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

1 . A boiler health and carbon-footprint monitor (BHCFM) tool, comprising:

a sensor system configured to collect operational data from a boiler system;

a fuel wastage engine, implemented by at least one processor operatively coupled to the sensor system, configured to generate a first indicator for monitoring fuel wastage of the boiler system based on a first comparison of the operational data, determine a cause of the fuel wastage by analyzing variations in air-to-fuel ratios based on the operational data, and generate a notification including the cause of the fuel wastage and operational recommendations for correcting the fuel wastage;

a carbon footprint engine, implemented by the at least one processor operatively coupled to the sensor system, configured to 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 to provide real-time environmental impact monitoring;

a cyclic load engine, implemented by the at least one processor operatively coupled to the sensor system, configured to generate a third indicator for monitoring tube-to-drum joints of the boiler system based on thermal cycle analysis of the operational data, determine an operational condition for the tube-to-drum joints by analyzing thermal cycle data, and generate a notification including the operational conditions and operational recommendations for maintaining tube-to-drum joint integrity;

a load swing engine, implemented by the at least one processor operatively coupled to the sensor system, configured to generate a fourth indicator for monitoring tube overheating of the boiler system based on a third comparison of the operational data, determine an operational condition for one or more tubes of the boiler system, and generate a notification including the operational conditions and operational recommendations for preventing tube overheating; and

a fuel gas compatibility engine, implemented by the at least one processor operatively coupled to the sensor system, configured to generate a fifth indicator for predicting flame disturbance of the boiler system based on operational data including a fuel composition and burner data, 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 operational recommendations based on the determination for maintaining flame stability.

2 . The BHCFM tool of claim 1 , wherein the operation data includes fuel composition and burner data, and wherein the sensor system includes sensors configured to measure the fuel composition and monitor burner operational parameters.

3 . The BHCFM tool of claim 2 , wherein the fuel wastage engine, the cyclic load engine, the load swing engine, the carbon footprint engine, and the fuel gas compatibility engine are each operatively coupled to the sensor system and configured to generate a report that includes data related to the first indicator, the second indicator, the third indicator, the fourth indicator, and the fifth indicator, respectively, wherein the reports include operational recommendations for optimizing boiler performance based on the respective indicators.

4 . The BHCFM tool of claim 2 , wherein the operational data includes a fuel composition and burner data, and wherein the sensor system includes sensors configured to measure the fuel composition and monitor burner operational parameters.

5 . The BHCFM tool of claim 1 , wherein the operational data includes a fuel flow and a steam flow from the sensor system, and wherein the carbon footprint engine uses a fuel composition and a real-time firing rate from the operational data to generate the second indicator.

6 . 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.

7 . The method of claim 6 , wherein the collecting operational data includes receiving real-time measurements from the temperature gauges, flow meters, and pressure sensors positioned throughout the boiler system, the method further comprising:

in response to the detection of the fuel wastage, determining a cause of the fuel wastage by analyzing variations in air-to-fuel ratios based on the operational data; and

generating a notification including the cause of the fuel wastage and operational recommendations for correcting the fuel wastage.

8 . The method of claim 6 , wherein the collecting operational data includes receiving real-time measurements from the temperature gauges, flow meters, and pressure sensors positioned throughout the boiler system, the method further comprising:

in response to generating the third indicator, determining an operational condition for the tube-to-drum joints by analyzing thermal cycle data from the operational data; and

generating a notification including the operational conditions and operational recommendations for maintaining tube-to-drum joint integrity.

9 . The method of claim 6 , further comprising: 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.

10 . The method of claim 6 , further comprising: 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 a recommendation based on the determination.

11 . 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.

12 . The non-transitory computer-readable medium of claim 11 , wherein the processor is operatively coupled to the sensor system including temperature gauges, flow meters, and pressure sensors positioned throughout the boiler system, and wherein the processor is operable to:

in response to the detection of the fuel wastage, determine a cause of the fuel wastage by analyzing variations in air-to-fuel ratios based on the operational data; and

generate a notification including the cause of the fuel wastage and operational recommendations for correcting the fuel wastage.

13 . The non-transitory computer-readable medium of claim 12 , wherein the processor is operable to:

in response to generating the third indicator, determine an operational condition for the tube-to-drum joints by analyzing thermal cycle data from the operational data; and

generate a notification including the operational conditions and operational recommendations for maintaining tube-to-drum joint integrity.

14 . The non-transitory computer-readable medium of claim 13 , wherein the processor is operable to:

in response to generating the fourth indicator, determine an operational condition for one or more tubes; and

generate a report including the operational conditions.

15 . The non-transitory computer-readable medium of claim 11 , wherein the processor is operable to:

in response to generating the fifth indicator, calculate Wobbe indices for a new fuel composition and a current fuel composition;

determine whether a difference between a 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.