Boiler Monitoring Systems – Sootblower Fouling Detection (SFD)

What are the benefits of boiler monitoring and analysis? 

Integrated Test & Measurement (ITM)’s boiler monitoring products provide a range of benefits to help improve the efficiency and reliability of boilers.

Contact our experts to learn more about our boiler monitoring solutions.

Some of the benefits of ITM’s boiler monitoring products include:  

Early detection of issues: ITM’s boiler monitoring products use advanced sensors and data analysis techniques to monitor the performance of boilers. This allows for early detection of issues such as fouling, corrosion or other problems.  

Increased efficiency: By detecting issues early, ITM’s boiler monitoring products can help to increase the efficiency and reliability of boilers. This allows operators to take action before problems become severe.  

Reduced downtime: By detecting issues early, ITM’s boiler products can help reduce downtime caused by boiler failure or maintenance. The costs of boiler downtime can vary depending on a number of factors, including the cause of the downtime, the length of the downtime, and the size and type of the boiler. However, some common costs associated with boiler downtime. 

If a boiler is down, it may not be able to produce the steam or heat needed for a facility’s operations, leading to lost production or revenue. This can be particularly costly for facilities that operate around the clock or have high demand for steam or heat. 

The cost of repairs or replacement will depend on the nature and extent of the problem, but it can be substantial. Maintenance or repair crews may need to work on a piece of equipment overtime to get the boiler back online. 

A facility may also need to rely on backup systems or outside sources of heat or steam, which can be more expensive than using the boiler. If a facility can’t provide service due to a boiler breakdown, it may lose customers or its reputation may be damaged. 

Predictive maintenance: ITM’s products can provide data that enables operators to schedule maintenance. Advantages include avoiding unnecessary maintenance and reducing costs and downtime. This can allow them to schedule maintenance and repairs before a problem becomes serious. 

Improved safety: ITM’s boiler monitoring products can help to improve safety by reducing the risk of boiler failure. This also reduces the potential for fires or explosions caused by issues such as fouling or corrosion. Boiler monitoring products are designed to ensure safety by constantly monitoring the various parameters and conditions of the boiler and its associated systems. These products typically include sensors, controllers and alarms that can detect and respond to potential problems before they become serious. 

Better data analysis: ITM’s boiler monitoring products provide detailed data on the status of boilers, allowing operators to analyze the data and identify trends. This can help optimize the performance of boilers over time.  

By analyzing data from boiler monitoring systems, engineers can identify issues in the boiler’s performance, such as high fuel consumption or low steam production. These issues can then be addressed to improve the efficiency of the boiler and reduce energy costs. 

Remote monitoring: Some of ITM’s boiler monitoring products can provide remote monitoring capabilities. This enables operators to monitor boilers from a remote location, improving management and maintenance. Today, boiler remote monitoring systems are an essential tool for maintaining the safety and efficiency of boilers. 

With the advent of the internet and IoT technology, remote monitoring systems have become even more advanced, allowing real-time data to be accessed and analyzed from anywhere in the world through a web-based interface. This has made it possible for engineers to remotely monitor the performance and safety of boilers, regardless of their location. 

Overall, ITM’s boiler monitoring products provide a range of benefits to help improve the efficiency and reliability of boilers. This provides advanced monitoring and analysis of boiler performance and enables operators to take proactive steps to improve the efficiency and reliability of their boilers, reducing downtime and maintenance costs.  

ITM’s Industrial Monitoring Systems 

The Sootblower Fouling Detection (SFD) System is an ITM proprietary technology for measuring soot buildup along the path of a sootblower in recovery and utility boilers. Use this system to identify problematic areas and optimize sootblowing. 

ITM’s Fouling Monitoring System (FMS) is a boiler optimization and preventative maintenance tool that continually monitors levels of ash/soot/slag buildup on platens/tubes of instrumented recovery and power boilers. 

The Clinker Detection (CDS) System is an ITM proprietary technology for measuring both the size and frequency of deposits that impact a utility boiler floor or bed. This technology enables operations personnel to shorten boiler outages, identify fouling problems and optimize soot blower operations. 

The Hopper Ash Level Thermocouple (HALT) System is a preventative maintenance and safety tool that continually monitors the levels of ash within a hopper. As the hopper plugs and the ash levels increase, the thermocouples will become insulated from the boiler heat by the ash.  Low temperature readings trigger visual and digital alarms which indicate that the hopper has plugged. 

The Boiler Thermocouple Monitoring System is used to acquire and archive data from thermocouples mounted on boiler tubes.  Since this system interfaces directly with Allen Bradley Control Logix PLCs via EthernetIP communication, significant cost savings can be achieved by using it as remote IO. 

Since 2001 ITM has installed structural strain based monitoring systems in the pulp & paper and energy generation industries. For these systems, our engineers and field service technicians turn structures into measurement instruments (load cells). Load outputs from the structural load cells are monitored and published by a realtime controller to its local interface or network historians and HMIs. 

Our team of experts specialize in predictive maintenance programs, data analytics, internet of things iot, analysis method, preventative maintenance, raw data, planned downtime, equipment failure, data sets, condition monitoring, manufacturing process, vibration analysis, statistical analysis, quantitative data, real time, early issues and much more. 

Contact us for more information about our boiler monitoring solutions, strain gauge, testing and data acquisition services.