The operating challenge
One drifting burner can disappear inside the average.
Without burner-level oxygen and temperature data, technicians may have to inspect the entire system to find the source of a change.
Industrial Combustion Monitoring System
Find the burner that changed, not just the furnace with a problem.
See excess oxygen and temperature at each monitored burner. Your team can compare conditions in real time, narrow the search for trouble, and investigate where tuning or maintenance may reduce fuel use.
Start with one furnace, boiler, or equipment group. We’ll review the application and define a practical starting scope.
Why teams can start here
- Field-deployed in active manufacturing
- Modbus TCP integration
- Wireless technology
Installed in active manufacturing
Field-deployed at a global aluminum manufacturer.
The customer is a multibillion-dollar producer with more than 20 manufacturing sites across 10 countries. Its installation gives D.B. Industrial Solutions direct experience in a demanding production environment.
- Environment
- Heavy industry
- Deployment
- Industrial system installed
The cost of the blind spot
A system average can tell you something changed. It cannot always tell you where to look.
Firing rate, wear, fouling, air leakage, maintenance, and operating demand can shift combustion conditions. On multi-burner equipment, that change can remain buried until the next inspection, a fuel-cost review, or a larger operating problem brings it to light.
The business difference
Show the team where its next hour is most likely to matter.
Live comparisons help prioritize troubleshooting, tuning, and maintenance. Before-and-after trends help document whether the work changed the condition.
Applications and users
From one measurement point to a multi-burner furnace.
The modular system can monitor one location or scale across a multi-burner installation. Final configuration reflects the equipment, site conditions, integration requirements, and operating objective.
Equipment applications
- Industrial furnaces and boilers
- Process heaters and steam generators
- Kilns and ovens
- Gas-fired engines and generators
Operational stakeholders
- Plant and operations managers
- Maintenance leaders and technicians
- Combustion and process engineers
- Controls engineers and capital approvers
How the system earns its place
Useful at the burner. Useful in the business review.
The Industrial system connects burner-level measurements to the people and systems that can act on them. The result is a clearer maintenance priority, a record of corrective work, and site data for evaluating economic value.
Find outliers faster
Compare continuous excess oxygen data and thermal context at individual burners instead of troubleshooting from a system-wide average alone.
Retrofit with less signal wiring
Where site conditions are suitable, LoRa moves data between distributed Monitoring Panels, the Ethernet Panel, and the Tuning Device.
Give technicians live feedback
Use the Industrial Tuning Device to identify outliers and observe conditions as qualified personnel make adjustments.
Keep the data working
Send aggregated measurements through Modbus TCP to plant historians, SCADA, or other infrastructure for trending, review, and reporting.
What happens inside the monitor
Current readings without relying on one noisy sample.
Both monitoring platforms acquire oxygen data every 100 milliseconds and temperature data every 1 second. The signal processing steadies the measurements so teams can compare equipment and follow trends with better context.
100milliseconds
Oxygen acquisition
A new internal oxygen measurement every 100 milliseconds provides a current view as combustion conditions change.
15samples
Continuously refreshed average
The 15-sample moving average refreshes with every valid reading. This smooths brief fluctuations while keeping the measurement responsive.
1second
Temperature acquisition
Each temperature measurement is taken once per second and averages 8 readings for a steadier thermal signal.
These are on-device measurement intervals. Display, network, and BAS update rates depend on the connected interface and system configuration.
At the furnace
Give the technician a starting point, not another mystery.
The Industrial Tuning Device shows live oxygen and temperature information at the equipment. Technicians can see which burners stand apart and watch conditions as they work.
- Compare live oxygen and temperature data across monitored burners.
- Identify the outliers that warrant a closer inspection.
- Use thermal and oxygen trends to add context to the service call.
- Record how conditions changed while field personnel made adjustments.
System architecture
From each burner to the systems your plant already uses.
Monitoring Panels collect local oxygen and temperature. LoRa connects the distributed hardware. The Ethernet Panel and Industrial Tuning Device make the information available to plant systems and field personnel.
- 01Industrial Monitoring PanelDBISIMP
Installed at individual burners or measurement locations to collect excess oxygen and temperature.
- 02Industrial Ethernet PanelDBISIEP
Aggregates module data and exposes it to plant historians, SCADA, or other infrastructure through Modbus TCP.
- 03Industrial Tuning DeviceDBISITD
Displays live burner data so technicians can compare measurements, identify outliers, and observe adjustments in real time.
Deployment and integration
Prove the value on representative equipment before you scale.
