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Predictive
Maintenance
Pay
Back Analysis
STEAM LEAKS
In a steam system with 150 lbs. of pressure and
a production cost of $6 per thousand pounds, a leak 1/32" in diameter (no larger than the tip of a ball point pen) can
cost $249 per year.
In a 50 p.s.i. system with a production cost of $8/1000 pounds, a number of small leaks totaling
about 1/4" will cost $8,339.52 in one year. Double the number of leaks to total 1/2" and the cost will be $33,358.08.
At Sun Co.'s Toledo, Ohio refinery, the Ultraprobe identified 188 malfunctioning steam traps. Savings from replacing
these traps have been in the range of $56,000 per year based on reducing 450 p.s.i. steam consumption by about 1,000 lb./hr.
STEAM FLOW THROUGH STEAM TRAP ORIFICE TABLE
To establish the approximate dollar loss,
take the lb./hr. figure X 24 hours (for a year X 8760) and multiply by your cost of steam. Ex: 1/8" orifice @ 50 psi
= 29.8 X 8760 = 261,048. At a cost of $5.00/1000 lb.: 261,048 X .005 = $1305.24.
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Orifice
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2 psi
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5 psi
|
10 psi
|
15 psi
|
25 psi
|
50 psi
|
75 psi
|
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1/32"
|
0.31
|
0.49
|
0.70
|
0.85
|
1.14
|
1.86
|
2.58
|
|
1/16"
|
1.25
|
1.97
|
2.80
|
3.40
|
4.60
|
7.40
|
10.3
|
|
3/32"
|
2.81
|
4.44
|
6.30
|
7.70
|
10.3
|
16.7
|
15.4
|
|
1/8"
|
4.50
|
7.90
|
11.2
|
13.7
|
18.3
|
29.8
|
41.3
|
|
5/32"
|
7.80
|
12.3
|
17.4
|
21.3
|
28.5
|
46.5
|
64.5
|
|
3/16"
|
11.2
|
17.7
|
25.1
|
30.7
|
41.1
|
67.0
|
93.0
|
|
7/32"
|
15.3
|
24.2
|
34.2
|
41.9
|
55.9
|
91.2
|
126
|
|
1/4"
|
20.0
|
31.6
|
44.6
|
54.7
|
73.1
|
119
|
165
|
|
9/32"
|
25.2
|
39.9
|
56.5
|
69.2
|
92.5
|
151
|
209
|
|
5/16"
|
31.2
|
49.3
|
69.7
|
85.4
|
114
|
186
|
258
|
|
11/32"
|
37.7
|
59.6
|
84.4
|
103
|
138
|
225
|
312
|
|
3/8"
|
44.9
|
71.0
|
100
|
123
|
164
|
268
|
371
|
|
13/32"
|
52.7
|
83.3
|
118
|
144
|
193
|
314
|
436
|
|
7/16"
|
61.1
|
96.6
|
137
|
167
|
224
|
365
|
506
|
|
15/32"
|
70.2
|
111
|
157
|
192
|
257
|
419
|
580
|
|
1/2"
|
O79.8
|
125
|
179
|
219
|
292
|
476
|
660
|
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Air Leak Cost Chart
|
|
Diameter of Leak
|
Cubic Feet/Minute
|
Cubic Feet/Day
|
Loss/Day Dollars
|
Loss/Month Dollars
|
Loss/Year Dollars
|
|
1/64"
|
1.60
|
2,304
|
$0.10
|
$3.00
|
$36.00
|
|
1/32"
|
3.66
|
5,270
|
$0.40
|
$12.00
|
$144.00
|
|
3/64"
|
6.45
|
9,288
|
$0.95
|
$28.50
|
$342.00
|
|
1/16"
|
14.50
|
20,880
|
$4.65
|
$49.50
|
$594.00
|
|
3/32"
|
25.80
|
37,152
|
$3.75
|
$112.50
|
$1,500.00
|
|
1/8"
|
58.30
|
83,952
|
$6.70
|
$201.00
|
$2,412.00
|
|
3/16"
|
103.00
|
148,320
|
$15.10
|
$453.00
|
$5,436.00
|
|
1/4"
|
162.00
|
233,280
|
$26.70
|
$801.00
|
$9,612.00
|
|
5/16"
|
234.00
|
336,960
|
$42.00
|
$1,260.00
|
$15,120.00
|
|
3/8"
|
1.60
|
2,304
|
$60.65
|
$1,819.50
|
$21,834.00
|
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Based on 100 PSIG, $0.18/MCF, 8,760 Hours/Year
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