Industrial boilers play a critical role in various industries, providing essential heating and steam generation for operations all over the world. However, maintaining these complex systems requires reliable remote monitoring solutions, especially in environments where conditions such as high humidity and steam exposure pose significant challenges. This case study explores how an industry-leading boiler manufacturer overcame the limitations of consumer-grade computing solutions by adopting an industrial-grade, rugged computing system for real-time monitoring and data collection.
The Company
As a leading provider of industrial steam boiler technology, this company specializes in high-efficiency and eco-friendly solutions for a wide range of industries. Their advanced boiler systems include remote monitoring and management capabilities to ensure optimal performance, safety, and energy efficiency. Since 2022, they have integrated industrial computing solutions to enhance the reliability and connectivity of their remote monitoring infrastructure.
The Challenge
The company required a low-power computing solution capable of operating in challenging environments, such as basements or enclosed cabinets, where boilers are typically installed. The primary function of this system was to monitor boiler conditions and status while ensuring seamless data transmission to their remote management platform. Previously, they had relied on consumer-grade computing solutions, but these devices were not rugged enough to withstand the high humidity and steam exposure in boiler rooms. The frequent failures of these consumer-grade systems disrupted monitoring and maintenance processes, prompting them to seek a more robust, industrial-grade solution. After struggling to find a suitable provider, they were referred to Premio by an existing connection in 2021.
The Solution
Upon assessment, Premio selected the BCO-1000 series as the primary option. The BCO-1000-ADLN was integrated into their remote management platform as an IoT gateway, enabling real-time data collection from boilers and secure transmission to their monitoring system. The compact size allowed for easy installation in basement locations and cabinets, while the fanless, industrial-grade design ensured reliable operation even in high-moisture environments.
Fanless & Industrial Grade Design
Built with a fanless design, this eliminated mechanical failures caused by high humidity and steam exposure. Its industrial-grade durability ensures uninterrupted operation in boiler room environments. Additionally, the small size of the BCO-1000 allows for easy installation in constrained spaces such as cabinets and basements, making it an ideal solution for the company's monitoring needs.
Low Power Efficiency
Supported by 12th Generation Intel Alder Lake-N processors, these embedded processors consume minimal power while maintaining a low TDP, reducing overall thermal and cooling costs.
Rich IIoT Connectivity
With on-board I/O, including serial ports, USB, and LAN, the BCO-1000 seamlessly integrated with various sensors and peripherals for efficient data collection and processing. This allowed the BCO-1000-ADLN to seamlessly collect, process, and send data to the company’s software platform in other locations to help monitor and manage the boilers.
The Benefits
By adopting the industrial computing solution, the company achieved significant improvements in system reliability, operational efficiency, and remote monitoring capabilities:
- Enhanced Durability: The rugged, fanless design eliminated failures caused by steam exposure, ensuring continuous operation in boiler room environments.
- Seamless Data Transmission: Acting as an IoT gateway, the system enabled real-time monitoring and remote access, allowing engineers to proactively address potential issues and optimize boiler performance.
- Compact & Low Power: The small form factor and low power consumption made it an ideal solution for installation in constrained spaces, such as boiler cabinets and basement locations.
- Reliable Partnership: With a trusted industrial computing provider, the company gained a long-term solution to their rugged computing needs, ensuring ongoing support and scalability as their monitoring infrastructure expands.
Through this collaboration, the company has strengthened its remote monitoring capabilities, ensuring that its boiler systems continue to operate efficiently and safely while reducing costly downtime and maintenance challenges.