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CHP monitoring at Enerquinn GmbH

Optimise predictive maintenance with mondas®.


The company Enerquinn Energiesystemtechnik GmbH in Weingarten plans, builds and operates combined heat and power (CHP) plants throughout southern Germany. While digitalisation is still being discussed in many places, the company has been using the mondas® monitoring platform to monitor its plants for years.

CHP units are used in various areas: in residential buildings, neighbourhoods, hotels, swimming pools and industrial operations

Power generation from combined heat and power (CHP) has become an integral part of our energy supply in recent years. In the past ten years alone, more than 50,000 CHP plants have been licensed in Germany. The majority of these are CHP plants with a capacity of less than one megawatt.

The market is growing. CHP units are increasingly being used to supply electricity and heat to residential buildings (tenants’ electricity) and to supply electricity to commercial enterprises. The company Enerquinn Energiesystemtechnik GmbH in Weingarten near Ravensburg has been planning, building and operating CHP plants throughout southern Germany for more than ten years.

While the benefits of digitization are still being debated in many places, Enerquinn is already using IoT technology to monitor the growing number of plants being built.

Efficient Maintenance Required

With 40 employees, Enerquinn is a rather small and medium-sized enterprise. Nevertheless, to date the team has connected several hundred CHP plants to the grid and also supports them in operation. In the beginning, hotels were still part of the main target group. Today, they are increasingly manufacturing businesses as well. Larger residential buildings and entire new construction quarters are also supplied with heat and electricity from Enerquinn plants. Today, Enerquinn installs an average of two new systems per week. Seven service specialists alone take care of the maintenance of the now 1,000 CHP plants on the grid. This places high demands on maintenance and servicing in terms of planning and logistics.

With the mondas® CoGenius monitoring platform, hundreds to thousands of decentralised CHP units can be monitored on a standardised platform.

IoT Monitoring for CHP

The two Enerquinn managing directors Mark Lehnertz and Stefan Oexle-Ewert want to continuously improve their service and maintenance area. Now also with the help of the mondas® IoT platform, which have been specially adapted to the needs of the CHP operator.

Fast Data Management

Today, Enerquinn can detect whether equipment is running efficiently or is in a critical operating state while still at the service center. The characteristic values and measurement data are transferred to the mondas® IoT platform via a web connection. There they are evaluated. This is done practically in real time, regardless of the number of CHP plants monitored. Newly added plants can be integrated into the system within a few minutes.

Digital Health Check

But how can mondas® tell how a plant is doing? Similar to a doctor who uses blood values and blood pressure to determine the risk of a heart attack, mondas® uses AI algorithms to analyze plant data and detect an impending malfunction. “If, for example, the number of CHP starts per day exceeds a certain value, the energy efficiency of a CHP can drop by up to 25 percent,” Key Account Manager Christian Neumann knows from his own planning experience. Therefore, early fault detection is important, he said. Expensive plant failures could thus be avoided.

Conventional Remote Monitoring Systems Overwhelmed

Conventional remote monitoring systems are usually overwhelmed with such tasks, as they usually only allow a selective and situational view of a plant. On the other hand, they cannot evaluate time series data of a large plant inventory, which is needed for a systematic error analysis.

In contrast, mondas® IoT monitoring generates concrete instructions for action at an early stage. This is particularly advantageous for older plants that are nearing the end of their technical service life. Then the maintenance and servicing costs increase disproportionately. An efficient and proactive maintenance routine is then particularly worthwhile.

Advantages for the User

Enerquinn Managing Director Stefan Oexle-Ewert benefits from going digital.

Enerquinn CEO Stefan Oexle-Ewert is also enthusiastic about mondas® IoT monitoring for CHPs: “This is a highly flexible visualization and evaluation tool that reliably detects critical operating states.” He expects significantly lower maintenance and servicing costs from the integration of his CHP plants on the mondas® IoT platform. In addition, the mondas® technology also offers more service for its customers, for example in billing.

Great Demand

Overall, the mondas® IoT platform offers excellent opportunities to save maintenance costs, optimally schedule scarce personnel resources, and also increase the service life of plants through predictive maintenance. For this reason, it makes sense to use the mondas® system for other supply engineering plants as well. This is because the same logic can also be used to monitor refrigeration and air conditioning systems, ventilation units or even air compressors.

There is still considerable potential for efficiency and cost savings here, which can be leveraged with the mondas® IoT software. Manufacturers of CHP plants are also interesting as a target group, as they can equip their products with the mondas® IoT software as standard.

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