Bigeta Energy Solutions LLP

Thermal Audit

Our thermal energy audit is structured around six core assessment areas. Each area combines field measurements, data analysis, and benchmarking against Indian and international efficiency standards.

Boiler Efficiency Assessment

Measurement of flue gas composition (O2, CO2, CO), stack temperature, radiation and convection losses, excess air levels, and combustion efficiency. We benchmark against BEE norms and identify optimisation opportunities including O2 trim control, soot blowing schedules, and burner tuning.

Steam System & Trap Audit

Survey of the entire steam distribution network — steam traps (tested ultrasonically), condensate recovery rates, distribution losses, pressure drops, and flash steam utilisation. Failed steam traps alone can waste 10–15% of steam generated.

Heat Loss & Insulation Audit

Infrared thermography of all insulated surfaces — pipes, ducts, vessels, and equipment — to identify hot spots, missing insulation, and degraded lagging. Quantification of heat loss in kW and fuel cost equivalent for each identified area.

Furnace & Kiln Evaluation

Assessment of combustion efficiency, air-to-fuel ratio, refractory lining integrity, heat distribution uniformity, and waste heat in flue gases. Recommendations cover burner upgrades, recuperators, regenerative burners, and process control improvements.

Waste Heat Recovery Analysis

Identification of all waste heat streams — flue gas, condensate, blowdown, process cooling streams — with quantification of recoverable energy. We evaluate the technical and economic feasibility of heat exchangers, economisers, waste heat boilers, and cogeneration.

Heat Exchanger Performance

Fouling assessment, heat transfer coefficient measurement, approach temperature analysis, and pressure drop testing across all major heat exchangers. We identify cleaning schedules, retubing requirements, and redesign opportunities to restore design performance.

Key Benefits of a Thermal Energy Audit

Fuel Cost Reduction

Direct reduction in natural gas, furnace oil, coal, or biomass consumption through improved combustion control and insulation — typically 10–25% savings.

Waste Heat Recovery

Monetise heat that is currently being vented or cooled away — through economisers, condensate return, blowdown heat recovery, and cogeneration.

Carbon Footprint Reduction

Lower fuel consumption directly reduces Scope 1 GHG emissions, supporting your ESG targets, carbon reporting, and net-zero commitments.

Improved Safety & Reliability

Identifying overheated equipment, failed steam traps, and degraded insulation reduces the risk of thermal accidents and unplanned shutdowns.

Regulatory Compliance

Align with BEE energy conservation norms, PAT scheme obligations, ISO 50001 requirements, and state-level energy audit mandates.

Extended Equipment Life

Reducing thermal stress on boilers, heat exchangers, and furnaces through proper combustion control and insulation prolongs equipment service life.

Frequently Asked Questions — Thermal Energy Audit

What is the difference between a thermal audit and a general energy audit?

A general energy audit covers all energy systems — electricity, thermal, compressed air, lighting, etc. A thermal energy audit specifically focuses on heat generation, distribution, and utilisation systems such as boilers, steam networks, furnaces, and heat exchangers. For facilities where fuel costs dominate, a dedicated thermal audit provides far more depth and actionable savings than a general audit alone.

How much fuel savings can we expect from a thermal audit?

Typical fuel savings from implementing thermal audit recommendations range from 10–25% of current fuel consumption. The exact figure depends on the current state of your boilers, steam traps, insulation, and combustion systems. A 15-year-old boiler running without O2 trim control can often achieve 8–12% efficiency improvement alone.

How long does a thermal energy audit take?

On-site fieldwork typically takes 2–4 days depending on the number of thermal systems and the plant's complexity. Report preparation and analysis takes an additional 3–4 weeks. Bigeta provides preliminary findings verbally before leaving the site so your team can begin planning immediately.

Do you also help with implementing the recommendations?

Yes. Bigeta provides implementation support for all thermal ECMs — from vendor identification and technical specification to commissioning support and Measurement & Verification (M&V) of actual savings post-implementation.

Is a thermal audit mandatory under BEE or PAT regulations?

Designated Consumers (DCs) under India's PAT scheme are required to conduct energy audits periodically, which includes thermal systems. Even for non-DCs, thermal audits are strongly recommended to meet energy conservation targets under the Energy Conservation Act and to support ISO 50001 EnMS implementation.
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