EddyBits' IoT for boiler monitoring system gives Indian plants PESO compliant boiler monitoring with real-time steam pressure monitoring, water level, fuel flow, flue gas temperature, and combustion efficiency — plus safety trip alerts the moment a reading drifts out of range, so your industrial boiler never becomes a compliance or safety blind spot.
A real fire-tube boiler, sensors live on the shell, live readings on screen, data streaming to the cloud and every connected device as it runs.
Tracks steam pressure continuously against the safety valve setpoint, so an overpressure trend triggers an alert hours before it becomes a trip event.
Monitors outlet steam temperature and saturation point in real time, flagging superheat or condensation drift before it affects downstream process quality.
Reads boiler drum water level continuously with instant low/high alarms — the same low-water condition that causes most emergency shutdowns, caught before it trips.
Tracks fuel flow rate and cumulative consumption in real time, correlating burn rate against steam output to catch efficiency loss as it happens, not at month-end.
Measures exit flue gas temperature continuously to calculate real-time heat loss and chimney draft status — a rising trend usually means it is time to clean the tubes.
Runs continuous O2/CO2 analysis to compute real combustion and fuel-to-steam conversion efficiency, catching burner tuning drift long before the next annual audit.
Logs every emergency shutdown, flame failure, and low-water cutoff with a timestamp — the exact audit trail a PESO inspection asks for, generated automatically.
Rolls up daily and monthly fuel consumption into a real cost-per-unit-of-steam figure, so a creeping fuel bill shows up as a trend, not a surprise invoice.
Full alignment with Petroleum and Explosives Safety Organization requirements. Boilers registered under Indian Boilers Act. Automated compliance documentation and e-portal submission ready.
Multi-layer safety interlocks: water level low/high shutdown, overpressure relief, flue gas temp limits, flame failure detection. Real-time alerts prevent dangerous operating conditions.
Every parameter change timestamped and logged. Complete audit history exportable as PDF/CSV for regulatory inspections. Data encrypted and backed up for 7 years.
Predictive alerts for tube replacement, burner cleaning, water softening recharge. Maintenance history linked to actual operating data — no guesswork.
Daily boiler performance summaries. Monthly PESO compliance reports. Automatic alerts to facility managers, operators, and compliance officers.
Cost per unit of steam produced. Daily fuel consumption vs. steam output correlation. Efficiency degradation alerts when fuel cost rises without load increase.
Emergency kill-switch accessible from mobile app. Authorized personnel only. Audit log records every shutdown command and actor for compliance.
Safe simulation environment for boiler operators. Practice procedures, understand pressure/temp relationships, review incident scenarios without risks.
The full data path from your boiler to your phone, start to finish.
PESO-certified pressure transmitters, RTD temperature sensors, and a fuel flow meter installed on the steam line, drum, and burner — integrated with existing instrumentation where it already exists.
An IoT gateway wired to the plant network via Ethernet aggregates every sensor over Modbus/4-20mA, with cellular fallback for network redundancy.
Data transmits through a secure VPN tunnel with TLS 1.2+ encryption to EddyBits' cloud infrastructure — built for sites without reliable Wi-Fi, which is most boiler houses in India.
Every reading is checked against PESO and manufacturer thresholds in real time, and compliance reports are auto-generated for e-portal submission — no manual paperwork.
Critical alerts reach operators and the compliance officer over WhatsApp and SMS the moment a reading drifts — not just email, which gets missed on the shop floor.
Curious what this looks like on your own boiler?Free site assessment, no commitment — we'll tell you exactly what's feasible.
Get a Free Site AssessmentGeneric IoT monitoring platforms are built for a global market. EddyBits is built specifically around how Indian facilities actually operate.
Most platforms default to email or app push notifications. Ours default to WhatsApp and SMS — the channels facility staff in India actually check first.
Cellular-first connectivity by default, so monitoring doesn't depend on a facility's internet infrastructure — the DG room and generator yard rarely have good Wi-Fi anyway.
Most facilities are live within 48 hours of installation, with a dedicated on-site engineering team handling setup — not a self-install kit shipped in a box.
High-steam-demand processes. Optimize fuel burn, prevent boiler downtime, ensure PESO compliance during inspections.
Pasteurization, sterilization, cooking. Track steam consumption per batch. Quality assurance via temperature logging.
GMP-compliant steam quality monitoring. Automated audit trails for regulatory submissions. Prevent contamination via boiler failure.
Precise steam control for brewing processes. Efficiency tracking, fuel cost per product unit, emergency shutdown capability.
Large-scale hot water + steam demand. Prevent cold water incidents, track utility costs, predictive maintenance.
Multi-boiler plants serving large complexes. Master control dashboard, load balancing, remote monitoring across multiple units.
Wherever process steam is a production input, pressure and temperature deviations have a direct cost.
Dyeing and finishing processes depend on steam held within a narrow pressure and temperature band. Continuous monitoring flags a drift before it shows up as an inconsistent batch.
Combustion efficiency and fuel consumption tracking turn boiler running cost from a monthly fuel bill surprise into a number the plant can actually manage day to day.
Steam sterilization and process heating both need auditable proof of correct operating conditions. Compliance-ready data logging replaces a manual logbook with a continuous, timestamped record.
Over-pressurization is a genuine safety hazard, not just an efficiency concern. Safety trip event logging gives a clear, immediate record of exactly when and why a trip occurred.
Brewing consistency depends on repeatable steam conditions batch to batch. Continuous pressure and temperature logging makes a process deviation visible immediately, not after a batch is already lost.
An IoT for boiler monitoring system uses sensors on the steam line, drum, and burner to track pressure, temperature, water level, and combustion efficiency in real time, sending instant WhatsApp/SMS alerts and generating PESO compliant safety records automatically.
Yes. Every parameter reading and safety trip event is timestamped and logged, producing an audit trail exportable for PESO inspections and Indian Boilers Act documentation — no manual logbook reconstruction needed.
Multi-layer safety interlocks track water level, pressure, and flame status continuously. A reading that crosses a manufacturer-specified threshold — low water, overpressure, flame failure — triggers an instant alert before it becomes a shutdown or safety incident.
Yes. EddyBits sensors are brand-agnostic and integrate via Modbus RTU/TCP or 4-20mA analog — the standard interfaces used across boiler instrumentation regardless of manufacturer.
No. Connectivity is cellular-first by default, so monitoring works even at boiler houses with no reliable Wi-Fi — a common condition on Indian industrial sites.
Yes. Fuel consumption is correlated against steam output automatically, giving you a real cost-per-unit figure and flagging efficiency degradation when fuel cost rises without a matching load increase.
Most single-boiler installations take a few hours with PESO-certified sensor installation, and facilities are typically fully live on the dashboard within 48 hours.
Why condition-based monitoring beats an annual inspection for boiler safety.
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