Boiler & Steam Monitoring
Bài toán
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.
Tổng quan giải pháp
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
Kiến trúc hệ thống
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.
Thành phần hệ thống
- 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
Năng lực phần mềm và AI
- Consumption baseline and deviation alertsTrong lộ trình
- Anomaly detection on trend dataTrong lộ trình
Các bước triển khai
- 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.
Giá trị cho khách hàng
- 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
Các giải pháp khác trong Industrial & Manufacturing
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