Insights 1/2013

Insights

Information for customers and employees of the Hoval Group

1/2013

GREEN E EXPERIENCED X P RESPONSIBLE E FRIENDLY PRACTICAL R INNOVATIVE T

Im Fokus Introduction

Dear Reader

People with expertise make the

In this issue of Insights, we are delighted to

difference!

present to you a few up-to-date examples of

Why do we trust someone? Because we have learned from experience that we can rely on that person. The same considerations apply when investing in heating and air-conditioning technology. Such systems need to function reliably over many years and offer the customer the best solution from both an economic and ecological perspective.

such ambitious projects for which customers have placed their trust in us.

We value that trust very highly and prove to our customers again and again that they are right to choose our company.

And we can only do this because we are aware of one fact: It’s people who make the difference!

So it is understandable that discerning investors will think very carefully before deciding in whom they can place their trust, especially when it comes to large-scale projects. It is not surprising that they often choose Hoval, as we have proved our worth by offering expert advice, top-quality products and reliable service over many decades. That is why it always fills us with pride to see the long list of world-famous buildings and distinguished projects, from Buckingham Palace to the Burj Khalifa, the highest building in the world, where customers have placed their confidence in our products, our solutions and our expertise.

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Peter Gerner, Hoval Group Management Board/CEO Heating Technology

Contents

Insights 1 / 2013

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5

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22

24

In focus

In the market

04 From the expertise of Hoval employees

18 New Hoval Training Centre

05 Winning a major order through competence

19 Hoval UK at Queen’s Coronation Festival

08 State-of-the-art technology in the Swiss Alps

In operation

10 Plentiful hot water supply for the Headline tower 11 Hotel Edelweiss in Wagrain backs the use of pellets 12 Hoval expertise for Mercedes-Benz 13 Energy efficiency at the VW production plant 14 Quality report for decentralised ventilation systems 16 Shopping centre in Poland relies on Hoval technology 17 Circus Krone renovates its heating system

In detail

20 Latest-generation heat pumps with top COP 22 Intelligent brain: Hoval control technology for district heating networks 24 Optimised rotating heat exchanger with maximum efficiency 26 Cogenerate heat and power – and save money 27 In retrospect

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In focus

From the expertise of Hoval employees.

One of Hoval’s core brand values is our expert knowledge. First

and foremost, this means that our employees are competent, qualified and well trained. In the diverse Hoval world, however, this term takes on a wider sense, because it also extends to aspects of functionality, safety and financial considerations.

guaranteed a safe product in perfect working order, can count on the longevity and reliability of a Hoval solution, and will ultimately save both time and money.

A winning, first-class performance

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and expertise make us specialists. Our in-depth understanding gives us a competitive advantage which in turn, works in the favour of our customers. It means they have learned about a subject in depth and are able to talk about and answer questions on this subject from a specialist’s perspective.

After a few more years’ experience, the expert starts to provide a competitive advantage in his or her field, which works to the benefit of the customer.

And because Hoval’s team includes several experts, it too can boast a real competitive edge.

Hoval employees prove just how valuable they are in a number of ways, including their skills in technical, commercial and industrial areas. This forms the basis for the success of our products, as well as

provided by Hoval is directly linked to the technical superiority of our products and solutions, as well as the Hoval employees themselves and their knowledge.

After all, selling a single product – as well as selling an entire system involving a range of components and interconnected elements – requires expert advice, precise project planning, intelligent process monitoring, professional installation and an experienced service provision. And let’s not forget the importance of aspects beyond this: reliable and precise goods management, logistics, accounting, IT and much more besides.

When all of these elements are perfectly coordinated and of the highest quality, the customer is

In a time when customers want more than just an average performance for their money, competition is intense and customer demands are constantly increasing, something exceptional is called for. Hoval can meet this demand by offering first-class performance with measurable added value from an ecological and economical perspective, and thanks to its expert employees who can provide one thing above all else: trust.

From trainees to trainers For Hoval, training is a top priority, because training young people in our company means passing on our specialist knowledge. It means sharing expertise on both a large and small scale and equipping the next generation with expert Hoval knowledge from the ground up.

But it’s not just trainees in seven different skilled trades who become experts at Hoval – our customers and partners learn too. The Hoval Training Centres in various countries bring specialist knowledge directly to the people.

The icing on the cake When the expertise of the Hoval employees is coupled with a family atmosphere and an inspiring sense of motivation, our customers can rest in the knowledge that we’re on top of things.

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In Betrieb Switzerland

Made-to-measure solutions for a complex district heating network.

Hoval’s winning formula combines expertise with

innovation and safety. For the district heating network which originates in the Bellinzona region in the south of Switzerland, the output from the transmission

stations ranges from less than 50 right up to 3500 kW. These stations showcase the innovative skills that are so typical of Hoval – and they’re causing quite a stir!

This is not just your ordinary network.

The waste incineration plant in the canton of Ticino, plus the Ticino electrical power station and the municipality of Giubiasco, form a district heating network which is set to extend to around 30 kilometres in length. It envisages supplying waste heat from waste incineration processes to 35,000 inhabitants, as well as industrial firms, vegetable growers, schools, homes and the regional hospital in Bellinzona, the capital of the canton. Teris AG, the company founded for this purpose of this project (Teris is short for “Teleriscaldamento” or, in English, “district heating”), is working on the basis of a total waste heat output of 30 MW. The dimensions of the project alone require top expertise and flexible planning and production capacity. Added to this are the technical requirements, which can only be met through a certain level of experience and innovation. But those in charge at Teris AG recognised that Hoval scores highly in all these areas: in the first leg of the project, involving a public invitation to tender for the 46 heat transmission stations, Hoval left eleven competitors behind it to become the clear winner.

No transmission station the same as the next “We design each of these transmission stations individually, according to local needs and performance requirements,” explains engineer Dino Bennardi. He manages the Hoval customer centre in Ticino and knows the Teris project inside out. “The smallest transmission stations

View of the low temperature transfer station with thermal heating power = 3.0 MW at Cattori Ortotomato, Giubasco.

are designed for an output of less than 50 kW; the largest for 3.5 MW.” He also explains that their varying nature poses a challenge to the project planners.

Back-up function included Teris also focuses on safety: 8 of the 46 transmission stations – 4 to the south of the central district heating plant in Giubiasco and 4 to the north – must be fitted with back-up functions. If, for whatever reason, there was no waste heat available from the waste incineration plant, these 8 units would have to produce heat themselves and feed it into the network.

From Dino Bennardi’s office at the Hoval customer centre in Manno, it is

around two dozen kilometres to the greenhouses of Cattori Orto Tomato in Giubiasco. The greenhouses cover a crop area of around 7000 m2, where they grow sweet, aromatic cherry tomatoes that end up on almost every table in Switzerland once they are harvested.

This is where the first transmission station with a back-up function has been operating since 1st October 2012.

A tight schedule Dino Bennardi remembers the date well: it was Friday, 24th August 2012 when two articulated lorries drew up to Cattori. It was an ambitious schedule – not to mention the fact that the weeks leading up to it had been a popular holiday period

Insights 01.2013 _ 5

In focus the design of the station had to be very long and slim.

The large Migros shopping centre in the neighbouring municipality of Sant’Antonino has also been connected to the Teris district heating network. The transmission station produces an output of 700 kW. Two heat exchangers per station

Arrival of the two trucks at Cattori Ortotomato with the modules for the transfer stations.

with lots of staff absences. In the end, however, everything went exactly to plan thanks in part to the fact that Yados in Germany had been manufacturing the required modules since mid-July. Hoval has had shares in Yados, which specialises in building heat stations, since 2010.

