A steam system left unmaintained can be a "Money Pit". Let's take a moment and review the math. A simple water meter costing about $ 1000 will monitor the amount of water going through your water softener to make up condensate not being returned to your boiler room. You probably already have this meter and should track the data. Let's look at an example. Assume you are operating (2) 300 HP boilers at about a 50% firing rate. You operate your steam system 20 days per month and purchase natural gas at per million BTUs.

You check the meter and your make up is 6,000 gallons per day or for a 20 day month 120,000 gallons. Water and sewer costs are about $ 10 per 1,000 gallons so the monthly water bill is $ 1200.

Water weighs 8.3 lbs per gallon so 120,000 gallons of water is 996,000 lbs of water per month. Since we are making steam with this water, we are making up a steam flow of 996,000 lbs per month. If your boilers are 75% fuel to steam efficient, then it is costing you $ 15 to produce 1,000 lbs of steam. The 996,000 lbs of make up is a potential loss of $ 14,940 per month or $ 179,280 per year.

Is the loss real? If the steam is being used in your facility in applications which use direct injection steam, then it is not a loss. If the condensate is being dumped due to potential contamination, then it is not a loss. For virtually ever other use of steam in your facility, you have a loss which should be examined as a potential opportunity to save real dollars with rapid payback. Take a brief moment and look for roof vents blowing vapor and condensate going down the drain. If you find them, you have an opportunity to save a lot of money.

If you have boilers more than 25-30 years old, new technology boilers will usually pay back in under 2 years. Failed steam traps and condensate pumps will pay back in typically 3-6 months. Most steam systems can yield an easy 15-20% reduction in fuel costs. We provide a full range of virtually any equipment used on a steam system.