Systems, devices, and methods for a boiler health and carbon-footprint monitor tool

A method for monitoring a boiler health and carbon footprint, comprising:

• collecting operational data from a boiler system via a sensor system including temperature gauges, flow meters, and pressure sensors;
• generating a first indicator in response to a detection of fuel wastage of the boiler system based on analyzing variations in air-to-fuel ratios from the operational data, and in response to the detection of the fuel wastage, determining a cause of the fuel wastage and generating a notification including the cause of the fuel wastage and operational recommendations for correcting the fuel wastage;
• generating a second indicator for monitoring a carbon footprint of the boiler system based on the operational data using an actual fuel composition and a real-time firing rate to provide real-time environmental impact monitoring;
• generating a third indicator for monitoring tube-to-drum joints of the boiler system based on thermal cycle analysis of the operational data, and in response to generating the third indicator, determining an operational condition for the tube-to-drum joints by analyzing thermal cycle data and generating a notification including the operational conditions and operational recommendations for maintaining tube-to-drum joint integrity;
• generating a fourth indicator for monitoring tube overheating of the boiler system based on analyzing rate of change data from the operational data, and in response to generating the fourth indicator, determining an operational condition for one or more tubes of the boiler system and generating a notification including the operational conditions and operational recommendations for preventing tube overheating;
• and
• generating a fifth indicator for predicting flame disturbance of the boiler system based on the operational data including a fuel composition and burner data, and in response to generating the fifth indicator, calculating Wobbe indices for a new fuel composition and a current fuel composition, determining whether a difference between the Wobbe index for the new fuel composition and a lower heating value for the current fuel composition is within a specified range, and generating operational recommendations based on the determination for maintaining flame stability.

A non-transitory computer-readable medium storing computer-executable instructions, which, when executed by a processor operatively coupled to a sensor system configured to collect operational data from a boiler system, cause the processor to:

• generate a first indicator in response to a detection of fuel wastage of the boiler system based on a first comparison of the operational data, and determine a cause of the fuel wastage and generate a notification including the cause of the fuel wastage;
• generate a second indicator for monitoring a carbon footprint of the boiler system based on the operational data using an actual fuel composition and a real-time firing rate;
• generate a third indicator for monitoring tube-to-drum joints of the boiler system based on a second comparison of the operational data, and determine an operational condition for the tube-to-drum joints and generate a notification including the operational conditions;
• generate a fourth indicator for monitoring tube overheating of the boiler system based on a third comparison of the operational data, and determine an operational condition for one or more tubes of the boiler system and generate a notification including the operational conditions;
• and
• generate a fifth indicator for predicting flame disturbance of the boiler system based on the operational data including a fuel composition and burner data, and calculate Wobbe indices for a new fuel composition and a current fuel composition, determine whether a difference between the Wobbe index for the new fuel composition and a lower heating value for the current fuel composition is within a specified range, and generate a recommendation based on the determination.