The on-site installation of the 8 modules took place over the last weekend in August; this involved 4 modules for a low-temperature station and 4 for a hightemperature station, including the back-up function. The back-up function itself consists of a propane gas boiler with a 5.5 MW output. Before being connected to the district heating network, Cattori used the boiler regularly; for example, by using its heat to dry the air in the greenhouses in summer.

A local heating contractor supplied the hydraulic connections for the transmission stations, while an electrical company provided the electrical installations. For the control technology, Hoval joined forces with Siemens, a partnership that was particularly important in view of the fact that an additional system had to be integrated into the control system for the greenhouses.

“There is no other system like this – certainly not in Switzerland,” continues Dino Bennardi. The sophistication of its technology reflects just how complex the project is.

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Limited space A stone’s throw away from the Cattori vegetable plantations, Forbo manufactures flooring in Giubiasco. The second transmission station featuring a back-up function has been operating here since February 2013. And once again, Hoval had a completely new problem to solve before operation could begin, as the boiler house was starting to show its age and there was not enough room available for the transmission station. The space had to be extended for the purpose of moving the oil-fired boiler, and in order to accommodate a transmission station with a thermal output of 1.5 MW in the same location as the original boiler,

The vegetable grower Serra Brusa in Giubiasco represents the fourth member of the group involved in this preliminary stage. The transmission station used here, like the one at Cattori, has two plate heat exchangers. “It’s an additional safety measure,” explains Dino Bennardi.

“With an output of 1 MW or more, Teris, in its role as the project owner, stipulates two heat exchangers. This means that, in an emergency, at least 50% of the output is available.”

Hoval has already been working on the design and execution plans for the next transmission stations for some time.

The project, which is currently unique in terms of its size and the technology involved, will continue to keep everyone on their toes well beyond 2013: from the specialists in Manno to those at the Hoval Switzerland office in Feldmeilen, Hoval’s headquarters in Vaduz, and Yados in Germany.

Qualitative and compact construction: module with pump station at Cattori Ortotomato, Giubasco.

Austria

Major order for district heating transmission stations.

KELAG Wärme GmbH is

Austria’s leading private heat supply company and the largest provider of heat from renewable energies. The company also expects quality and expertise from its suppliers. And over the next four years, it is Hoval who has been appointed to supply district heating transmission stations all over Austria.

When it comes to the size and importance of KELAG Wärme GmbH, the figures speak volumes: as a subsidiary of the energy supplier Kärntner, KELAG operates around 80 district heating networks and a total of 900 heating systems across the whole of Austria. This means that the company can react quickly and flexibly to market demands and offer its customers financially attractive rates. As a certified company, KELAG Wärme GmbH also looks for high quality standards among its partners.

of district heating transmission stations up to the middle of 2016.

“We were particularly pleased with the expertise and quality Hoval could offer for this order,” explains Günther Stückler, managing director of KELAG Wärme GmbH. Amongst the major advantages that Hoval provided, he points out the state-of-the-art control technology (read more about Hoval control technology in the TopTronic ® supervisor article on page 22), as well as the many years of expertise that Hoval employees have within the field of district heating. “The teams from Hoval and KELAG Wärme GmbH worked together perfectly to provide a comprehensive and knowledgeable customer service,” stresses Günther Stückler.

“Not only are we happy about this important order; we are also proud to have established ourselves among Austria’s leading heat suppliers,” says Christian Hofer, managing director of Hoval Austria. The order encompasses the delivery, installation and commissioning of a three-figure number

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In focus Switzerland

State-of-the-art technology you can rely on.

Once again, history is in the making at Andermatt in the

Swiss Alps. Not only is Egyptian investor Samih Sawiris building six hotels and almost 500 holiday apartments there. Together with the community of Andermatt and other investors,

Heizwerk Gotthard AG is in the process of realising a topographically challenging district heating network.

In Göschenen, the cars disappear into the St. Gotthard Tunnel. They pass beneath the Alps, far below the Gotthard massif, on their way to warmer, southern regions. The world above them is rugged and stark. It is also a landscape shrouded in legend. Long ago, the inhabitants of the dark, stony Schöllenen Gorge above Göschenen made a pact with the Devil: They asked for his help in building a bridge over the Gorge. In return, the Devil demanded the first soul to cross the new bridge. When the bridge was completed, the inhabitants chased a billy goat across it. Angered by their trick, the Devil picked up a rock, intending to use it to destroy the bridge. But the rock missed its target, because a pious woman had scratched a cross on it.

You can still see the Teufelsstein (Devil’s Rock) today – below the Gorge in Göschenen. After successfully crossing the Schöllenen Gorge, the Urserental, a delightful high Alpine valley, opens up before you.

Investment of more than 1 billion Swiss Francs Andermatt, the main town in the valley, has also signed a pact. A modern, future-oriented pact. With Egyptian investor Samih Sawiris. He aims to make the village, where many Swiss spend some time during military service, a tourist resort. Six hotels, 490 holiday apartments in 42 buildings, around 20 villas and 1970 parking spaces are planned. In addition, there will be 35,000 square metres of commercial premises, a sport and leisure centre, a congress and concert hall and a golf course. The project represents a total investment well in excess of one billion Swiss Francs.

Andermatt is re-inventing itself – with the

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help of Samih Sawiris, his Swiss Alps AG and the open-mindedness and commitment to innovation of its inhabitants.

water 350 metres high. In comparison: the famous “Jet d’eau”, the landmark of Geneva, produces a fountain of water 140 metres high.

Heating network for the local population

Giga-size boiler

The locals have another ambitious plan: a district heating network for Göschenen and Andermatt, capable of meeting the heat requirements of the two communities as well as those of Andermatt Swiss Alps AG and Armasuisse Immobilien.

Armasuisse Immobilien manages the real estate owned by the Swiss ministry of defence.

The heat will be supplied by a woodfired heating plant in Göschenen, for which planning permission has now been granted. The plant will be built and operated by Heizwerk Gotthard AG, a subsidiary of the local Zgraggen EnergieHolding AG. Starting in October 2013, wood energy will be used to meet requirements in the high-temperature range and waste heat energy from the Armasuisse Immobilien installations will cover the low-temperature range. The district heating network will then be up and running.

One boiler will cover the peak loads in winter. Hoval has already delivered it: The 5-MW Hoval Giga-3 (5000) boiler has been in operation since 5 November 2012. On that day, following a construction period of only three months, power company Andermatt AG put its distribution centre into operation and supplied heat for the first time.

The Hoval Giga-3 (5000) currently replaces the wood-fired heating plant in Göschenen. Its diameter alone gives some idea of its size: The diameter of the Hoval Giga-3 (5000) is greater than the average height of a human being.

Hoval has also delivered a boiler for the establishment of a mobile heating plant to Andermatt: a Hoval Giga-3 (2500).

Hoval also provided support during the design and construction engineering phase for the mobile heating plant.

Challenging topography This means that by autumn 2013 - a tight schedule, indeed - the pipelines will also have to be laid through the Schöllenen Gorge. Not exactly an everyday undertaking when you look at the forbidding topography of the Alps. A pressure of 35 bar is required to pump the hot water from Göschenen to Andermatt over a difference in altitude of around 350 metres. In other words, the pumps need to produce a jet of

Heat transmission station Hoval TransTherm PRO for outputs from 50 kW upwards.

In Betrieb First transmission stations in operation More than four kilometres of district heating pipeline have been laid in Andermatt to date. Before the onset of winter, power company Andermatt AG connected the first 20 premises, among them hotels, to the district heating network. The building shell of Samih Sawiris’ five-star hotel The Chedi was also completed and then needed to dry out before completion of the interior.

