Enter the number of traps, steam pressure, orifice size and your latest survey results to see how much steam escapes and what it costs per year. Compare it with the cost of a survey and replacement program.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
Napier’s formula with the discharge factor entered, at three steam pressures.
Steam lost through open and leaking traps, plus the annual program cost.
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Cash flow of the improvement: investment in year 0 and annual savings escalated at the rate entered, discounted at the MARR.
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By Napier’s formula, a 1/8 in orifice at 150 psig passes about 62 lb/h of steam through a clear orifice. With a 50% discharge factor that is about 31 lb/h; over 6,000 h a year, about 187,000 lb, roughly $1,900 at $10 per 1,000 lb.
Without a survey program, audits find 15% to 30% of traps failed. With annual testing and replacement of failed units, the rate stays below 5%.
It loses no steam, but condensate backs up in the equipment: heat transfer drops and water hammer and corrosion appear. The cost is in production and maintenance and is not counted as steam here.
Napier’s formula assumes a fully open orifice passing only steam. In practice condensate passes too and the orifice may be partly blocked; savings verification guides use 50% to avoid overstating the gain.
Important notice: Indus Metrics tools produce estimates and pre-sizing results from the data you enter and from published engineering methods. They do not replace design, calculations or reports signed by a licensed professional engineer (PE), nor verification against the applicable codes, standards and regulations, such as OSHA rules and the ASME codes. Material and fuel properties vary: check manufacturer data or your own process analyses before deciding. By using this site you agree to the Terms of Use.
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