Why Monitoring Flame and Boiler Conditions is Critical in Coal-Fired Power Plants

Monitoring Flame and Boiler Conditions is Critical

Coal-fired power generation remains a vital energy source across the globe, but maintaining efficiency, safety, and compliance in these facilities requires proactive monitoring of your combustion system. At the heart of reliable performance lies one essential question:

Have you seen your burner flames lately?

With today’s advanced technology, plant operators no longer need to rely solely on indirect indicators or guesswork when it comes to burner health and boiler performance. Your boiler environment operates under extreme conditions where small inefficiencies or overlooked problems can quickly escalate. SAS Global Corporation’s High-Temperature Camera Services provide operators with real-time visibility into their flame and boiler conditions—unlocking valuable insights that drive efficiency, reduce downtime, and prevent costly failures.

This high-definition footage is delivered directly to you in digital format, allowing your operations and maintenance teams to review conditions, track performance trends, and make informed adjustments.

Common Issues Identified Through Burner Flame Evaluation

Real-time flame monitoring often reveals performance challenges that traditional inspections miss. Among the most common issues uncovered are:

• Flame instability/detachment – indicating poor combustion control.
• Tube leaks – which, if undetected, can escalate into major failures.
• Eyebrows – localized ash deposits that reduce heat transfer and efficiency.
• High unburned carbon (LOI) – signifying incomplete combustion and wasted fuel.
• Slagging – leading to fouling, reduced boiler efficiency, and unplanned outages.
• Fuel or flame impingement – causing hot spots and accelerated tube wear.
• CO and O₂ imbalance – reflecting inefficient fuel-air ratios.
• Secondary air and low NOx burner adjustment issues – resulting in emissions concerns and compliance risks.

By visually identifying these issues early, operators can take corrective action before they impact boiler reliability, fuel efficiency, or regulatory compliance.

Benefits of Proactive Flame & Boiler Monitoring

Monitoring your burner flames with SAS Global’s high-temperature camera systems provides measurable operational advantages:

• Improved Efficiency – Optimized combustion reduces fuel waste and lowers operating costs.
• Reduced Emissions – Balanced air-fuel ratios help meet stringent NOx and CO regulations.
• Enhanced Reliability – Early detection of leaks, slagging, and impingement prevents forced outages.
• Lower Maintenance Costs – Identifying and correcting problems before they escalate reduces repair expenses.
• Informed Decision-Making – Digital footage provides documentation to support tuning, maintenance, and capital investment planning.

SAS Global’s Commitment to Performance

At SAS Global Corporation, we understand that every coal-fired plant is unique—and so are its combustion challenges. Our Power Burner Flame Evaluation Program is designed to deliver clear, actionable insights. Once performance issues are identified, our experts provide tailored recommendations to restore efficiency and reliability.

With decades of experience supporting the power generation industry, SAS combines cutting-edge technology with real-world expertise to help operators run safer, cleaner, and more cost-effective plants.

Contact SAS Global Corporation today to schedule your Power Burner Flame Evaluation and see what your boiler has been hiding.