The transmission stations – also supplied by Hoval – are located in the individual installations and are of two type families: stations of type TransTherm Giro up to an output of 50 kW, and stations of the specially designed type TransTherm PRO for outputs from 50 kW upwards.

Competence and reliability “We can offer a one-stop solution,” comments Reto Nufer, head of sales and service at Hoval Central Switzerland.

It was probably the fact that Hoval has the full range of competences required to set up a district heating network which prompted the clients, Heizwerk Gotthard AG and Netzgesellschaft Andermatt AG, to select the company.

When Reto Nufer submitted quotations first for the transmission stations and later for the boilers, he drew attention not only to their cutting-edge technology, but also to Hoval’s excellent aftersales service and reliability.

“With a 30-million-Franc project and a very tight time frame for realisation, service and entrepreneurial reliability are all the more important considerations.”

In spring 2013, Hoval is to deliver further transmission stations to Andermatt. Like those already supplied, they will be equipped with the TopTronic ® com control unit, which will allow them to communicate directly with the specific control system of the heating network. The experts at Hoval are masters of heating technology. They have developed a control technology

© Andermatt-Urserntal Tourismus

software which can help to optimise any district heating network. (Read more about Hoval control technology on pages 22/23) Significantly reduce heating oil consumption As a result of its communal energy policy, Andermatt was awarded the title of Energiestadt in 2010. Over the next ten years, the municipal council plans to reduce its current annual heating oil consumption of 1.5 million litres by 1 million litres per year. And Samih Sawiris’ Andermatt Swiss Alps AG is to produce energy for the entire resort using CO2-neutral methods.

The inhabitants of Göschenen are also already aware of the benefits of being connected to a district heating network.

It can only be a question of time until the power company Netzgesellschaft Göschenen AG is founded.

You can have a warm and cosy home and hot water without being dependent on oil, even if you don’t live in a big city.

Andermatt is pointing the way and overcoming the harsh Alpine topography in the process.

The GöschenenAndermatt district heating network in figures Transmission stations: ■ Hoval TransTherm Giro ■ Hoval TransTherm PRO ■ all equipped with TopTronic ® com control unit Heat generation: ■ wood-fired heating plant in Göschenen with an output of 8 MW and heat recovery ■ waste heat from Armasuisse Immobilien in Andermatt ■ 1 Hoval Giga-3 (5000) oil-fired boiler and 1 mobile heating plant with 1 Hoval Giga-3 (2500) oil-fired boiler to cover peak loads Connecting pipeline: ■ difference in altitude 350 m ■ pressure 35 bar ■ temperature 95° C ■ max. output 13 MW

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In operation Austria

Plentiful hot water supply for new tower.

The 49-metre-high

tower which houses the Headline complex

represents a new landmark for Innsbruck. Its heating and hot water system is setting standards – in terms of both technology and cost-effectiveness.

In particular, the hotel in the tower requires large quantities of hot water.

The Headline complex and its tower in Innsbruck: modern architecture combined with hi-tech heating and hot water solutions.

Innsbruck’s Headline complex consists of a multi-storey base structure, as well as a tower measuring 49 metres in height and comprising three storeys and an underground garage. Not only that, but the building’s interior houses a hotel, restaurants, offices and retail outlets.

The complex was inaugurated on 26th November 2012 after 955 days of construction.

“Intelligent, hi-tech solutions” “Nothing is too modern for us: innovation and intelligent, hi-tech solutions are our stock in trade.” That was the message from the Innsbruck family-run company Ortner GmbH, who worked with Hoval Austria in planning the heating and hot water systems for the Headline building, as well as carrying out the subsequent execution work.

UltraGas® as a twin boiler unit The building is heated by means of two Hoval UltraGas ® gas condensing boilers with a heat output of 650 kW each. Using a 210 kW preheating unit and a 320 kW additional heater, the water heating system charges two stainless steel storage tanks with a volume of 4000 l each. This ensures that the four-star hotel – which boasts 100 double rooms, a restaurant

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and a spa – has all the hot water it needs.

Hygiene a paramount consideration Hotels, as well as hospitals, retirement and nursing homes and spas, all rely on impeccable levels of hygiene in the provision of their hot water. It must be available in sufficient quantities and at the correct temperature at all times.

And, of course, the system should also be economical, energy-efficient and environmentally friendly.

buffer circuit provides optimum cooling in the buffer circuit of the heat recovery system. This means that even the waste heat from any cooling devices is used efficiently.

The TopTronic ®, Hoval’s command centre, has a place in the Headline complex too, where it is used to regulate the water heating system reliably and precisely. It also ensures that the processes of discharging the buffer storage tank and charging the storage tank are managed intelligently.

Two-stage hot water system Hoval can provide all of this in one. The Headline planners opted for the Hoval TransTherm Aqua two-stage hot water system, which is manufactured on an individual basis according to the project specifications. The water is preheated using a heat exchanger and then immediately conducted via an additional heater, which heats it to 60°C during normal operation. This ensures impeccable levels of hygiene during operation, as stipulated by the ÖNORM B5019 Austrian standard. As the system does not use a cyclical heating-up process at the preheating stage, it offers improved energy efficiency.

Furthermore, the performance-focused design of the volume circulated in the

Hoval UltraGas ® gas condensing boilers combine maximum cost-effectiveness with rapid payback. As twin boiler units, they cover a power range of 250 to 2000 kW.

Austria

Hotel Edelweiss in Wagrain backs the use of pellets.

The Hotel Edelweiss in Wagrain, a town in

the state of Salzburg, is providing sustainable care for the environment – all the time and in

everything they do. The Bergmüller family of hotel owners chose to purchase two Hoval BioLyt pellet boilers with a total heat output of 300 kW in order to renovate their heating system.

Hotel owner Erich Bergmüller is thrilled: “Because we use energy and water sensibly, avoid waste and use renewable raw materials and environmentally friendly products, the Austrian Ministry of Life has awarded us the Austrian and European eco-label.” Development work on the hotel last year included an extension to the heating system. “Naturally, we only considered renewable energy sources.

Hoval’s pellet system solution won us over straight away,” says Erich Bergmüller, summing it up. Installation engineer Wilhelm Hutz explains the decision:

“The compact design of the high-performance twin boiler unit was the perfect solution for the Hotel Edelweiss.”

Cost-effectiveness and the environment When the new pellet heating system is compared with a notional oil heating system, it’s clear to see that the Bergmüller family is saving around 20,000 euros a year in operating costs. The environment is getting a good deal too, with around 130 tonnes of CO2 saved each year. The BioLyt (50-150) epitomises environmentally friendly heating, as the sophisticated combustion method helps the Hoval pellet boiler attain top marks for efficiency and cleanliness. With the aid of the integrated lambda sensor, the microprocessor-driven combustion controller consistently achieves ideal combustion conditions with minimum pollutant emissions. BioLyt emissions are already below the strict fine dust emission guideline of 20 mg per m³ planned for Europe. The system detects variations in pellet quality automatically and compensates for them. Thanks to Both the Hoval BioLyt pellet boiler and the Hotel Edelweiss have been awarded the Austrian eco-label.

Environmental concerns are a priority for many guests when choosing a hotel these days. Two Hoval BioLyt pellet boilers provide the hotel, complete with its new development, with comforting, environmentally friendly heat.

this and the patented “thermolytic” heating surfaces, it ensures optimum heat transfer while maintaining high levels of efficiency.

