Plant Utilities worked example

Steam Leak Cost at 92% leaks active during operating hours: a worked example

What does the result look like when leaks active during operating hours reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when reviewing steam leak cost for a utility budget, maintenance priority, capacity check, energy project, or production support plan.

The inputs for this scenario

  • Steam leaks found: 8 leaks (unchanged)
  • Estimated steam cost per leak: 680 $ / leak (unchanged)
  • Leaks active during operating hours: 92 % (raised for this scenario; the documented default is 80)
  • Access, insulation, and repair adder: 350 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total steam leak cost = steam leaks found × estimated steam cost per leak × leaks active during operating hours + access, insulation, and repair adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,355 $ for total steam leak cost, the number this scenario is built around.
  • At this operating point the engine returns 669 $ / item for cost per item or period.
  • At this operating point the engine returns 5,005 $ for variable steam leak cost.
  • At this operating point the engine returns 350 $ for fixed utility adder.

How this compares with the baseline

  • Against the tool's baseline example, where leaks active during operating hours sits at 80% and the headline result is 4,702 $, this scenario comes in 13.88% above the baseline at 5,355 $.
  • A figure at this level is achievable when leaks active during operating hours is genuinely sustained, not just peaked for a shift. The per-leak cost is an estimate that depends heavily on leak size, steam pressure, and fuel price, so the total is only as accurate as that assumption — meter or size leaks where possible.

Results at a glance

  • Total steam leak cost: 5,355 $ (headline result)
  • Cost per item or period: 669 $ / item
  • Variable steam leak cost: 5,005 $
  • Fixed utility adder: 350 $

Run it with your numbers

  • Every input above is editable in the live Steam Leak Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.