Plant Utilities worked example

Steam Leak Cost at 58% leaks active during operating hours: a worked example

This worked example runs the steam leak cost numbers for a tougher week than the baseline: 58% leaks active during operating hours instead of the typical 80%. Estimate steam leak cost exposure from leak count, estimated loss value, operating share, and repair adders.

The inputs for this scenario

  • Steam leaks found: 8 leaks (held at the documented default)
  • Estimated steam cost per leak: 680 $ / leak (held at the documented default)
  • Leaks active during operating hours: 58 % (the input this scenario stresses; the baseline uses 80)
  • Access, insulation, and repair adder: 350 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total steam leak cost = steam leaks found × estimated steam cost per leak × leaks active during operating hours + access, insulation, and repair adder.
  • Total steam leak cost works out to 3,505 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per item or period works out to 438 $ / item at these inputs.
  • Variable steam leak cost works out to 3,155 $ at these inputs.
  • Fixed utility adder works out to 350 $ at these inputs.

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 25.45% below the baseline at 3,505 $.
  • Use it after a steam-trap or leak survey to quantify total loss and build the business case for a repair campaign. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total steam leak cost: 3,505 $ (headline result)
  • Cost per item or period: 438 $ / item
  • Variable steam leak cost: 3,155 $
  • Fixed utility adder: 350 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Steam Leak Cost calculator, set leaks active during operating hours to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.