Fully automated operation The fully automated BioLyt pellet supply system transports the pellets from the storage facility to the boiler hopper without generating dust. Thanks to its flexibility, the suction supply system can even cope in situations with constraints on space.

High-performance renovation Particularly where renovations are concerned, the compact nature of this high-performance solution makes it an ideal choice. In cases where boilers are being replaced, the Hoval BioLyt is sure to find space in almost any boiler room.

The boiler body, trim and controller are delivered separately and assembled on site. This means that, even in cramped conditions, the system is easy to introduce into buildings. Using cascade solutions with two or three pellet boilers, or incorporating the old boiler as a means of covering peak loads, allows for

environmentally friendly and costeffective heating with a power output of up to 450 kW. At the Hotel Edelweiss in Wagrain, a water heating system featuring a high-performance Hoval fresh water station has been installed.

Operational safety The TopSafe® maintenance agreement from Hoval Austria provides hotel owner Erich Bergmüller with a practical all-round protection package and a full twelve-year warranty. The heating is monitored by the TopTronic ® online, which can be used to control and optimise the heating system remotely. If necessary, this can also be managed directly by Hoval customer service, which is available anywhere in Austria, at any time of day, 365 days a year.

The Bergmüller hotel owners and, between them, installation engineer Wilhelm Hutz are pleased with the Hoval BioLyt pellet boilers.

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In operation

Germany

Hoval expertise for Mercedes-Benz.

Mercedes-Benz’s star is now shining

even brighter thanks to the opening of its most advanced utility vehicle centre in Frankfurt am Main. Concentrated automotive skills meet intelligent system technology thanks to a Hoval PowerBloc combined heat and power (CHP) unit and a Hoval UltraGas ® gas condensing boiler.

The centre, which occupies 43,000 m2 at Frankfurt’s Heinrich-Lanz-Allee 33, is a haven for those who are passionate about heavy-duty vehicles. Along with spaces for administration and storage, the three-storey main building also houses a showroom. On one side, this is connected to the lorry workshop, complete with a car wash and water treatment facility; while on the other, it is connected to the transporter vehicle workshop and its service areas. In short, the new Mercedes-Benz utility vehicle centre is the place to be if you want to admire the latest models, buy used cars, hire a vehicle or have any kind of work carried out, right up to a full service.

CHP unit provides electricity and heat Even early on in the project, the building captured the imagination of engineering firm Billasch and the specialists from Hoval Germany – albeit for a different reason. Today, the building houses a masterpiece of heating technology, executed by Kuhnert Haustechnik GmbH. The utility vehicle centre is heated by a Hoval UltraGas® (500) condensing boiler and a Hoval

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PowerBloc EG-50 combined heat and power (CHP) unit. Designed as a compact module and mounted on a base frame, the CHP unit produces 50 kW of electrical power and 81 kW of thermal power. This energy is produced by a gas Otto engine, which is coupled with an air-cooled synchronous generator in order to generate a three-phase alternating current.

Buffer storage tanks extend operating time and reduce costs The CHP unit is equipped with its own control system. This controls the buffer charging of two Hoval EnerVal (2000) buffer storage tanks with a capacity of 2000 litres each. The two storage tanks extend the operational life of the CHP unit, making it even more cost-effective to run. The heating installation – hot water pump heating in a two-pipe system – is designed as a closed system in accordance with DIN 4752/2.

Two distributors divide the installation into heating groups within the heating system. The rooms on the ground floor, including the administration area, are fitted with an industrial underfloor

heating system, while those on the first and second floors are heated with radiators.

High-pressure cleaning needs hot water too The boiler/CHP system generates hot water for the sanitation facilities and for high-pressure cleaning. A Hoval FWM-E fresh water station with 145 kW is used in the sanitation area, while the high-pressure cleaning equipment uses a Hoval FWM-E with 245 kW. In each case, a 500 l Hoval EnerVal buffer storage tank provides the fresh water stations with heat.

What is more, the new Mercedes-Benz utility vehicle centre in Frankfurt has no need for a building management system: all the heating circuits and the water heating system are controlled entirely by four Hoval TopTronic ® T heating regulators.

The Hoval UltraGas® (left) and the Hoval PowerBloc (right) represent technology at its peak.

Centre: the Hoval EnerVal buffer storage tank.

Germany

Energy efficiency at the VW production plant.

What do the new VW Golf and

the Hoval ProcessLine have in common? Some would say it is the innovation skills of those who developed the products. Others would say it is energy efficiency. In fact, they’re both right –and VW’s Salzgitter site is where automotive and hall ventilation technology combine their strengths.

ProcessLine, the Hoval system solution for production halls, recovers the heat itself from the process extract air, which at that point is still contaminated with residual pollutants such as swarf, oil or cooling lubricant. Where conventional systems would blow out this heat energy without using it, ProcessLine combines exhaust air purification, oil-tight heat recovery, room ventilation and air conditioning. This reduces the need for ventilation heat and, therefore, cuts energy requirements by up to 98%.

In total, six systems have been installed at this cylinder head production line.

VW is making use of the opportunities this system offers in its Salzgitter production plant. The primary VW plant for engine production also manufactures the cylinder heads for the new VW Golf.

And in the exact location where these cylinder heads are being produced, the comprehensive Hoval ProcessLine system provides a healthy climate in a clean and energy-efficient manner.

ProcessLine – the complete system

A group extraction system collects the extract air from six to eight machine tools at a time. The extract air is purified with dry filters which are fitted with special, highly efficient filter plates.

Explosion and fire prevention When the act of machining aluminium is combined with fine particles of cooling lubricant and the corresponding oxygen, an explosive dust/air mixture may form as a result. In order to prevent this, a special additive is used during filtering.

This tested inerting procedure thus provides explosion and fire protection.

Hoval has incorporated the technology for purifying the extract air, developed by a cooperation partner, into the system solution in the form of ProcessClean.

Following extract air purification, the ProcessVent air conditioning unit is where the heat is recovered using the oil-tight plate heat exchanger, and the fresh air, which enters the room via an existing supply duct system, is conditioned. Together, ProcessClean and ProcessVent make up ProcessLine, an innovative and strong package that helps resources to be used sparingly.

Easy to control The two systems, ProcessClean and ProcessVent, are connected to one another via a control system and can be integrated into the building management system, as is the case at VW in Salzgitter.

As ProcessLine is installed directly where the action happens – that is, in the immediate vicinity of the machines – there is no need for long pipes. The ProcessLine units can also be controlled individually, whereas central systems are almost impossible to operate efficiently in partial load operation.

This is another bonus when it comes to energy efficiency.

ProcessLine – the Hoval system solution for production halls.

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In operation

Austria

Green means go.

Experts confirm impeccable supply air quality for decentralised ventilation units in sports facilities.

Text: Thomas Bacik Over the last ten years, many Austrian communities and private operators have chosen Hoval system solutions when building, renovating or extending sports and multi-purpose halls. The ventilation and air conditioning systems and units have the task of supplementing the other building systems in order to create an indoor climate that creates hygienic con-ditions from a physiological perspective and offers an optimum level of air quality. It is essential to plan and design the systems correctly, and to maintain them and change the filters regularly, in order to monitor the supply air quality and thus ensure the well-being of the users.

Because the ventilation and air conditioning systems are so complex, they need consistent maintenance.

Expert Ludwig Rüdisser from Vorarlberg visited the system in use at the secondary school in Oberndorf an der Melk to take an on-site measurement of the air distribution from the unit outlet, as well as the actual quality of the supply air that was brought in.

