PlantPulse provides industrial boiler monitoring that covers the entire system, not just the boiler itself. Most unplanned boiler trips actually start with the auxiliaries — feedwater pumps, forced- and induced-draft fans, and blowers — so we add vibration monitoring to that equipment alongside pressure, temperature, and water-level trending on the boiler.
The result is real-time, predictive boiler condition monitoring that flags developing problems weeks ahead: feed-pump cavitation, fan and blower bearing wear, and boiler tube-leak signatures before they force a costly shutdown. Unplanned boiler failures average roughly $127K per event, and tube-leak shutdowns can run far higher — early warning protects both production and safety.
Because PlantPulse retrofits any boiler from any manufacturer over cellular in a single day, you get whole-system coverage across mixed and aging fleets with no SCADA integration, no plant-network changes, and no IT involvement.
What we monitor on your boiler system
The boiler and the auxiliaries that cause most unplanned trips.
Boiler — pressure, temp & level
Continuous trending on steam pressure, temperature, and water level to flag abnormal operation early.
Feedwater pumps
Vibration monitoring that detects cavitation and bearing wear before a feed-pump trip takes the boiler down.
FD / ID fans
Forced- and induced-draft fan vibration signatures that reveal imbalance and bearing degradation.
Blowers
Condition tracking on combustion and process blowers across the boiler room.
Failures we catch early
The developing faults behind most unplanned boiler downtime.
Boiler tube leaks
Early signatures of developing tube leaks before they force an emergency shutdown.
Feed-pump cavitation
Abnormal vibration that flags cavitation and impeller wear weeks ahead of failure.
Fan & blower bearing wear
High-frequency vibration on FD/ID fans and blowers — a leading cause of trips.
Fouling & scale
Efficiency drift from fouling and scale that quietly wastes 10–20% of your fuel.
Why plants choose PlantPulse for boilers
Whole-system coverage that OEM-locked platforms miss.
Same-day cellular install
Sensors mount directly on your boilers and stream over cellular the same day — no SCADA tie-in, no plant network, no IT tickets, no capital project.
Whole system, not just the boiler
We add vibration monitoring to feedwater pumps, FD/ID fans, and blowers — the auxiliaries that cause most unplanned trips.
AI insights in plain language
Our AI models watch vibration, temperature, and pressure trends and tell your team what is failing and roughly when — not just another alarm to triage.
Audit-ready records
Continuous condition trending is retained for the life of the equipment, giving you documented evidence for inspections, insurers, and internal reliability reviews.
A companion to your inspections
Condition monitoring complements — it does not replace — required jurisdictional and National Board inspections, and produces continuous evidence for insurers and reliability programs.
- ASME BPVC & National Board / NBIC — Continuous monitoring supports the inspection and integrity programs adopted across all 50 states.
- NFPA 85 & ASME CSD-1 — Boiler and combustion safety codes that frame our alerting around the most safety-critical conditions.
- Equipment-breakdown loss control — Documented condition trending is recognized loss-control evidence for HSB-style insurers.
- ISO 20816 / 10816 & DOE/FEMP — Vibration-severity standards for pumps and fans, plus federal efficiency guidance behind fuel-savings tracking.
Built for your facility
- Hospitals & healthcare
- Food & beverage
- Universities & district energy
- Chemical processing
- Manufacturing
- Commercial facilities
Questions operations teams ask
Straight answers on installation, coverage, and compliance.
Will it work with my existing boilers from any manufacturer?
Yes. PlantPulse retrofits to any brand and any age of boiler, unlike OEM-locked platforms that only watch their own equipment.
Do you monitor feedwater pumps and fans, or just the boiler?
Both. We add vibration monitoring to feedwater pumps, FD/ID fans, and blowers — the auxiliaries that cause most unplanned trips — alongside pressure, temperature, and level on the boiler.
Can it detect a boiler tube leak or feed-pump cavitation early?
Yes. Trending flags developing issues weeks ahead, including tube-leak signatures and feed-pump cavitation before failure.
Does this replace my required boiler inspections?
No. It complements jurisdictional and National Board inspections and supports NFPA 85 / ASME CSD-1 and equipment-breakdown insurance loss control.
How fast can you install it?
Same day, over cellular, with no plant network or SCADA integration required.
Schedule a same-day boiler-room assessment
Tell us about your boilers and auxiliaries, and we will scope whole-system monitoring you can stand up today.