Steam Audit Helps Customers Lower Operating Costs


By Steve Connor M


any customers are looking to reduce operating costs during these challenging economic times. Increasing the efficiency of a boiler or steam


system can offer a quick rate of return on investment. Finding these inefficiencies starts with a steam audit, a comprehensive analysis of energy used within a facility, process and equipment and includes recommendations for energy conservation measures. Reducing fuel cost is the number one reason for a steam audit. Money saved on fuel can be reinvested in the business or can provide liquidity when cash flow is tight. There are two types of steam audits: a simple boiler


room audit and a complete facility audit. In a simple audit, a professional evaluates the boiler and accessory support equipment. In a complete facility audit, auditors evaluate the boiler, steam system and all the components through- out a plant, including steam traps, piping, valves, steam users, etc. Audit customers will be provided with a report that


details how the facility and its equipment use energy, along with costs and utility data affecting energy con- sumption. In addition, they’ll be provided with an analy- sis that shows potential measures to make energy use more efficient, less expensive and more environmentally friendly. A simple boiler room audit costs approximately $2,500,


whereas a complete facility audit — depending on the complexity and the size of the plant — can cost several thousand dollars.


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Steam audit process During a simple boiler room audit, facilities should


operate as normal so that the auditor can spot visual indi- cations of energy loss and possible operational and safety issues. The boiler, controls and all connected systems for feedwater, fuel, etc., will be inspected to identify ineffi- ciencies and inequities. The auditor will conduct an inven- tory of key equipment, looking for energy-saving meth- ods, areas to improve engineering practices and health and safety concerns. In a complete facility audit, auditors also will focus on potential energy improvements throughout the facility. In addition to the boiler room, they’ll audit steam flow, pres- sures, temperatures, air handling, steam trapping, piping ancillaries (including valving and insulation), condensate pumping, etc.; seeking energy savings along with identi- fying safety and reliability issues.


Important steam audit findings Both types of audits determine the condition of the cur-


rent boiler system, looking beyond age at issues such as: • Pressure vessel condition • Evidence of overheating and poor combustion • Outdated burners and controls Many times what is found is a well-maintained boiler


that requires an updated burner and/or combustion control system for improving the fuel/air mix and repeatability. Retrofits are significantly cheaper than boiler replacement


Continued on page 77 January 2011


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