14 _ Insights 01.2013

Today’s regulations and hygiene requirements, as well as heightened requirements concerning air quality and general structural conditions, prompted the team responsible at Hoval to arrange for an expert third party to examine the current state of affairs in

sports and multi-purpose halls which use decentralised ventilation units. The expert – Ludwig Rüdisser (from the company Rüdisser RLT-Optimierung in Vorarlberg, Austria) – visited two selected systems in Hollabrunn (built in 2003) and Oberndorf an der Krems (built in 2009) and measured the air distribution from the unit outlet as well as the actual quality of the supply air that was brought in, then tested the surface and airborne germs in a comprehensive microbiological examination. The surface and contact plate samples confirmed that the Hoval RoofVent ® and TopVent ® roof ventilation units tested were just as clean as they looked, and showed that they had been maintained consistently.

Put simply, microbiological testing revealed no evidence of allergen contamination in the ventilation and air conditioning indoor climate systems, or any compromise in the air quality, at the time the measurements were taken in August 2012. All air quality measurements (concentration of germs on the surfaces and in the air) taken at the supply air outlet confirm that the supply air quality in the systems is flawless from a microbiological

perspective. This achieves the objective of meeting the latest hygiene requirements and maintaining a high standard of air quality when bringing in supply air. Microbiological laboratory analyses have confirmed that the systems don’t simply look clean – they are clean.

with a centralised unit, and this makes the overall supporting structure of the hall lighter. In particular, the low weight and compact design mean that the system is also easy to incorporate into the roof structure when carrying out upgrades. There is no need for an additional equipment room.

Users enjoy the comfortable conditions in the room, while operators love the system’s energy efficiency.

Hygiene, however, is just one of the many advantages of decentralised systems, which are particularly effective in sports and multi-purpose halls. The fact that no ducting is required, coupled with the low weight and compact design of the units, results in a considerable weight saving of up to 70% compared

Hoval RoofVent installed on the roof of the secondary school in Oberndorf an der Melk. ®

The ventilation and heating units are supplied ready-to-connect, fully assembled and pre-wired, reducing the cost and time required for planning.

The same applies to installation, which is also quick and easy.

Extract from lab results/ Oberndorf secondary school Sampling location

MP 4: Supply air from MP 5: Supply air from MP3: distributors, circulating distributors, fresh air Fresh air in roof area air operation operation

Total number of germs (CFU/m2)

430

190

350

Mould fungus (CFU/m2)

380

160

320

Bacteria (CFU/m2)

50

20

20

Yeast (CFU/m2)

< 10

10

10

Insights 01.2013 _ 15

In operation Poland

Top prize for shopping centre with hidden values.

And the “Oscar” went to...Poland! In fact, it was

Cannes where the Galeria Echo in Kielce, one of the largest shopping centres in Poland, received its accolade from a retail property trade fair. The jury’s choice for the world’s most successful renovation project is full of Hoval’s energy-efficient technology.

Echo by name, echo by nature: in the evening after a busy, bustling day, with dusk descending, the Galeria Echo in Kielce, southern Poland, starts to light up in a multitude of colours as though literally echoing the day just gone. The shopping centre, which originally had two floors and a total area of around 30,000 m2, has added parking spaces for 2300 cars and been transformed into a taller arcade with an area of 160,000 m2.Today, the Galeria Echo houses 300 retail outlets as well as a seven-screen cinema, a bowling alley, a disco and a fitness centre.

To enable the low-temperature system to work as efficiently as possible, the heat source must be able to deal with low parameters and the water must be heated at low parameters too. The return temperature of the boiler water is 20°C. Based on this, the solution that makes the most sense and is the most beneficial is a gas condensing heating system with no lower limit.

system by means of the control system Hoval TopTronic ® T. Four Hoval CombiVal ER hot water storage tanks with a capacity of 1000 l each prepare the hot water that the Galeria Echo requires in huge quantities.

Thanks to this heating and hot water concept, the Galeria Echo fulfils European Directive 2002/91/EC, the Energy

It wasn’t just the architectural design and attractive lighting concept which won the “property Oscar” in Cannes for the construction company, Echo Investment SA. The jury, made up of international professionals, also took into account the building’s functionality and technology when making their decision. The Galeria Echo beat prominent contenders from Italy and Germany to take the prize for best shopping centre renovation project.

The heating and ventilation systems in the Galeria Echo are based on water/air heat pumps which work in a loop: heat energy is transported from areas where there is a surplus amount to locations where it is required. In the shopping area of the Galeria Echo, the lighting, equipment and flows of shoppers generate heat. The excess from this can heat the fresh air in the centralised air conditioning units for the whole winter – and in Poland, this means heating around 650,000 m3 of fresh air per hour for heating periods of six months at a time. The centralised units are fitted with heat exchangers for the parameters 30/24°C and are operated with the recirculated water from the heat pumps.

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The Galeria Echo shopping centre, featuring a Hoval solution.

After the construction company Echo Investment’s previous positive experiences with the Hoval UltraGas® condensing boiler, it decided to equip the heating room with an Hoval UltraGas® (1440 D) twin boiler and an Hoval UltraGas® (720). Automatic operation of the boiler cascade is integrated into the Galeria Echo’s overall building management

Performance of Buildings Directive (EPBD), with the energy efficiency of Kielce’s shopping, entertainment and leisure centre meeting all the values that this directive stipulates. So you could say that this centre has hidden values – and these have been recognised by its “property Oscar” too.

Germany

Circus Krone renovates its heating system.

Roll up, roll up! Each winter, the Circus

Krone presents three different circus programs at its main site in Munich. Hoval has already performed its own feat, providing Europe’s largest circus with state-of-the-art technology.

The white-faced clown with the raised eyebrows sums it up: “Winter means one thing: it’s time for Krone!” If you’re looking for amazing sights, dreamlike events, laughter and breathtaking excitement during the colder months, there’s nowhere better than the Marsfeld area of Munich, which plays host to the Circus Krone over the winter.

The first Krone building opened there as early as 1919. During the Second World War it was razed to the ground by aircraft bombs three days before Christmas Eve 1944 – but just one year later, a new one had sprung up in its place. “Not so much a splendid building, more of a makeshift solution,” says the chronicle charting the history of Circus Krone, which begins with the birth of Carl Krone in 1870. On 23rd December 1962, the Sembach-Krone family inaugurated the third Krone building by welcoming 3000 guests.

Now the circus has a new chapter in its history book, at least as far as its technological accomplishments are concerned: working together with Hoval, the specialist guild organisation Heizung-Obermaier GmbH in Munich has renovated the Circus Krone heating system. The system is located in the basement of the second Krone building and presented the

specialists with a few fairly unusual challenges. Firstly, the system needs to heat an extensive building complex and supply it with hot water; secondly, the site is home to a whole combination of heating systems reflecting the use of energy down the ages.

As an initial stage, the two old cast iron boilers were replaced with two UltraGas® (300) condensing boilers. The heating load for the building was designed to be around 400 kW, with 200 kW calculated for heating drinking water. The old system prompted the decision to separate the system because of the mix of materials.

The first heating period using both UltraGas® boilers demonstrated this equipment’s high level of energy efficiency and noticeably reduced gas consumption. This meant that, in a second stage in spring 2012, it was possible to replace the old charging system for water heating with a highperformance Hoval Modul-plus F32 water heater. This product takes sudden power surges – just like the ones experienced in hotels and sports facilities – in its stride and supplies water with an impeccable level of hygiene. At the Circus Krone, the artists, workers and audience all need hot water – as do the elephants

and horses who enjoy most of the fresh water, measured precisely to the degree to accommodate their highly sensitive skin.

