SARK ENGINEERS & CONSULTANTS
A Thermal Energy Audit is a comprehensive evaluation of fuel-fired and heat-based systems to identify heat losses, combustion inefficiencies, and process optimisation opportunities.
At SARK Engineers & Consultants, our thermal energy audits are measurement-driven and process-focused, helping industries reduce fuel consumption, improve thermal efficiency, and achieve sustainable operating cost reduction.
What Is a Thermal Energy Audit?
A thermal energy audit focuses on how heat is generated, transferred, utilised, and lost across industrial systems such as boilers, furnaces, kilns, dryers, heaters, and thermal fluid systems.
It is recommended when:
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Fuel costs are high or increasing
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Steam or heat losses are suspected
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Process heating efficiency is critical
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Energy intensity reduction targets are planned
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PAT / BEE compliance is required
BEE Certified
Most of our team members are BEE certified Energy Auditors and Managers
Experience
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500+ Thermal Audits
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27 + Types of industries
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Pan India Functioning
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Global Audits in 11 nations
Results
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Fastest Paybacks in a month.
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Highest Savings achieved had been 45%
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More than INR 47 crores saved per annum
1
Combustion Performance Assessment
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Excess air and flue gas analysis
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Burner efficiency and flame quality evaluation
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Fuel-to-air ratio optimisation
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Stack temperature and heat loss assessment
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Identification of incomplete combustion losses
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Combustion stability and turndown analysis
2
Heat Distribution System Analysis
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Steam and hot water distribution losses
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Pressure drop and temperature loss evaluation
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Insulation condition and heat leakage assessment
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Condensate return system effectiveness
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Heat loss from valves, flanges and fittings
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Distribution layout optimisation opportunities
3
Process Control & Temperature Evaluation
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Process temperature setpoint optimisation
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Overheating and underutilised heat detection
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Control logic and manual intervention review
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Batch and cycle time impact on energy use
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Heat demand vs supply mismatch analysis
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Process stability and repeatability assessment
4
Thermal Equipment & Heat Exchanger Analysis
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Boiler, furnace and kiln efficiency evaluation
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Heat exchanger and coil performance assessment
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Fouling, scaling and heat transfer degradation
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Capacity utilisation of thermal equipment
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Maintenance impact on thermal performance
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Opportunities for equipment retrofit or upgrade
5
Operational & Management Practice Review
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Firing and start-up practices review
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Shutdown and standby heat loss assessment
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Maintenance discipline affecting heat efficiency
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Operator practices impacting fuel consumption
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No-cost and low-cost improvement opportunities
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Documentation and monitoring gaps
6
Thermal Optimisation & Fuel Saving Opportunities
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Identification of thermal Energy Conservation Measures (ECMs)
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Quantification of fuel and energy savings
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Waste heat recovery and reuse options
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CAPEX–OPEX analysis with payback estimation
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Prioritisation of short-term and long-term actions
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Implementation roadmap for sustained fuel savings
How We Conduct a Thermal Energy Audit
Our methodology follows a structured and proven approach:
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Fuel & Process Data Review
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On-Site Measurements & Thermal Profiling
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Combustion & Heat Loss Analysis
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System Efficiency Benchmarking
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Identification of Thermal ECMs
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Financial & Payback Analysis
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Detailed Audit Reporting
01.
Measure & Diagnose
On-site measurements and thermal profiling are conducted to assess combustion performance, heat losses, and system inefficiencies.
02.
Optimise Heat Utilisation
Audit findings are converted into practical heat recovery, combustion optimisation, and process improvement measures.
03.
Assure Sustainable Savings
We deliver implementation-ready recommendations with quantified savings and payback analysis to ensure lasting results.
Deliverables You Receive
May Vary
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Thermal efficiency and heat loss analysis
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Combustion and excess air assessment
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Identified fuel saving opportunities
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Waste heat recovery feasibility
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CAPEX–OPEX and payback calculations
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Prioritised thermal optimisation roadmap
Get your Detailed audit quote now!
We will get back to you with your customized offer at the earliest.
Frequently Asked Questions – Thermal Energy Audit
1. What systems are covered in a thermal energy audit?
Thermal energy audits cover boilers, furnaces, kilns, heaters, steam systems, hot water systems, and process heating equipment.
2. How much fuel savings can a thermal energy audit identify?
Thermal audits typically identify 10–35% fuel saving potential, depending on system condition and operating practices.
3. Is a thermal energy audit required under PAT Scheme?
Yes. Thermal energy audits are critical for PAT-covered industries where fuel and heat form a major part of SEC.
4. Does the audit include waste heat recovery analysis?
Yes. Waste heat recovery opportunities are a key component of thermal energy audits.
5. How long does a thermal energy audit take?
Most audits are completed within 3–4 weeks, including measurements and reporting.
6. Will the audit disrupt plant operations?
No. Audits are planned to minimise operational disruption and align with normal plant running.
Reduce Fuel Costs with a Thermal Energy Audit
A thermal energy audit is the most effective way to cut fuel costs, stabilise processes, and improve thermal efficiency.