How to advance your boiler control system? (Energy Efficiency Tip of the Day)

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Tip summary

  • Mainly there are three areas to improve control in boilers. Steam side, water side and firing side.
  • For the burners, an alternative to complex linkage designs, modern burners are increasingly using servomotors with parallel positioning to independently control the quantities of fuel and air delivered to the burner head.
  • Controls without linkages allow for easy tune-ups and minor adjustments, while eliminating hysteresis, or lack of retraceability, and provide accurate point-to-point control.
  • These controls provide consistent performance and repeatability as the burner adjusts to different firing rates. Variable frequency drives (VFDs) can also be used to more accurately control the air supply.
  • Other technologies included in combustion controls are metered control, cross limited control and oxygen and carbon monoxide trim controls.
  • From the water side steam drum water level control and automatic blow down based on conductivity is the two opportunities.
  • Advanced boiler controls are generally one of the first energy-efficiency measures a facility will implement to improve boiler energy efficiency.

Proposed actions

  • Review your current control system
  • Determine the areas to implement advanced process control (APC) and the expected savings.
  • Evaluate the economics of the required changes.



  • System retrofit will have low to medium cost but quick ROI.



  • Estimated energy savings range: 3% of boiler energy use.



  • Advanced boiler controls: savings of 3% of boiler energy use.
  • Please share this tip with others to share knowledge and increase energy efficiency awareness.
  • Please contact me for any advice or support about this issue or other energy management issues.

Tip video


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#Energy #energyefficiency #energymanagement #steam #steamsystem #sustainable #sustainability #engineering #engineer #chemicalengineering #dearator #360practiveengineer #controlsystem


Magdy Aly

Energy manager, Energy efficiency consultant Passionate to help others to save Energy and Environment.

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