Automated monitoring
Automatic monitoring and visualisation of important operating parameters of a hot water boiler system allows faults to be detected more quickly and optimisation potential to be identified more easily.
For example, the following values can be monitored and evaluated:
- Flue gas temperature
- Flow and return flow temperature
- Heat quantities and fuel consumption
- Operation and speed of the circulation pumps
- Burner load, burner starts and pre-purging, CO and O2 values in flue gas
- Water values
Condition monitoring
During operation, appropriate operational monitoring and maintenance should be carried out in order to achieve optimum annual efficiency of the hot water boiler system. In this case, it is important to monitor and compare the respective parameters of a boiler system over a longer period of time in order to be able to react appropriately in the event of a deterioration in operating conditions or an operational change in boiler operation.
The monitoring and analysis of energy production and consumption is required in many companies as part of the overall energy management system and represents a potential for fuel or electricity savings that should not be underestimated, as savings can often be achieved without additional investment costs, simply by adjusting the operating data.
Information about boiler control
This task can be partially performed by automated condition monitoring. The following operating data is recorded and evaluated:
- Display of operating hours, start frequency, number of cold starts over time
- Detection of unfavourable start-up conditions
- Detection of soiling on the water and flue gas side or unwanted condensation
- Generation of maintenance messages as required
- Display of fuel and water consumption over time
- Representation of the heat quantity over time
- Display of the boiler load profile over time
The system data is analysed and evaluated by the software and displayed to operating personnel using a traffic light model: Green means everything is OK. Orange and red indicate an increasing deviation in the boiler’s operating mode or inefficient operation. This means that operating modes that result in inefficiency, increased wear or unplanned downtimes can be identified and avoided in good time.
The high level of data transparency also facilitates optimal boiler operation in terms of energy efficiency. Potential optimisation opportunities are identified and presented by determining and displaying meaningful system data, such as the boiler load profile or the number of burner cycles.
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Condition monitoring of the BCO boiler control system