SteamIQ
SteamIQSteam Trap Intelligence

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Steam Loss Calculator

Calculate the financial impact of a failed steam trap. See how much energy and money a single failed trap costs your facility annually.

Steam Loss Calculator

Calculate steam losses using modified Grashof's equation
Config:
Boiler:%
$/therm
Steam Loss
72.1lb/hr
Energy
57,779BTU/hr
Therms/Year
5,061
Annual Cost
$4,555.29
1/8"
1/16"
1/2"
Sample Trap Orifices:
Higher pressure = higher energy loss
psig
0300 psig
100%
0%100% (Fully Failed)
8,760 hr/yr
1 hr8,760 hr (24/7)

Calculation Breakdown(Boiler: 80% × Line: 93.75% = 75.0% eff.)

1. Steam Flow Rate
SL = K × π × (d/2)² × P^0.97 × LF
= 72.1 lb/hr
2. Steam Props @ 150 psig
h₃=338.3 h₅=1195.6
λ = 857.2 Btu/lb
3. Flash Steam
= (h₃ - 180.1) / 970.3
= 16.3% (11.8 lb/hr)
4. Loss Mechanisms
L₂: 13,200 (flash)
L₄: 15,453 (boiler)
L₅: 18,544 (latent)
5. Hourly Fuel Energy
= (L₂+L₅)/eff + L₄
= 57,779 BTU/hr
6. Annual Therms
= (BTU/hr × 8,760) / 100k
= 5,061 therms
7. Annual Cost
= 5,061 therms × $0.90/therm
= $4,555.29/yr

How It Works

Uses a modified Grashof's equation with steam system attributes and recovery options.

Orifice Size

A failed steam trap acts like an open orifice. Larger orifices = more steam loss. Common failure sizes range from 1/16" to 1/2".

Energy Calculation

Steam flow is calculated using modified Grashof's equation, then combined with ASME steam table data and system recovery factors.

Annual Cost

Energy loss is converted to therms (1 therm = 100,000 BTU) and multiplied by your cost per therm to get annual losses.

Why Steam Trap Failures Matter

15-30%
of steam traps in a typical facility are failed at any given time
$5,000+
annual cost per failed trap at 150 psig running 24/7
3-6 mo
typical payback period for continuous monitoring

Multiply by Your Fleet Size

If one failed trap costs $5,000/year, what does a 15% failure rate cost across your entire fleet? SteamIQ monitors every trap 24/7 and alerts you the moment failures occur.

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