Automatic monitoring
Faults can be found more quickly and potential for optimisation more easily identified by monitoring and visualising important operating parameters of a steam boiler system.
The following values can be monitored and evaluated, for example:
- Flue gas temperature
- Average operating pressure
- Level, pump starts, pump run time
- Burner load, burner starts and pre-ventilation, O2 value in flue gas
- Conductivity and blowdown rate
- Water values
Continuous water analysis
The following savings in the area of water treatment can be made through continuous water analysis:
- Energy (minimisation of exhaust vapour losses)
- Use of chemicals (requirements-based dosing)
Condition Monitoring
Optimum annual degree of utilisation of the steam boiler system during continuous operation should be captured through appropriate status monitoring and maintenance. To do so it is important to observe and compare the various parameters of a boiler system over a longer period in order to be able to respond appropriately to any deterioration in operating conditions or changes to the mode of operation of the boiler for operational reasons.
In many firms, monitoring and analysis of the energy generated and consumed is a requirement as part of their overall energy management strategy because the potential for fuel or electricity savings is not insignificant and can often be achieved with no additional investment costs simply by adapting the operating data to the actual situation.
This task can partially be undertaken 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 service reports according to requirements
- Display of energy losses as a result of bottom blowdown and surface blowdown
- Display of fuel and water consumption over time
- Display of steam removal rate over time
- Display of boiler load profile over time
The software analyses and evaluates the system data, then displays the results to operating personnel according to a traffic light system: green means everything OK. Orange and red indicate that the boiler is increasingly not running as it should be or is not running economically. As a result, modes of operation that lead to inefficiency, increased wear or unplanned downtimes are identified on time and avoided.
The high data transparency also makes it easier to energetically optimise boiler operation. Any scope for improvement is identified by acquiring and displaying meaningful system data, such as the boiler load profile, number of burning switching operations or heat losses resulting from surface blowdown and bottom blowdown.
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Condition Monitoring of the Boiler Control BCO
MEC Optimize
MEC Optimize, the digital efficiency assistant, is a further development of Condition Monitoring. It is integrated into the boiler control and records all data of the steam boiler, water treatment, heat recovery equipment and other connected system components.
The operating data is stored locally over the years and evaluated using trend analyses. If the fuel consumption increases for example due to excessive blowdown rates or contamination in the boiler, the efficiency assistant detects this and provides information on the possible causes. In defined cases, messages can also be sent directly via the MEC Remote remote maintenance system to the mobile phone of the operator.