Understanding how your heating and utility systems perform is the first step toward optimization. GyanTosh plant audits cover energy, steam, and utility systems — delivering actionable recommendations for efficiency, reliability, and cost reduction.
Capabilities
- ✓Energy audits for heating systems
- ✓Steam system audits and loss identification
- ✓Utility system operational assessments
- ✓Fuel consumption analysis
- ✓Improvement roadmap and ROI estimates
What an audit measures
A plant audit measures where the fuel goes. At the boiler: flue gas analysis for oxygen, carbon monoxide and stack temperature, which together show how much heat is leaving up the chimney and whether combustion is complete; blowdown rate and water chemistry; unburnt carbon in the ash on solid-fuel units; and the surface losses from the shell.
Beyond the boiler, the steam system: traps that are failed open and passing live steam, uninsulated pipework and valves, condensate that is being dumped rather than returned, and distribution mains sized for a load that no longer exists. On many plants the distribution losses are larger than the boiler's.
From findings to a roadmap
Every finding is written up with what it is costing, what fixing it involves, and roughly what it would take — so the report can be read as a list of decisions rather than a list of problems. Items are ordered by payback, because a plant with limited budget should fix a failed trap population before it buys an economizer.
The steam cost per tonne comes out of the same data, which gives the plant a baseline it can track. Our steam cost and condensate recovery calculators under Tools use the same method, and are a reasonable first look before an audit.
When an audit is worth doing
Before a capital decision — a new boiler, a retrofit, a fuel change — because it sizes the decision against measured load rather than nameplate figures. When fuel cost has risen and nobody can say why. And on a plant that seems to run well, because the losses that cost most are usually the ones nobody is looking at: a boiler can be perfectly reliable and still wasteful.