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Boiler Houses

Reducing Energy Costs with Online Water Quality Monitoring

Enhance Energy Efficiency: Elevate your boilers performance through online water quality monitoring. Recent research demonstrates that optimizing parameters like total water hardness, in addition to conductivity via online monitoring can lead to substantial annual savings in energy and downtime expenses. Additionally, this practice extends boiler lifespan, translating to significant capital equipment and investment savings.

What are the effects of scaling?


Even in small amounts, lime scale reduces heat transmission, causing an immediate drop in heating capacity—a significant contributor to increase energy expenses. As lime scale accumulates, it not only diminishes pipe cross-sections but also heightens flow resistance, affecting overall system efficiency. Furthermore, its build-up on heat transfer surfaces can cause local overheating and surface cracks on tubes, reducing longevity.

For instance, a layer of 0.04 inches (1.0 mm) of lime scale lowers heat transfer by around 80%, resulting in up to a 30% decrease in heat transfer efficiency. Even an inconspicuous layer measuring just one-hundredth of an inch can lead to a  12% increase in energy cost.

Do down-times for boiler maintenance really affect typical operating costs?

Plant down-times are an essential cost factor in the decision to better monitor water quality with an online analyzer. Plants or facilities have to be shut down when a boiler needs to be cleaned. This occurs more frequently if water hardness has lead to increased lime scaling. Plant operators and facility managers can significantly lower these costs through monitoring water hardness with a Testomat EVO or Testomat 808.

Return on investment?


The return on investment of a Testomat EVO is can be realized in just one year. Return on an investment in the basic Testomat® 808 analyzer model is realized even earlier.

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