A representative installation lets the plant evaluate reliability, technician usefulness, integration, and economic potential using agreed baseline conditions. Where site conditions are suitable, LoRa can reduce the need for extensive new signal wiring.
Choose the right starting point
Select a boiler, furnace, or burner group where the operating question and potential value are clear.
Agree on the plan
Confirm measurement locations, safety boundaries, communications, installation, integration, and commissioning.
Record the baseline
Measure representative operating conditions and agree on the evidence needed to judge reliability, usefulness, and economic potential.
Document the result
Review drift, corrective work, integration performance, and site results before deciding whether broader deployment makes sense.
Safety boundary
The system does not replace certified burner-management, combustion-control, or safety systems. Those systems remain responsible for safety-critical functions.
Technical review
The details your engineering and controls teams will ask for.
Final configuration and pricing reflect the monitoring-point count, gateway and tuning-device requirements, site conditions, commissioning, integration, and requested engineering support.
| Component | Part number | Role |
|---|---|---|
| Industrial Monitoring Panel | DBISIMP | Installed at individual burners or measurement locations to collect excess oxygen and temperature. |
| Industrial Ethernet Panel | DBISIEP | Aggregates module data and exposes it to plant historians, SCADA, or other infrastructure through Modbus TCP. |
| Industrial Tuning Device | DBISITD | Displays live burner data so technicians can compare measurements, identify outliers, and observe adjustments in real time. |
OVERVIEW
Executive combustion-monitoring overview
Available from the product teamINTEGRATION
Modbus TCP planning
Defined during application reviewARCHITECTURE
Site-specific system configuration
Developed for the proposed installationPILOT
Baseline and success measures
Established with the facility teamMeasurement context
Temperature trends add thermal context to oxygen readings and can help teams recognize changes associated with load, heat transfer, or equipment condition. They do not identify root cause on their own. When a measurement represents flue-gas temperature, a defensible efficiency estimate still requires fuel information.
Industrial FAQs
Questions from engineering, operations, and finance.
Application-specific installation, safety, integration, and performance requirements are confirmed during project definition.
How can burner-level monitoring help lower operating cost?
It helps teams find combustion outliers sooner, focus troubleshooting, and check whether tuning or maintenance changed the condition. When elevated flue-gas oxygen is caused by excess combustion air, more heat can be carried out through the stack. Oxygen trends can identify a condition worth investigating, but they do not establish a safe target by themselves. Actual savings depend on the starting condition, load profile, fuel cost, and corrective action.
How do we evaluate whether a larger deployment is worth it?
A representative installation can establish the baseline, operating hours, fuel cost, service objective, and success measures. It can then document reliability, integration performance, maintenance usefulness, and any measured change after corrective work. That site evidence gives finance and operations teams a sounder basis for a rollout decision.
What does the Industrial system monitor?
Monitoring Panels collect continuous excess oxygen, temperature, and equipment health data at individual burners or measurement locations. Temperature trends add thermal context to oxygen readings and can help teams recognize changing conditions. Excess oxygen and temperature still need to be evaluated with fuel information, operating state, and combustion-air conditions for a defensible efficiency estimate.
How frequently does the system measure oxygen and temperature?
Both Industrial and Commercial Monitoring Panels acquire oxygen data every 100 milliseconds and temperature data every second. Each valid oxygen measurement refreshes a 15-sample moving average, while each temperature measurement checks and averages eight readings. Display, network, and BAS update rates depend on the connected interface, polling, and system configuration.
How does information move through the system?
Monitoring Panels communicate with the Ethernet Panel and Industrial Tuning Device over LoRa. The Ethernet Panel aggregates module data and exposes it to plant historians, SCADA, or other infrastructure through Modbus TCP.
Can the system be added to existing equipment?
The Industrial system is designed as a retrofit monitoring layer. Installation, wireless coverage, mounting, shutdown requirements, and integration scope are confirmed for each site. Existing certified burner-management, combustion-control, and safety systems remain responsible for safety-critical functions.
Does monitoring guarantee savings or emissions results?
No. Monitoring provides the oxygen and temperature visibility needed to identify drift and evaluate corrective action. Economic and environmental results depend on the equipment’s starting condition, operating profile, fuel cost, fuel composition, and the actions taken. The system is not a direct carbon-dioxide emissions monitor.
Industrial application review
Bring us the equipment that is costing you time, fuel, or certainty.
Share the equipment type, burner count, existing plant systems, and the decision your team needs better evidence to make.
Request an Application Quote