Plant Utilities worked example

Steam Trap Loss at 98% share of surveyed traps confirmed leaking: a worked example

What does the result look like when share of surveyed traps confirmed leaking reaches 98%? The full calculation is worked below with real intermediate numbers. Use it when reviewing steam trap loss for a utility budget, maintenance priority, capacity check, energy project, or production support plan.

The inputs for this scenario

  • Failed-open steam traps found in survey: 12 traps (unchanged)
  • Estimated annual steam loss cost per failed trap: 420 $ / trap (unchanged)
  • Share of surveyed traps confirmed leaking: 98 % (raised for this scenario; the documented default is 85)
  • Trap survey and repair mobilization cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total steam trap loss cost = failed open steam traps × estimated steam loss cost per trap × traps confirmed leaking + survey and repair setup cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,189 $ for total steam trap loss cost, the number this scenario is built around.
  • At this operating point the engine returns 432 $ / item for cost per item or period.
  • At this operating point the engine returns 4,939 $ for variable steam trap loss cost.
  • At this operating point the engine returns 250 $ for fixed utility adder.

How this compares with the baseline

  • Against the tool's baseline example, where share of surveyed traps confirmed leaking sits at 85% and the headline result is 4,534 $, this scenario comes in 14.45% above the baseline at 5,189 $.
  • A figure at this level is achievable when share of surveyed traps confirmed leaking is genuinely sustained, not just peaked for a shift. Per-trap loss cost is a blanket average; real loss varies enormously with orifice size, steam pressure, and hours of operation, so a mixed population of large high-pressure traps can be badly under- or over-estimated by one flat rate.

Results at a glance

  • Total steam trap loss cost: 5,189 $ (headline result)
  • Cost per item or period: 432 $ / item
  • Variable steam trap loss cost: 4,939 $
  • Fixed utility adder: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.