As a complete boiler, burner, and controls upgrade project, we undertook a full modernization to enhance system efficiency, reliability, and monitoring capabilities. Central to this upgrade was the installation of an economizer, which increased the feedwater temperature by 20°C—resulting in an estimated 4% improvement in thermal efficiency. Temperature sensors were strategically installed for data logging and trend analysis.  

We replaced the aging integral burner with a bespoke, high-efficiency Limpsfield burner capable of achieving a 7:1 turndown ratio while consistently maintaining 3% O₂ across the full firing range. The blower motor was fitted with a variable speed drive (VSD), which not only contributed to significant electrical savings but also provided more precise combustion air control for improved burner performance. 

A major focus of the upgrade was the integration of a new Autoflame control system. We installed the Autoflame Mk8 MM Controller, which provides advanced burner management and precise control over fuel-air ratio via servo motors. This was paired with the Autoflame DTI (Data Transfer Interface) module, enabling seamless Modbus communication and full integration with the site’s building management system for real-time monitoring, remote access, and performance tracking. Additionally, we implemented the Autoflame Exhaust Gas Analyzer (EGA) for continuous oxygen trimming and emissions monitoring, ensuring optimal combustion and compliance with environmental standards. 

We also replaced the outdated Honeywell gas train components with a new Dungs gas train, enhancing safety and reliability. A fully custom electrical control panel was designed and installed to support the new system architecture. Water-side controls were upgraded with Spirax Sarco self-checking level controls for improved reliability and safety, and total dissolved solids (TDS) management was enhanced with a modulating control valve to maintain consistent boiler water quality. All engineering, installation, and commissioning were completed entirely in-house by our experienced technical team.