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Boiler Houses

Reducing Energy Costs with Online Water Quality Monitoring

Recent studies indicate that optimizing parameters such as total water hardness and conductivity through online monitoring in boiler houses can result in significant annual savings in energy and downtime expenses. This proactive approach also extends the lifespan of boilers, leading to substantial capital equipment and investment savings.

What are the Effects of Scaling?


Even in small amounts, lime scale reduces heat transmission, causing an immediate decline in heating capacity—a major contributor to increased energy expenses. As lime scale accumulates, it diminishes pipe cross-sections and increases flow resistance, impacting overall system efficiency. Moreover, build-up on heat transfer surfaces can lead to local overheating and surface cracks on tubes, reducing longevity.

For example, a 0.04-inch (1.0 mm) layer of lime scale lowers heat transfer by approximately 80%, resulting in up to a 30% decrease in heat transfer efficiency. Even a subtle layer measuring one-hundredth of an inch can lead to a 12% increase in energy costs.

Impact of Boiler Maintenance Downtime

Plant down-times significantly impact operating costs and are a crucial factor in deciding to monitor water quality with an online analyzer. Increased lime scaling often necessitates more frequent boiler cleaning, leading to more frequent plant shutdowns. Monitoring water hardness with a Testomat EVO® or Testomat 808® allows plant operators and facility managers to reduce these costs substantially.

Return on Investment


The Testomat EVO® offers a return on investment within just one year, while the basic Testomat® 808 analyzer model yields returns even earlier.

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