Typical recoverable heat losses from boiler shells, steam lines, and turbine casings in power generation facilities.
Average payback period for insulation improvements on high-temperature boiler and steam distribution assets.
Average annual CO2 reduction achieved through insulation upgrades identified in power station heat loss audits.
Power Generation
Heat Loss Audit
Power generation facilities rely on boilers, steam turbines, and extensive distribution networks — all major sources of thermal loss. Our specialised heat loss audits for the power sector use advanced infrared and drone-based thermography to pinpoint where your plant is losing energy, delivering actionable recommendations to improve efficiency, cut fuel costs, and reduce emissions.
The Heat Loss Challenges
Facing Power Generators
From boiler shells to turbine casings and steam lines, every thermal surface holds untapped savings potential.
Boiler Shell Losses
Boiler casing heat loss through degraded insulation, damaged lagging, and air leaks reduces overall plant efficiency and increases fuel consumption significantly.
Steam Distribution Losses
Extensive steam pipe networks with missing or degraded insulation, leaking traps, and poor condensate return waste enormous amounts of thermal energy.
Turbine Casing Heat Loss
Turbine and generator casings operating at high temperatures radiate significant heat when insulation deteriorates, impacting cycle efficiency.
Emissions Pressure
Rising carbon costs and tightening emissions regulations mean every unit of wasted heat translates directly into unnecessary emissions and financial liability.
Our 4-Stage
Methodology
A structured approach tailored to power generation environments, combining drone thermography with detailed on-site assessment.
Comprehensive Heat Loss Audit
Thorough evaluation of your facility combining advanced infrared thermography, environmental data logging, and hands-on on-site inspections to pinpoint every source of thermal loss.
Our engineers deploy drone-based infrared thermography for elevated or hard-to-reach assets such as rooftops, flue stacks, and overhead pipework, while ground-level inspections use calibrated IR cameras to capture surface emissivity variations. The resulting thermal profile is cross-referenced with ambient temperature, wind speed, and process data to quantify real-world heat dissipation rates.
Detailed Reporting & Analysis
Comprehensive deliverables including annotated thermal images, calibrated heat maps, and quantitative data that clearly highlight priority areas of concern.
Each report includes high-resolution thermograms with temperature gradients, a ranked deficiency register prioritised by energy impact, and projected annual savings in both kWh and cost. Where applicable, we benchmark your facility against industry norms so you can measure performance relative to best practice.
Insulation & Mitigation Solutions
Tailored engineering recommendations covering insulation thickness calculations, material selection, and installation techniques suited to your operating environment.
We specify insulation systems based on operating temperature, pipe diameter, and ambient conditions, selecting from mineral wool, calcium silicate, cellular glass, and flexible elastomeric foams. Every recommendation addresses condensation prevention, safe-to-touch surface temperatures, and corrosion under insulation (CUI) risk, supported by a full cost-benefit analysis that includes projected CO₂ reduction and payback period.
Partnership with AAI Drones
Strategic partnership with AAI Drones delivering drone-based infrared thermography that safely surveys hard-to-reach, elevated, or hazardous areas without scaffolding or shutdowns.
Drone surveys eliminate the need for costly access equipment and reduce on-site safety risk, while covering large roof areas, storage tanks, and elevated pipework in a fraction of the time of conventional methods. High-resolution radiometric sensors capture pixel-level temperature data, enabling our engineers to detect insulation voids, moisture ingress, and thermal bridging with pinpoint accuracy.
What You
Receive
Actionable intelligence, not just a report — everything you need to make investment decisions.
Thermal Survey Report
Comprehensive infrared thermographic survey of all boilers, turbines, and steam networks with annotated thermal images and heat maps.
Heat Loss Quantification
Precise calculation of heat loss rates across all surveyed assets with comparison to design specifications and industry benchmarks.
Boiler Efficiency Analysis
Detailed assessment of boiler shell losses, air ingress points, and insulation condition with efficiency improvement recommendations.
Steam System Assessment
Evaluation of steam pipe insulation, trap performance, condensate return efficiency, and distribution network thermal losses.
Carbon Reduction Roadmap
Phased plan showing CO₂ reduction trajectory from insulation improvements and efficiency gains aligned with Net Zero targets.
ROI & Investment Case
Board-ready financial analysis with NPV, IRR, and payback calculations for each recommended improvement measure.
Proven Results
in Power Generation
Based on completed heat loss audits across thermal power stations and CHP plants.
Power Generation
Audit Questions
Common questions from power station operators about our heat loss audit service.
Ready to Reduce
Heat Loss?
Our power generation specialists are ready to identify thermal savings across your plant.
- Advanced infrared & drone-based thermography
- Power Generation-specific thermal benchmarking
- Detailed insulation & CO₂ impact report