How much loss does a small steam leak create?

At a pressure of 7 bar(g), a 1 mm hole leaks approximately 3 kg of steam per hour, a 3 mm hole 26 kg, and a 5 mm hole 72 kg. The loss increases with the square of the hole diameter.

How to detect a faulty trap?

With ultrasonic listening, temperature measurement (excessive heat of the line after trap) and sight glasses. Regular steam trap surveys should be carried out several times a year.

Steam Leakage Calculation – Steam Escaping Through the Hole and Annual Cost

Small holes in flange seals, valve packing, and steam traps stuck open look small, but they lose a significant amount of steam throughout the year. This tool calculates the steam flow rate passing through a hole of a certain diameter; if the running time and steam cost are entered, it also shows the annual loss . The same method is used for the capacity of measurement and throttling orifices.

Method

Cv(equivalent) = C· (d/4,654)² → ṁ = valve equation (IEC 60534)

d: hole diameter (mm), C: discharge coefficient (≈ 0.6–0.7 for a sharp-edged hole). Flow into the atmosphere is usually critical; flow depends only on the inlet pressure.

Example

A 3 mm leak in a 7 bar(g) steam line loses approximately 26 kg of steam per hour. In 8,000 hours per year, this means 207 tons of steam; if steam costs 800 ₺ per ton, the annual loss is approximately 166,000 ₺.

You can find the cost per ton of steam with the steam cost calculation . To evaluate your steam system as a whole, you can take a look at our steam boiler guide and get a free quote for your project.

Steam Leakage and Orifice Flow Rate Calculation

Method

Example

Frequently Asked Questions