Thursday, March, 30 | 3:00 PM - 3:30 PM

Session: B1: New Technologies | Track B: Advanced Technologies and Renewable Energy

John Puskar

Prescient Technical Services LLC. | President

Presentation Title:

Optimizing Central Boiler and Steam Plant Operations with Data Analysis and New Qualitative Tools


Operating legacy industrial energy systems efficiently is challenging due to original equipment constraints, changed operating environments, and economic realities. The analytical methods presented in this paper made for no-cost operational changes that allow for cost savings of over $500,000 annually, significant carbon emissions reductions, and water savings for a 60-year-old industrial boiler house facility. While this facility operates high-pressure steam turbine generators and burns multiple fuels, the methods discussed offer optimized operating strategies for any industrial central steam generation facility, with or without power generation.
The applied methods utilized both quantitative and qualitative analysis tools. The quantitative methods include analyzing and confirming philosophies for configuring turbines versus motors using free DOE-developed modeling software, creating KPIs (key performance indicators) for turbine heat rates, and considering the combined combustion and thermal efficiencies of different boiler combinations.

The qualitative tools developed included a software auditing app and a low-cost $400 infrared iPad tool. The auditing app allows for more meaningful and complete inspection rounds when operators are conducting regular field inspections. The infrared imager allows operators to screen equipment conditions against reference images. Overall, this allowed paper logs to be converted to iPad apps providing valuable real-time operating decision information for the staff.


Mr. Puskar is the President of Prescient Technical Services in Cleveland, Ohio. Mr. Puskar has been a licensed Mechanical Engineer for more than 35 years. Mr. Puskar has conducted more than 200 energy audits throughout his career with a focus on industrial facilities including chemical plants, refineries, auto plants, and steel plants. Mr. Puskar is a former corporate energy systems engineer and also has also directed many implementation projects as a licensed contractor. Mr. Puskar’s perspective is unique, very practical, and has a focus on operations and “real world” solutions.

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