The Modul-plus has also made an impression through another advantage it offers to the Krone building: it only requires a very small installation area.

The UltraGas® condensing boiler is equally capable of fitting into a restricted space. However, the two boilers really come into their own with the cascade solution that they form together: after all, safety is always a top priority when it comes to heat supply solutions. And in case anything ever does go wrong, the SMS module that has been installed will inform Hoval customer service straight away.

Renovated heating system with Hoval UltraGas ® and Hoval Modul-plus F32.

Insights 01.2013 _ 17

Einblicke

Im the In Fokus market

Hoval focuses on expertise in training.

Top-quality products need a top-quality workforce.

Hoval has always stressed the importance of good training and in-depth technical

knowledge for its service team and customers alike. With this in mind, it has invested in a modern Training Centre at its headquarters in Vaduz, Liechtenstein, which aims to make practical training sessions even more accessible than before.

The Training Centre is used primarily for training Hoval employees – as well as partners and customers – in the specialist areas of heating and climate technology. Having direct access to the product during the process of learning and practising skills is a valuable way of supplementing the theoretical modules. Ten different stations provide a variety of training opportunities for Hoval heating technology products, thanks to the fact that the connection points provided can be fitted with different products in order to meet the many and varied requirements that training brings. By contrast, some products are permanently installed: these include a Hoval PowerBloc (CHP) unit, two heat pumps and two HomeVent® RS-500 systems.

A solar collector and a RoofVent® are continuously in operation on the roof, while additional units can be added as temporary measures to accommodate training requirements.

At the new Training Centre in Vaduz, future trainees will have the opportunity to learn about combined heat and power (CHP) units, district heating, gas and oil condensing technology, solid fuels, solar technology, heat pumps and climate technology.

the “train the trainer” principle, the product managers from head office teach those in charge at the national Hoval companies about specific product innovations.

These people then pass on their newly acquired knowledge to the Hoval service technicians. Alongside the set training modules, a more flexible, supply-and-demand approach ensures Hoval expertise remains dynamic and keeps its finger on the pulse.

Balance is key As with any learning exercise, it is important to offer the right amount of theory and practice in the right ratio. This allows even technically demanding content to be communicated accurately. The aim is that everyone who participates in a Hoval training session will take home in-depth knowledge, logical reasoning skills and a sense of confidence.

Hoval Training Centre: placing technology in the limelight!

Given that Hoval always prioritises an efficient approach that focuses on solutions, the heat produced by the units in the Training Centre is used for the underfloor heating in the cloakrooms and changing rooms, and to heat the water for the main building.

An international, versatile facility To say that Hoval is playing host to the world is no exaggeration.

A wide range of national Hoval companies, technical Hoval committees, partners from around the world, specialist guilds and guests are all welcome at the new Training Centre. The Centre also serves as a way of multiplying knowledge: following The Hoval PowerBloc CHP unit provides several areas of the Hoval building with heat and hot water.

18 _ Insights 01.2013

Im Fokus Am Markt

Welcome to Hoval’s Alpen Campus!

Hoval Italy’s search for a suitable space to house its own Training Centre at the Grassobbio site presented the company with a major challenge. The existing building was already being used to its full capacity, except for a very spacious entrance hall with a flight of steps up to the office areas. It wasn’t long, however, before the planners realised that it was in fact this very entrance hall that could provide the space they needed for the Centre. In line with Group communication, which aimed to emphasise and illustrate the Italian Training Centre’s strong Alpine roots and understanding of harsh climatic conditions, the Centre was christened the Alpen Campus. It provides three levels of training with the aim of creating “Alpinists”; that is, true experts.

1. Hillwalking – basic knowledge of subject-specific technology.

This consists of a half-day training session, including a small practical component.

Fact Box Size: 55 m2 Products: UltraGas® (15), Thermalia® (8), UltraOil® (16), BioLyt (23), AgroLyt ® (25), Belaria® R (8), TopGas® comfort (16), TopGas® combi (21/18), Belaria® SR (16), 2 collectors WK 251A on the roof, 1 Solex Mini, CombiSol S (1200/300), HomeVent ® RS-250;

2. Summit ascent – in-depth training on individual products and systems. This consists of a day-long training session and includes a detailed practical component.

3. Scaling the heights – workshop on complex topics. This consists of a one or two-day training session and includes an interactive practical component.

The Training Centre was completed on 23rd November 2012, with an official event held to mark its opening. The training sessions got under way in January 2013, and around 1200 people are expected to visit the new Training Centre in Grassobbio each year.

Buckingham Palace Garden to host Coronation Festival for Royal Warrant holders. five years to the Households of The Queen, The Duke of Edinburgh or The Prince of Wales. Warrants have always been regarded as hallmarks of quality, excellence and service.

Hoval Ltd was awarded its Royal Warrant in 1995 and its prestigious Royal appointment now sees Hoval join over 200 Royal Warrant Holders at this unique event.

By Appointment to Her Majesty the Queen Boiler Manufacturers & Engineers Hoval Limited, Newark

The Gardens at BUCKINGHAM PALACE will be the venue for a one-off event this summer for holders of Royal Warrants to celebrate the 60th anniversary of The Queen’s Coronation.

Hoval Ltd will be taking part in the four day celebration between the 11th and 14th July 2013.

The Coronation Festival will celebrate innovation, excellence and industry showcasing the broad range of fine brands, including Hoval, which have earned the recognition of a Royal Warrant over the years.

The Coronation Festival will be split into four specific showcase areas: Design and Technology; Food and Drink; Style Pursuits and Pastimes; Homes and Gardens. There will also be a section for The Queen Elizabeth Scholarship Trust (QEST), the charitable arm of the Royal Warrant Holders Association, which helps financially disadvantaged, experienced crafts people to further their skills through the funding of further education and training.

Hoval Ltd, as a proud Royal Warrant holder, is delighted to be part of The Coronation Festival this summer.

Go to hoval.co.uk to see the promotional festival film.

Royal Warrants are a mark of recognition to individuals or companies who have supplied goods or services for at least

Insights 01.2013 _ 19

In detail

At 4.23, the Belaria compact IR has the best COP in Europe ®

Hoval is staying true to its promise of continuing to

develop heat pump technology. The latest evidence for this is the Belaria ® compact IR air/water heat pump, with a coefficient of performance (COP) that’s the best in Europe in its performance class, and a design that could not be more compact.

Peter Gerner, heating technology CEO, made a big promise over a year ago: “We are going to take the development of the heat pump technology to the next level.”

It was a bold statement, but one with a solid foundation: at that time, Hoval had just set up its new test facilities for brine/ water and air/water heat pumps at its head-quarters in Vaduz. The test facilities are among the largest in Europe and, since they were built, have accelerated and strengthened development processes within the company.

Excellent test results “We have both improved and extended the heat pump range,” reports Martin Woerz, head of product management for heat pumps and storage tanks.

“The brand-new Belaria® compact IR, which we have added to our portfolio, achieved excellent results in the tests for the European Heat Pump Association (EHPA) certification – in fact, they were absolutely outstanding.”

20 _ Insights 01.2013

At an outside temperature of 2°C and a flow temperature of 35°C, it produces a coefficient of performance (COP) of 4.23. “No other compact air/water heat pump in Europe has achieved this value before now,” states Martin Woerz.

In summer 2013, the new Belaria® compact IR water/air heat pump will initially be put on the market in Liechtenstein, Switzerland, Austria and Italy, with other countries following afterwards. It will be available in three models with standard output levels of 7, 9 and 11 kW.

