Safety pressure bar d30
Maximum temperature °C 235
Fuel – Oil, gas
Table 3 Specifications UNIVERSAL steam boiler
The 4 ... 5-digit number in the boiler name
corresponds to the respective steam output
in kg/h.
1 kg/h corresponds to 0.65 kW burner
output.