Can I add up the five boiler and heater savings in the Panipat survey table?

Not safely. The survey prints each row alone and does not say what it is measured against. If the fixes overlap, adding overstates the total, and counting each on the fuel left is the cautious way. For a boiler, 24.5 to 43% added up becomes 23.0 to 38.5%. These are our sums.

The five rows, as printed

• Three pass boiler with heat recovery, in place of a single pass boiler: 15 to 27%, payback up to 18 months.
• Economiser on a boiler: 5 to 8%, up to 8 months.
• Air preheater on a thermic fluid heater: 4 to 9%, up to 11 months.
• Air to fuel ratio controller: 8 to 14%, 8 to 12 months.
• Surface insulation: 1.5 to 2%, up to 3 months.

Why adding can overstate it

Take a unit that burns 100 tonnes of fuel. A first fix that saves 10% leaves 90 tonnes. A second fix that saves 10% of what is left saves 9, not 10. So the second row is worth less once the first is done. Two 10% savings make 19%, not 20%. The survey prints no combined figure and does not say what each row is measured against. Our reading, not the survey’s: each row was most likely worked out alone, so when fixes overlap the sum overstates. If every row is measured against the same original fuel and the fixes do not overlap, adding is right and multiplying would understate. Multiplying is a cautious way to count, because it treats each fix as cutting only what remains.

Not every row fits every machine

The air preheater is for the thermic fluid heater. The economiser is for a boiler. The three pass row is only for the few single pass boilers, and TERI says it already carries a heat recovery mechanism, so a maker may include some control and heat recovery in the price. That is why the boiler set below leaves the economiser out. Ask what is in the quote before you count the same saving twice.

One row to read with care

In the insulation row, the existing column says “Non-insulated surfaces” and then “Surface temperature with insulation”, giving 80 to 110 degrees Celsius against an ambient of 30. The words do not make clear whether 80 to 110 is the bare surface today or the insulated surface after. Ask the contractor for the surface temperature you will have after, measured, before you count on 1.5 to 2%.

Example: the boiler set and the heater set

• Boiler set (three pass boiler, controller, insulation), low ends: 15 + 8 + 1.5 = 24.5% added up
• Multiplied: 1 − (0.85 × 0.92 × 0.985) = 1 − 0.770 = 23.0%
• High ends: 27 + 14 + 2 = 43% added up. Multiplied: 1 − (0.73 × 0.86 × 0.98) = 1 − 0.615 = 38.5%
• Heater set (air preheater, controller, insulation), low ends: 4 + 8 + 1.5 = 13.5% added up. Multiplied: 1 − (0.96 × 0.92 × 0.985) = 13.0%
• High ends: 9 + 14 + 2 = 25% added up. Multiplied: 1 − (0.91 × 0.86 × 0.98) = 23.3%
• On a heater burning 20 tonnes of pet coke a month: 13.0% is 2.6 tonnes and 23.3% is 4.7 tonnes a month, where adding would have said 2.7 and 5.0

Our arithmetic on the survey’s printed ranges. The economiser is left out of the boiler set because the three pass row already includes heat recovery. Pet coke is a hard black fuel left over from refining oil. A real unit will land inside or outside these figures depending on its starting condition.

What Senseible does here

Senseible reads your fuel invoices into monthly records, so the tonnes of fuel bought each month are on file. Set them against the combined saving you expect. It does not read a boiler or heater, so the before and after records come from your own invoices.

• Green loan readiness check
• Panipat air to fuel controller
• Panipat boiler economiser
• Panipat thermic heater air preheater
• Panipat single pass or three pass boiler

Sources: TERI, Energy Profile: Panipat Textile Cluster, 2016 (SAMEEEKSHA)

Last reviewed 2026-11-07. Figures are from the Panipat survey of 2014-15, published in 2016. The survey table prints each saving as a range with no boiler size, fuel tonnes or equipment cost. Check a current quote and your own fuel records before you rely on any payback.