Sophisticated technology So where does this exceptionally good performance rating come from? Martin Woerz puts it in a nutshell: “The pump features a special evaporator, a nextgeneration fan as well as an electronic expansion valve. The cooling circuit works with the new R 410 A coolant, while the automatic heat pump machine, which is also new and acts as the actual brain of the system, harmonises the individual components to maximum effect.”

Thermalia® twin benefits too The Thermalia® twin brine/water and water/water heat pump is also reaping the benefits of Hoval’s surge forward in its development process, which led to the Belaria® compact air/water heat pump. Instead of a thermal expansion valve, it too now features an electronic one. This, coupled with the new R 410 A coolant, allows it to achieve an even higher COP. The series of models, which previously offered an output range of 20 to 35 kW, now reaches as much as 42 kW with the addition of the fourth model. The new Thermalia® twin 42, which is just as compact as its smaller siblings, replaces the previous Thermalia® dual 43. And that’s good news for the customer, as the change has an instant effect on the value for money the units offer.

Great performance in a small space The Belaria® compact IR clearly proves that superior performance and excellent energy efficiency do not need a great deal of space: in fact, the system only requires a single square metre, something which also makes installation easier. And it’s flexible too: the heating flow and return as well as the hose for the condensation process can be positioned on the right or left.

Energy buffer storage tank In this system, energy efficiency is the name of the game. To reduce the need for switching on and off (a process known as clocking), whilst also guaranteeing that the energy required for the defrosting process will always be available, the Belaria® compact IR has an energy buffer storage tank. To accommodate this, the Hoval developers designed a space-saving double base which also keeps noise emissions low.

Martin Woerz’s conclusion:

“The Belaria® compact IR is the perfect system for the prefabricated building industry, for example: it’s compact, reliable and has a COP which is currently unrivalled.”

And that’s one promise that Hoval has certainly delivered on.

Also improved: the popular split heat pump The Belaria® S has undergone some improvements and is now on the market as the Belaria® SRM. This heat pump is also available as the Belaria® compact SRM with an integrated water heater. Both systems are available with six different output ratings: 4, 6, 8, 11, 14 and 16 kW.

Low noise level Martin Woerz explains the latest generation of low-noise fans: “We chose to use a particularly quiet centrifugal fan. However, the automatic heat pump machine controls it in such a way that the noise emissions are already fairly low anyway.”

The latest generation of split heat pumps is equipped with a new control unit. The operating controls can be placed in the unit, on the wall or even in the living space. This makes operation considerably easier. The current consumption – one of a number of new functions – can be given a time limit, something which has a positive impact on both energy costs and the use of solar energy. The more precise regulation concept results in a higher heat output and an even higher COP.

4.23: The best COP in Europe as tested and certified by the Austrian Institute of Technology.

As a new feature, an extremely energy-efficient circulating pump has been integrated into the internal unit of the split units. The Belaria® compact SRM has a floor-standing internal unit with an integrated stainless steel water heating boiler, which holds 180 litres in the 4 kW model and 260 litres in all other models.

Insights 01.2013 _ 21

In detail

Control technology optimises operation.

District heating makes sense – both for your purse and the

environment. To ensure even more efficient use of energy and further boost cost effectiveness, intelligently designed control technology is required. With this in mind, Hoval has developed the TopTronic ® supervisor software.

All information at a glance: Martin Köb, head of control and regulation technology, demonstrates the user-friendly platform Hoval TopTronic ® supervisor.

A heating plant, a network of pipelines linking it to the connected installations and their transmission stations, a pumping station: yet there is more to a district heating system than that. It also requires efficient control technology.

“This is one of the most important tools the operator of the system has at his disposal,” says Martin Köb. He is responsible for the control and regulation technology and software product lines in Hoval’s heating technology division.

“We install our TopTronic ® supervisor control technology software on the master computer. It collects the data and prepares it for analysis to allow further optimisation of the system.” The control technology is the brain of the system, on which the master computer

22 _ Insights 01.2013

and the network depend in order to function efficiently.

The district heating network becomes visible Hoval TopTronic® supervisor control technology allows visualisation of the overall system with the heating plant, transmission stations and secondary systems.

What is the temperature of the heating water when it is fed into the connected installations? How warm is the return flow? Do these temperatures correspond to the setpoint values required for energyefficient operation? How much energy is consumed by the system per day, per week, per month, per year? Hoval TopTronic® supervisor control technology pro-

vides all this information - and then some.

“The heating engineer can immediately identify inaccurate settings – and potential for optimisation,” explains Wolfgang Leitner, head of control technology development at Hoval: If the “energy signal lamp” integrated in the schematic is green, this of course means that everything is OK. An orange or red signal lamp, on the other hand, indicates that adjustments need to be made. The heating plant and transmission stations can be accessed directly via the master computer.

Monitor the hydraulic system, too If desired, you can also connect a web cam in the heating plant with the Hoval TopTronic ® supervisor for live monitoring.

As an option, you can also display the entire hydraulic system of the heating plant, making further optimisations possible: The differential pressure is an important parameter for efficient operation of the network pumps.

Pinpoint problems immediately “As the operator of a district heating network is bound by contract to provide a specified output, it is naturally in his interest to be able to supply this output one hundred per cent and with the lowest possible expenditure of energy,” says Wolfgang Leitner. “And it follows that it is also in the interest of the operator to immediately identify and remedy problems, for example a leak in the heating plant. Hoval TopTronic ® supervisor allows him to do all this.”

Incorporate the control technology in the design…

To allow the Hoval control technology to communicate with and monitor all techni-cal components of the district heating network, the transmission stations must be equipped with the district heating controller Hoval TopTronic ® com. In addition, to allow encoded data transfer between Hoval TopTronic ® com and Hoval TopTronic ® supervisor, underground cables are laid at the same time as the district heating water pipes. These two preconditions can easily be met if the Hoval TopTronic ® supervisor control technology is factored into the district heating network right from the design phase. … and integrate it into the ERP system Ideally, the operator of the district heating network will also have an Enterprise

The district heating controller Hoval TopTronic com allows communication with the Hoval ® TopTronic supervisor control system. ®

Resource Planning system or for short: an ERP system, as this system can also be “hot-wired” to the Hoval control technology: The data gathered by the Hoval TopTronic ® supervisor software flow via the master computer into the ERP system, which then generates the monthly accounts for the connected heating consumers. Martin Köb sums it up:

And it goes without saying that the data can also be accessed via the Internet – without the installation of additional software such as Java or ActiveX. Thanks to Hoval TopTronic ® supervisor, operators of multiple district heating networks can even display all their networks on one and the same screen, compare their efficiency or cumulate all data. This is exactly the transparency required to cut operating costs and protect the environment at the same time.

“Our control technology doesn’t only make district heating networks more efficient and thus more profitable. It also simplifies and automates accounting, thus reducing personnel costs.”

ENERGIEZENTRALE ENERGIEZENTRALE

1 2

2

1: District heat station with Hoval TopTronic ® supervisor 2: control technology: Hoval TransTherm district heating transmission stations with Hoval TopTronic ® com

Insights 01.2013 _ 23

In detail

As leak-proof, compact and efficient as it gets.

In its new rotating heat exchanger,

Hoval has succeeded in reducing the system-related leakage normally found in such systems by up to 70%. Behind this achievement – and the superior efficiency levels that come with it – lies technological expertise.

It’s a very simple concept: a ventilation system is designed to bring fresh air into a building. But the more fresh air is lost during transport and the more the ventilation system draws in false air from the integrated rotating heat exchanger, the less fresh air is supplied to the building. Not only is the air recirculated by the ventilation unit of little use, it also uses up energy unnecessarily.

