Temperature Monitoring
Monitor boiler water, steam, and flue gas temperatures.
Detect overheating, scaling, or poor heat transfer.
Track temperature differential between inlet and outlet lines.
Verify proper combustion and heat exchanger performance.
Optimize firing rate and load control for efficiency.
Pressure Monitoring
Monitor steam drum, feedwater, and fuel line pressures.
Detect overpressure or under pressure conditions.
Identify leaks, blockages, or pump malfunctions.
Ensure safety valve operation and compliance.
Provide real-time alerts for abnormal pressure fluctuations.
Water Level Monitoring
Measure boiler drum or tank water levels continuously.
Prevent low-water conditions that can cause dry firing.
Detect overflow conditions or feedwater control issues.
Enable automatic makeup water control.
Support predictive maintenance by analyzing fill trends.
Fuel Flow & Combustion Monitoring
Monitor natural gas, diesel, or other fuel consumption rates.
Measure combustion air/fuel ratio for efficiency.
Detect incomplete combustion through oxygen or CO levels.
Verify burner ignition and flame stability.
Optimize firing controls to reduce fuel waste and emissions.
Feedwater Flow & Quality Monitoring
Track feedwater flow rate and temperature.
Measure water conductivity to detect impurities or scaling risk.
Monitor pH balance to prevent corrosion or deposit buildup.
Identify malfunction in feedwater pumps or control valves.
Support automatic water treatment and conditioning systems.
Steam Flow Monitoring
Measure total steam production rate.
Detect leaks or inefficiencies in the steam distribution system.
Monitor load variations for energy management.
Calculate system efficiency (energy in vs. steam output).
Support cost tracking and performance benchmarking.
Flue Gas & Exhaust Monitoring
Measure exhaust gas composition for combustion efficiency.
Detect incomplete combustion or burner issues.
Track emissions for regulatory compliance.
Optimize burner tuning and air-to-fuel ratio.
Identify fouling or clogging in heat exchangers or economizers.
Vibration & Motor Monitoring
Monitor boiler feedwater and circulation pump motors.
Detect imbalance, bearing wear, or motor overloads.
Identify blower and fan mechanical issues early.
Support predictive maintenance scheduling.
Reduce downtime by catching mechanical problems before failure.
Electrical Monitoring
Measure power consumption of pumps, blowers, and control panels.
Detect abnormal current draw indicating equipment wear.
Track total system energy use for cost management.
Identify inefficient operation or power phase imbalance.
Provide energy efficiency insights in real time.
Safety & Alarm Monitoring
Monitor safety interlocks and shutdown systems.
Detect flame failure or unsafe combustion conditions.
Provide alerts for pressure or temperature limits exceeded.
Track system trips and fault histories for diagnostics.
Enhance compliance with industrial safety standards.
Water Treatment & Chemical Monitoring
Monitor feedwater and condensate chemical balance.
Detect contamination or hardness buildup.
Track corrosion inhibitor and treatment chemical levels.
Automate chemical dosing for consistent water quality.
Prevent costly scaling and corrosion inside the boiler.
Ambient & Environmental Monitoring
Detect leaks of natural gas or fuel oil around the boiler room.
Monitor ambient temperature and humidity to prevent condensation.
Track air quality and emissions around the boiler area.
Provide safety data for operators and maintenance staff.
Support ventilation and exhaust control systems.
System Performance & Analytics
Calculate boiler efficiency (fuel input vs. steam output).
Track operating hours and maintenance intervals.
Identify performance degradation trends.
Predict failure points using temperature, pressure, and vibration data.
Generate performance and energy reports through our dashboard.