Case Studies
Real engineering investigations showing how Floworx platforms reveal system behavior and validate performance in real operating conditions.
Case Studies
Thermal Performance Drift — Large Residential Tankless Water Heating System
System Context:
A large residential home in the southwestern United States using a
centralized gas-fired tankless water heating system serving variable
domestic hot water demand.
Engineering Question:
Was gradual scale accumulation affecting thermal performance despite
normal operation and no fault indications?
Why Direct Measurement Was Not Possible:
Scale formation inside operating heat exchangers cannot be directly
observed without shutdown and physical inspection.
What Was Measured:
- Inlet and outlet water temperature
- System flow rate
- Energy input
- Time-based operating behavior
What Became Observable:
Changes in the relationship between energy input and thermal output
over time revealed performance drift consistent with fouling and
measurable recovery following intervention.
Energy Input vs Output Mismatch — Residential Hydronic Boiler System
System Context:
A high-end residential hydronic heating system utilizing a modulating
boiler operating across wide seasonal load variation.
Engineering Question:
Why was energy consumption increasing without a corresponding increase
in delivered thermal output?
Why Traditional Diagnostics Fell Short:
No alarms or control faults were present, and steady-state efficiency
assumptions masked part-load behavior.
What Was Measured:
- Supply and return temperature
- System flow rate
- Fuel energy input
- Operating cycles over time
What Became Observable:
Insight revealed periods of increasing energy input without proportional
heat delivery, indicating declining heat transfer effectiveness under
normal operating conditions.
Performance Verification After Intervention — Tank Water Heater System
System Context:
A large residential tank-type water heater system following maintenance
and operational changes intended to improve efficiency.
Engineering Question:
Did the intervention result in a measurable change in system
performance?
Why Verification Was Required:
Visual inspection and control feedback could not confirm whether
system behavior had materially changed.
What Was Measured:
- Temperature rise across the heater
- Flow rate during draw events
- Energy input before and after intervention
- Time-based performance trends
What Became Observable:
Before-and-after analysis showed a clear shift in energy-to-output
behavior, enabling objective verification of system changes.