Now let’s look at another very simple concept: people using a building need fresh air. For this reason, new guidelines such as VDI 3803, Sheet 5, stipulate that a ventilation unit with a rotating heat exchanger has to increase in size according to the amount of leakage.

“Not only does recirculated air need more energy, it also increases the size of the ventilation unit and, therefore, the price,” states Remo Hotz, heat recovery product manager at Hoval. “This is why we made our rotating heat exchangers more leak-proof.” To the best of his knowledge, they are the most leak-proof products of this type available on the market right now.

The new rotating heat exchanger isn’t just beneficial in terms of its technology – its modern design is also a winner.

24 _ Insights 01.2013

Now with a peripheral slide seal The wheel seals used in conventional systems remain fixed even when the wheel is in motion. This is not the case for the seal on the Hoval rotating heat exchanger, however:

“We have mounted constant-force springs on the wheel casing,” explains Remo Hotz. “Because these springs are constantly adjusting themselves to the movement of the wheel, they continuously press the peripheral seal, which is made of wear-resistant polyethylene, against the casing.” This results in a sustainable leakage reduction of up to 70% compared with fixed systems.

It’s an exclusive Hoval innovation that has already been granted a patent.

Smaller and better value for money This innovation means that the size of the ventilation units can be kept to a minimum while still providing the same quantity of fresh air. In turn, this reduces production costs and, subsequently, operating costs too.

Calculating leakage According to Remo Hotz, this represents another exclusive Hoval innovation:

“We can calculate precise leakage values for the wheel and thus provide evidence of the quality of our sealing system.”

This is a key point in view of the VDI 3803, Sheet 5 specifications, which state that a value of 10% has to be assumed if no specific leakage figures are provided. The scope of VDI 3803 is likely to spread beyond Germany.

Flexible purge sector And Hoval has even produced a third exclusive innovation: the purge sector, which prevents extract air from getting into the supply air, can be adjusted and

The patented, self-adjusting slide seal in Hoval rotating heat exchangers reduces leakage by up to 70% compared with conventional systems.

optimised individually according to the pressure in the ventilation unit when the rotating heat exchanger is installed. The higher the pressure, the smaller the purge sector can and should be. This minimises energy loss from the purge sector and increases efficiency.

Infinitely adjustable drive The 3-phase gear motor with belt pulley and v-belt is installed on a rocker in the corner of the casing. The speed of rotation is infinitely adjustable.

Wheels with sorption technology Hoval is also a pioneer within the field of rotating heat exchangers with a sorption coating. Not only does this coating only allow heat to be transferred, but it also enables constant moisture transmission throughout the whole year.

In winter, this stops the building from drying out, whilst in summer, the air in the building remains pleasantly dry – even if the environment is humid with storms on the horizon.

has a huge impact on investment and operating costs, as the predried air reduces the required cooling capacity by a third. This means that the size of the cooling system can be reduced accordingly, without affecting its performance. The result is considerably lower investment costs and, as a result, energy costs.

Maximum efficiency The Hoval rotating heat exchangers can achieve heat recovery efficiency values of up to 90%. They are produced as one-piece rotating heat exchangers in sizes up to 2620 mm and as segmented heat exchangers in sizes up to 3800 mm. The heat exchangers are available in condensation, enthalpy and sorption wheel formats.

Particularly when combined with mechanical cooling devices, this effect

Insights 01.2013 _ 25

In detail

Cogenerate heat and power – and save money.

Generate power decentrally and use the

heat gains for heating and producing hot water: this is exactly what a combined heat and power unit does. In this way, it saves primary energy and at the same time reduces CO2 emissions. Hoval’s PowerBloc and other tried and tested components offer made-to-measure overall solutions.

He knows every detail of the functions and advantages of combined heat and power (CHP) units. Urs Westreicher is the head of product management for district heating / CHP units, and he has made the calculations: “By utilising the heat gains from power generation, the primary energy is used with a total efficiency of 90% and more. In comparison, a conventional combination comprising a local heating system and a central power station has an efficiency of only 30 to 50%. Thus, decentralised combined heat and power units can mean savings of 40% and more on primary energy.”

For residential homes, private households and industry Combined heat and power units are ideal for use in indoor swimming pools, hospitals, nursing homes and hotels which require power and energy the whole year through as well as for industrial buildings using process heat.

Multi-family houses are equally ideal for cogeneration, and residential buildings can be connected within a local or district heating network.

Otto engine, a power generator, heat exchangers for the recovery of thermal energy, electrical switching and control devices for power distribution and hydraulic equipment for heat distribution.

Attractive individual solutions Hoval offers made-to-measure overall solutions for a combined heat and power unit and local or district heating networks. For example, the Hoval PowerBloc CHP unit has an electrical output of 43 to 404 kW as a natural gas module and an electrical output of 46 to 365 kW as a biogas or sewage gas module. Parallel operation of several modules is also possible. Ideally, a Hoval UltraGas® condensing boiler is connected in series to cover peak loads.

Urs Westreicher also has a few tips on how to save money with combined heat and power generation:

How a CHP unit works Urs Westreicher takes a look inside a combined heat and power unit: “A combustion engine, for example a motor or gas turbine, drives a generator.

The generator supplies the connected households or companies with electricity.

The heat gains from the engine block are transferred to cooling water or oil and used to heat heating water via a heat exchanger. The energy in the exhaust gas can be used to generate process heat or to heat domestic hot water via the heat exchanger.”

A Hoval CHP unit comprises the following main components: a gas The Hoval PowerBloc with an electrical output of 43 - 404 kW and a thermal output of 65 - 520 kW.

26 _ Insights 01.2013

“The higher and more constant the heat requirement, the longer the combined heat and power unit will be in operation over the year. And the longer the CHP unit is in operation, the lower the electricity generation costs. A high number of annual operating hours and thus high profitability are achieved where the system output is low in relation to the required heat output.”

The expert adds: “The larger the plant, the lower the investment costs and the overall life cycle costs.” And Hoval always offers an overall solution which is tailored to customer requirements and both economically and ecologically attractive.

Im retrospect In RĂźckblick Fokus

Design drawing from 1942.

Despite being in the middle of an economic crisis, the young head of operations Gustav Ospelt, together with his brother, succeeded in expanding the business under the most difficult financial circumstances. Money from the bank was scarce.

18 Teams folgten beim Markenerlebnistag in Vaduz den Spuren der Marke - Hoval das sind wir!

Länderhead

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Einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung einleitung Gustav Ospelt gave his idea of building his own central heating cooker time to develop. Together with his loyal employee Albert Sprenger, he developed and tested the idea, often working well into the night. But in 1938, the project came to fruition: the first self-built central heating cooker worked successfully and, as a result, paved the way to the future.

The war dawned shortly afterwards. The workforce had grown to twenty men and huge efforts were required in order to find room for them all to work. Materials had become scarce and people had to fight to get their hands on what they needed. The only way to survive was to make products

which conserved iron â&#x20AC;&#x201C; and this meant switching to new products. Wood gas generators and charcoal gasifiers were supplied to Swiss automotive firms, because people still needed to drive their cars despite the fact that petrol had become the most scarce of all goods.

Ever the optimist, Gustav Ospelt was focused on the future: for him, it was all about developing his central heating cooker.

And so he started building, measuring levels of efficiency and making every possible preparation for launching an excellent, state-of-the-art product on the market at the earliest opportunity.

Not, however, until normality had been restored.

Insights 01.2013 _ 27

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