Optimizing Boiler Performance with Data Driven Insights
Food processor and manufacturer improve boiler performance with a new digital tool
BOILER JOURNEY: Cleaver-Brooks is pursuing strategic acquisitions under Miuira's ownership. (Staff photo)
Advanced digital solutions such as myBoilerRoom are improving operations, enabling facilities to optimize efficiency, enhance reliability, and achieve substantial cost savings. By leveraging a data-driven approach to asset management, myBoilerRoom empowers facilities to manage their boiler operations with precision and efficiency.
Prometha, an intelligent monitoring system, harnesses real-time data to detect issues before they escalate into costly problems or unplanned shutdowns (see Figure 1).
With continuous performance tracking, Prometha enables informed decision-making, ensuring optimal boiler operation while maximizing uptime and reliability.
More than a data visualization tool, Prometha translates complex data into actionable insights, guiding facilities toward improved efficiency and reliability. Its Boiler Score Insight provides a clear, real-time snapshot of boiler performance.
Facilities benefit from continuous tracking through standard snapshot reports highlighting boiler performance metrics, with options for custom reports tailored to specific operational needs.
Figure 1: Example of data tracking from Prometha. (All images courtesy of Cleaver-Brooks)
Remote Expertise Enables Swift Recovery
One weekend, the primary boiler in an Arkansas manufacturing facility failed, alerting the facility manager (Figure 2). The secondary boiler was offline due to an erratic water level. Since a technician couldn't arrive immediately, the Prometha team worked remotely with the local representative and on-site operators to diagnose the problem.
They found that a low O2 level had caused the shutdown. Investigation revealed a failed O2 sensor. On the secondary boiler, recent maintenance on the water level transmitter's leaky fitting had left the boiler water level erratic, fluctuating between minus 2 and plus 5 inches.
After replacing the O2 sensor, the primary boiler resumed operation. Venting the airlines cleared trapped air in the secondary boiler, normalizing its water level. Having production running Saturday night instead of Monday morning saved an estimated $300,000 in lost production costs.
Data Insights Improve Weekend Operations
A large Ohio food processor sought ways to improve boiler system efficiency. Prometha data revealed excessive cooling during weekend shutdowns.
Graphs showed steam pressure between 78-88 psi and shell temperature ranging from 314 to 318 degrees Fahrenheit. Data revealed the boiler typically remained off for 11 minutes, 30 seconds before going to low fire for 3 minutes, 55 seconds — about five cycles per hour during weekends.
The solution: reconfigure boiler control to provide night setback or hot standby for short-term layup, keeping boilers warm and production-ready for Monday morning.
Implementing hot standby mode on Friday evenings significantly reduced boiler cycling, improving system efficiency and reliability. This change projects to save about $9,200 in annual operating costs.
Figure 2: Receipt of a system alert on mobile phone.
Addressing Issues Upstream of the Boiler
Prometha's insights extend beyond the boiler itself, identifying issues in upstream systems that affect performance. Through Prometha data, a North Carolina manufacturing facility discovered feedwater temperatures frequently dropped below design criteria several times daily.
Low feedwater temperature from the deaerator causes parasitic loss of steam output and increases fuel usage. The issue can also lead to oxygen contamination and corrosion, causing tube and tube sheet deterioration and leakage.
A technician identified and corrected the root cause, reducing fuel consumption and the facility's carbon footprint.
Similar success stories include:
- A Nova Scotia food processing plant saved more than $10,000 annually by optimizing oxygen trim settings
- An Arkansas manufacturing facility identified inadequate gas pressure, preventing excessive fuel use of 100-150 MMBtu per week
- A Georgia chemical plant standardized its boiler blowdown procedures, enhancing safety and consistency
As these facilities discovered, Prometha integrates with building management and other data collection systems. With purpose-built tools, facilities can more effectively manage their boiler equipment's entire lifecycle.
Digital Solutions Drive Results
Implementing advanced digital solutions enables facilities to move beyond traditional boiler management and embrace data-driven, intelligent operations (see Figure 3).
These solutions enhance efficiency and reliability while delivering significant cost savings and sustainability benefits.
Cleaver-Brooks offers the tools and expertise needed to simplify a boiler room's digital transformation. To receive a complimentary Boiler Plant Optimization (BPO) evaluation, learn more about Prometha, or request a demo, visit cleaverbrooks.com/myboilerroom or email info@myboilerroom.com.
Figure 3: Digital solutions harness real-time data to detect issues early.
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