PureSys Engineering Services
Steam Audit Services
A comprehensive, site-specific survey of your steam network to quantify losses, identify inefficiencies, and deliver a prioritised action plan with a clear return on investment.
What Is a Steam Audit?
A steam audit is a systematic, measurement-based inspection of every component in your steam generation and distribution system — from the boiler house to the point of use. Unlike a theoretical review, a PureSys steam audit is conducted on-site by experienced steam engineers using calibrated survey instruments.
Steam networks lose energy through failed steam traps, inadequate insulation, uncontrolled flash steam venting, leaking joints, and poorly sized pressure reducing valves. These losses are often invisible to plant operators but can represent 20–35% of total steam generation cost.
Our audit transforms invisible losses into measurable data — giving your engineering and energy teams the evidence to justify capital investment and drive operational improvement.
Typical Findings
- ⚙ 15–40% of steam traps failed open or closed
- ⚙ Uninsulated steam mains losing significant heat
- ⚙ Flash steam vented rather than recovered
- ⚙ Pressure set higher than process requires
- ⚙ Condensate return below 60% of steam generated
- ⚙ Boiler running inefficiently due to poor feedwater
Our Audit Methodology
Pre-Audit Review
Review P&IDs, boiler logsheets, energy bills, and existing maintenance records. Identify scope boundary and safety considerations.
On-Site Survey
Physical inspection using ultrasonic testing equipment, thermal imaging cameras, and flow measurement to capture real operating data.
Steam Trap Survey
Every trap tested individually for pass-through, blow-through, or blocked condition. Each result tagged to plant asset register.
Condensate Analysis
Measure condensate return rate, temperature, and quality. Calculate lost energy and water treatment cost from condensate not returned.
Pressure & Control Review
Assess PRV settings, control valve sizing, and steam pressures at point of use. Identify oversized or maladjusted control equipment.
Audit Report & ROI
Deliver a detailed written report with every finding quantified, a ranked action list, estimated savings per action, and payback period calculations.
What the Report Covers
Every PureSys steam audit concludes with a structured written report submitted to your engineering team within 5 working days of the site survey. The report is designed to serve as an actionable engineering document, not just an observational summary.
- ✓ Full steam trap register with condition status for every trap
- ✓ Thermal imaging photographs of heat loss points
- ✓ Condensate recovery rate and improvement potential
- ✓ Energy loss calculations in kWh and ₹/year
- ✓ Prioritised recommendations ranked by ROI
- ✓ Product specifications for recommended replacements
- ✓ Summary for management sign-off on capital spend
Industries We Audit
Request a Steam Audit
Contact our engineering team to discuss your site, define the scope, and schedule your on-site survey. Most industrial plants see payback within 6–18 months.