Proven Results

Unlocking Savings Through Steam Optimization

April 16, 2026

Advanced control and burner management integration help facilities reduce trips, improve combustion efficiency, and support lower emissions.

The Challenge

Maintaining reliable boiler performance can be difficult when steam demand changes rapidly due to process upsets or shifts in plant operating conditions. Poorly controlled boilers may trip through the burner management system (BMS), creating downtime, reducing profitability, and complicating troubleshooting efforts. Boiler efficiency can also suffer when excess oxygen is not properly managed or when fuel BTU content varies, resulting in increased fuel consumption and emissions.

Common Challenges

Boiler trips caused by sudden load swings or changing operating conditions
Limited troubleshooting capabilities when BMS and control systems are separate
Excess oxygen levels reducing combustion efficiency
Variable fuel quality and multiple fuel sources affecting performance
Increased fuel costs and greenhouse gas emissions

The Solution

Spartan Controls delivers Steam Boiler Optimization using the DeltaV™ process control system, combining advanced combustion control, real-time performance calculations, and integrated burner management capabilities.

Advanced control strategies to minimize stack excess oxygen while maintaining complete combustion
Fuel property calculations that account for changing BTU content and multiple fuel types
Real-time boiler efficiency calculations using the ASME heat loss method
Characterization of dampers, fuel valves, and boiler feedwater control valves
Integrated yet separate burner management system with first-out troubleshooting capabilities
Common operator interface for both boiler control and BMS troubleshooting

The Value

Steam Boiler Optimization helps facilities improve operational performance while reducing operating costs and emissions. Benefits identified in the solution include: