Boiler & Steam Monitoring

The problem

Boiler efficiency, steam flow and condensate return are recorded by hand in the boiler house, so fuel waste and steam losses stay hidden between inspections.

Solution overview

MILESGO gateways collect data from boiler and burner controllers, steam flow meters, gas meters, pressure transmitters, PT100 / PT1000 temperature probes over Modbus RTU / Modbus TCP / HART, and deliver it to SCADA, the energy management system, SMS, email and messaging alarms as OPC UA / MQTT / BACnet/IP. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

boiler and burner controllers
steam flow meters
gas meters
pressure transmitters
PT100 / PT1000 temperature probes

Protocol path

Modbus RTU / Modbus TCP / HART → OPC UA / MQTT / BACnet/IP

Implementation checklist for the project manager

Fire and life-safety systems are monitored read-only; control stays with the certified fire system.
Commission in read-only mode first; enable write / control points only after the client approves each one.
Collect register maps and protocol documents from every equipment vendor early; a missing map is the most common delay.
HART instruments are read through the HART converter; list device addresses and variables for each loop.
For hard-wired signals, list each DI/DO/AI/AO with its type (dry contact, 4–20 mA, 0–10 V, PT1000) and choose I/O modules accordingly.
Define an alarm matrix (priority, recipient, escalation) and test every alarm end to end at SAT.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

System architecture

Field layer: boiler and burner controllers, steam flow meters, gas meters, pressure transmitters, PT100 / PT1000 temperature probes, connected over Modbus RTU / Modbus TCP / HART. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: SCADA, the energy management system, SMS, email and messaging alarms, which receives the data as OPC UA / MQTT / BACnet/IP. Remote access for maintenance runs over VPN rather than open internet ports.

System composition

Field devices: boiler and burner controllers, steam flow meters, gas meters, pressure transmitters, PT100 / PT1000 temperature probes
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: SCADA, the energy management system, SMS, email and messaging alarms (OPC UA / MQTT / BACnet/IP)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Software and AI capabilities

Consumption baseline and deviation alertsRoadmap
Anomaly detection on trend dataRoadmap

Delivery steps

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Customer value

Consumption visible by area, system and time period
Abnormal conditions seen early, before they become failures
Reliable trend data for optimisation and fault diagnosis
Monitoring added without changing existing control programs

Tell us about your project

Send the protocols, point count and target system. A sales and engineering pair reviews every submission.

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