Cloud-based Maintenance for Steam Generators

For its electrical EMX steam generators, Certuss uses Turck's TX series HMI controllers – including condition monitoring and remote maintenance via Turck Cloud Solutions

Steam generators made by Certuss GmbH & Co. KG supply customers worldwide with process heat and process steam in over 100 sectors. Certuss relies on Turck automation technology for the development of its compact and modular EMX series – from pressure transmitters to BL20 I/O systems and TX series HMI controllers, right through to the cloud connection for remote maintenance using Turck Cloud Solutions. Turck's extensive consulting support, service, development service and, not least, the functionality of its products as well as the scope of its portfolio have impressed the company.

  • The measured data provided by the pressure transmitters is routed to the BL20 I/O system

  • “As a manufacturer with limited resources, we rely on partners who can offer us a complete package.''

  • Turck provided the required sensors, I/O system, HMI and edge controlers with integrated cloud connection

  • Turck upgraded the TX705 HMI to provide the exact Certuss GUI and user experience

  • If more steam is needed, the EMX steam generators can be expanded with additional modules

  • The compact PT pressure sensors accurately measure the pressure in the system

Electrically driven steam generators increasingly more important

The highly compact steam generators of Certuss were for a long time mainly driven with gas and oil. However, Certuss and its customers have recently been increasingly using electrically driven steam generators, which can also operate more sustainably. “For the customer, the supply of steam must be as convenient and reliable as the supply of electricity from a power outlet,” explains Thomas Hamacher, managing partner and technical manager at Certuss.. “Ideally, the customer is hardly aware of the location or function of the steam generator.”

Modularity, space saving and remote monitoring

The electric steam boilers of the EMX series can be expanded in modules. Thanks to their upright design, they can be combined into space saving assemblies. The main module can be expanded with additional units if the requirements increase. Certuss has also equipped the systems with an online connection for monitoring system status remotely. 

Sensors, I/O technology, visualization and cloud connection from a single source

When the EMX series was developed, Turck was able to support Certuss with an integrated solution, from the sensors to the I/O technology, controller with visualization, right through to the cloud connection. The compact Turck PT pressure transmitters precisely measure the pressure in the system and send the values to the modular BL20 I/O system and from there on to the TX700 edge controller. This monitors and controls the input and output signals as well as the connection to the cloud. The TX705-HMI is then used as the operator panel and visualizes the processes. “As a niche manufacturer with limited resources, we rely on partners who can offer us a complete package. This is what we have with Turck,” says Hamacher. “Turck has proved to be a reliable partner who supplies us both with the required switching devices and components as well as enabling an integrated cloud connection.”

Cloud connection: proactive operation and continuous optimization

The cloud connectivity provides Certuss customers with important functions. As the data is transferred from the EMX steam generator in real time, the plant can report service issues to the Certuss maintenance personnel directly. Certuss can view all sensor values and follow how the plant is operating, even over long periods – providing that the customer has allowed access. This enables the manufacturer to operate proactively instead of only responding to inquiries. The integrated status monitoring regularly checks whether threshold values are exceeded. This enables the maintenance personnel to detect immediately if something is not working properly and respond immediately – thus reducing downtimes to virtually zero. 

Higher pressures and greater availability

The EMX steam generator offers users a critical added value: they generate steam at a pressure of up to 16 bar. This was previously only possible with steam generators driven by fossil fuel. However, these will increasingly be replaced since Certuss customers are endeavoring to minimize their CO2 footprint. “We also intend to build steam generators that run on hydrogen with the latest control technology. We firmly intend a close collaboration with Turck in this project”, Hamacher adds.

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