How much steam is lost?
An opening of just a few millimeters allows steam to escape continuously under pressure. At 5 bar(g) and a 3 mm opening, approximately 21.6 kg of steam is lost per hour. Over a year of 8,000 operating hours, that amounts to 173 tons, or approximately €8,640 at a steam cost of €50 per ton. Per leak.
At 5 bar(g) and 8,000 operating hours per year.
Preferably use your own calculated steam cost. This varies greatly per installation, depending on fuel price, boiler efficiency, and the rate of condensate return.
Calculate it for your own installation
Enter your leak size, pressure, operating hours, and steam cost to immediately see the annual cost.
What do you look for during a walkthrough?
Flanges and connections
- A visible plume or a hissing sound
- Traces of moisture around the connection
- Damaged or wet insulation, often the first sign
Valves
- Stem packing and stuffing box
- Flange and welded connections
- Seating faces of the seat
Steam traps
- A failed-open steam trap allows live steam to pass through and is the most expensive type of leak
- Diagnosis is done by measurement, not by sight: a trap that feels warm may be functioning perfectly
- Record the type and position of each trap so you can compare during the next walkthrough
Prevent steam loss at the source
Some leaks are not in the piping but in the valve itself. The KVN valve operates using elastic sealing rings and is not pressed against a conventional seat. This construction combines uniform operating torque, a protected sealing surface, and a self-cleaning effect, which reduces the risk of leakage at the valve.
Frequently asked questions
I am a heading
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How large is a visible steam leak?
Smaller than you think. The visible plume is condensed vapor and is many times larger than the opening the steam escapes from. Estimate or measure the opening, not the plume.
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How many steam traps leak on average?
That depends heavily on the maintenance regime and the age of the installation. An audit with measurement is the only way to know for your specific installation. What we do observe: the percentage increases the longer systematic checks have been neglected.
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What does steam cost per ton?
This varies per installation. Fuel price, boiler efficiency, the rate of condensate return, and water treatment all determine the cost. Use your own figure if available; €40 to €60 per ton is a common range to start with.
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Have it measured
What your installation is actually losing only becomes clear during a walkthrough with measuring equipment. Our technicians map it out per measurement point and provide a report with prioritization.
Related expertise
Steam Trap Audit
Defective steam traps cost thousands of euros per year. Our steam trap audit shows you exactly which traps are leaking, what that costs, and the best order in which to address them.
Custom insulation jackets
Stopping heat loss where insulation is missing
On-site support
On-site troubleshooting, audits, product advice, and training.
*Indicative values for saturated steam escaping to the atmosphere through a circular opening. Actual values depend on the shape of the opening, the state of the steam, and local conditions. Intended as a commercial first indication, not as a guaranteed saving.