getting efficiency up (steam)

billygoat22

Went to a home this week to put in a water hearter and power exhauster on steam boiler. While there the homeowner comments that his gas bill is highest on the street, even though not nearly the largest house, about 3500/yr.
That seemed like a lot to me, so I was looking the boiler over and noted the cutout set at 4 psi, and the headre was wrong. The mains were tapped BETWEEN the 2 taps off boiler. I ran the boiler about 1/2 hr and noticed the equalizer never got hot, hardly lukewarm, so I assume the carryover water is going up the mains. On the boilers I've piped in with correct header, the equalizer gets real hot pretty quick on startup.
Would correcting the headre have a big effect on fuel useage? I recommended cutting back pressure, redo header, and probably some vents would be needed (high psi setting to "fix" that?) The mains aren't insulated either, but some of the basement is livable space.
If anybody can give a idea how much these tweaks can affect fuel use (lots vs some.etc) I'd appreciate it since fuel prices are up winter and I'd like to be ready with some solutions when it gets cold and people start to get those big bills in!
Sorry for the long poat