The Cost of Steam System Inefficiency in India
Steam is one of the most expensive utilities in Indian manufacturing. With natural gas, coal, and furnace oil prices continuing to rise, inefficient steam systems directly impact production costs and competitiveness. Studies show that the average Indian industrial steam system loses 20–30% of generated steam before it reaches the process — through steam trap failures, uninsulated pipes, distribution leaks, and poor condensate recovery.
PureSys India offers a complete range of products and services to identify and eliminate these losses.
1. Steam Trap Survey & Maintenance
Failed steam traps are the single largest source of steam waste. A steam trap that fails open wastes live steam continuously — a single failed DN25 trap at 10 bar g can waste over ₹5 lakh worth of steam per year.
Regular steam trap surveys using ultrasonic and infrared thermography identify:
- Failed-open traps (blowing live steam)
- Failed-closed traps (flooding condensate, reducing heat transfer)
- Bypassed traps (indicating process problems)
Our steam audit service includes a comprehensive trap survey with energy savings report. We replace failed traps with high-quality GESTRA and Spirax Sarco steam traps.
2. Condensate Recovery
Condensate is hot, treated water. Returning it to the boiler instead of draining to waste saves energy, water, and chemical treatment costs. Our condensate recovery systems deliver rapid payback — typically 6–18 months.
3. Steam Pressure Optimisation
Many plants run steam at higher pressures than required. Reducing distribution pressure where possible increases steam latent heat and reduces distribution losses. Pressure reducing valves enable right-pressure steam at each application point.
4. Pipeline Insulation
Bare or poorly insulated steam pipes lose significant heat. Even a 50mm bare steam pipe at 10 bar loses over 500 W/m of heat — equivalent to wasted fuel running every hour the plant operates. Proper insulation with calcium silicate or mineral wool jacketing is one of the most cost-effective energy saving measures available.
5. Isolation Valve Management
Steam supplied to idle equipment wastes energy. High-quality isolation valves — including GESTRA bellows seal valves and Spirax Sarco piston valves — provide reliable shut-off to take steam sections offline when not needed.
6. Boiler Blowdown Optimisation
Excessive boiler blowdown wastes energy and water. Automated TDS control using GESTRA blowdown systems ensures blowdown is only as much as necessary to maintain water quality.
Start with a Steam Audit
PureSys India’s steam audit service provides a complete energy assessment of your steam system — identifying losses and prioritising improvements with clear financial justification.
Contact PureSys India to schedule your steam audit today.