Technical monitoring is all about tracking performance and optimizing the operations of process engineering systems such as P2X electrolysis and end-to-end P2X systems. All relevant measured variables within the process and at the external and internal boundaries – for example, those separating individual plant components – have to be captured, processed and assessed to this end.
This inceptive task at the beginning of each monitoring process is to develop a monitoring concept tailored to the given plant, regardless of which of the measured variables are to be tracked. This requires a detailed analysis of the plant and includes a definition of the process and plant that describes the target figures. This definition provides the blueprint for determining the appropriate measuring points and, if necessary, selecting additional measuring equipment. In the best case, this concept will have already been created at an early turn during the plant’s initial design. The next step is to install the monitoring system. This includes deploying sensors, data acquisition devices, local memory such as a database server to store readings, and automated, computer-assisted tools to further process captured data.
Once the monitoring system is in place it is brought online to assess measured data and develop an automated report tailored to the plant and purpose. This report that may provide a general, integral overview or track the measured parameters in greater detail over time, as the situation may require.
Drawing our conclusions from this data analysis, we can then develop recommendations to improve plant operations and pinpoint possibilities for optimizing processes. Technical monitoring can also provide the underpinning for DIN EN ISO 50001-compliant plant energy management systems (EMS) – for example, for energy-intensive companies to obtain a partial exemption from the EEG levy.
ZSW has comprehensive interdisciplinary know-how all along the technical monitoring process chain and across various performance classes from decentralized energy systems such as combined heat and power generation in household energy supply systems to centrally installed energy systems in the industrial megawatt performance range. With this expertise, we are able to help partners and customers develop concepts, and implement and optimize systems. Our references include technical monitoring for Audi AG’s 6-MW power-to-gas plant at Werlte (WOMBAT), technical monitoring for Energiedienst AG’s 1-MW hydrogen production plant at Grenzach-Wyhlen (PtG-BW), and scientific monitoring for Callux, a lighthouse project aimed to ramp up fuel-cell heating appliances for market launch.
As part of our services, we:
• Develop monitoring concepts and engage in detailed engineering
• Install the monitoring system (which includes supervising sensors’ deployment)
• Support the active monitoring phase by
o Acquiring and processing measured data
o Developing tailored and automated reports
o Extrapolating proposals for optimizing processes