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Steam Leakage
Quantification and Cost
Kelly Paffel
Technical Manager
Swagelok Energy
440-649-2738
Kelly.paffel@swagelok.com
Swagelok Energy
• Energy losses
• Increase in Emissions
• Loss of reliability
• Production issues
• Safety
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Swagelok Energy
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STEAM LEAKAGE CORRECTION Swagelok Energy
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BASICS Swagelok Energy
P1 = ?
P2 = 0
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• A constant has to be
used in the equation to P2 = 0
compensate for this
factor
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P1 = ?
P2 = 0
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BASICS Swagelok Energy
P2 = 0
6” Volume
6”
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• Volume is depended on
orifice diameter and
pressure
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1/8" Leak
Pressure Steam Loss (pph) Cost / Hour Days / Year Cost / Year
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3/8” STEAM LEAK Swagelok Energy
3/8" Leak
Pressure Steam Loss (pph) Cost / Hour Days / Year Cost / Year
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Swagelok Energy
Distance: 6”
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Valve size: ¾”
Valve opening: 1/3
¼” leak
Pressure: 140 psig
Cost: $ 14,367.00
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Swagelok Energy
Distance: 14”
Valve size: ½”
Valve opening: 3/4
3/16” leak
Pressure: 150
Cost: $ 11,605.00
Swagelok Energy
Swagelok Energy
Distance: 40”
Leak: 3/16
Pressure: 250
Cost: $ 18,651.00
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Best guess
Extremely hard to
determine diameter of
the orifice
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WHAT CAUSES STEAM LEAKS Swagelok Energy
• Piping/tubing
– Connections
• Threaded connections
Expansion and contraction
–
CO2 corrosion
–
– Erosion
• Steam Component Failures
– Valves
– Steam traps
– Etc.
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• Expansion and
contraction from steam
system start up and
shut downs
• CO2 Corrosion or
carbonic acid
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Tubing
Pipe Threaded
Connections
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CO2 CORROSION Swagelok Energy
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EROSION
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RELIABILITY Swagelok Energy
• Valve selections
– Isolation valves are purchased already have internal leakage
occurring
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VALVE FAILURES Swagelok Energy
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• Lower pressures =
lower temperatures,
which create problems
in the tracer system
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SOLUTIONS TO PREVENT STEAM
LEAKAGE Swagelok Energy
• Product selection
• System design
• Installation design
• Operation
– SOP’s
• Root cause analysis has to be part of the program
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Swagelok Energy
• Tubing/tubing
connectors
– Eliminate threaded
connections
– Threads are used so the
plant does not have to
weld
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Standard Pipe Connections Swagelok Energy
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• We can no longer
accept steam losses
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TODAY’S STEAM SYSTEM OPERATIONS Swagelok Energy
• No steam leaks
• No steam loss to
atmosphere
Swagelok Energy
Mission Statement
Provide world class energy services to help Swagelok customers
optimize their in-plant steam and condensate operations.
World-Class Services
• Standardized training programs
• Customized training programs
• In-plant steam system audits
• Steam and condensate system
design
• Project management and
consulting services
• Engineering Support Services
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