Steam leaks are a common problem in industrial manufacturing facilities, and they can be costly in terms of both energy waste and lost productivity. However, many companies underestimate just how much money they can save by a prompt internal pipe repair.
So, What Is a Steam Leak?
A steam leak is an unintended release of high-pressure steam from a system due to a breach in containment. When steam leaks out of a system, energy is lost and must be replaced by additional energy. It can also pose safety hazards, including burns, and may also result in energy loss and equipment damage.
According to the US Department of Energy, steam leaks can account for up to 20% of total steam production in an industrial facility. A significant portion of the energy used to produce steam is wasted. In addition, leaks can result in increased maintenance costs and downtime, as well as safety concerns for workers.
How Do Companies Solve This Problem?
To address these issues, many industrial facilities have implemented steam leak detection and internal pipe repair programs. These programs involve regular inspections to identify and repair leaks in the steam system.
What Are Other Benefits of Internal Pipe Repair?
One study by the US Department of Energy found that steam leak detection can result in significant cost savings for industrial facilities. The study examined five manufacturing plants that implemented steam leak detection and repair programs. The results showed that these programs resulted in an average energy savings of 15%, with a payback period of less than one year. More specifically, these plants combined saved over $1 million in costs.
Analyzing the results of this study tells us repairing steam leaks will cause industrial manufacturing facilities to realize significant cost savings. For example, a steam leak with a diameter of just 1/8 inch can waste up to 2,500 pounds of steam per year. Assuming a cost of $10 per 1,000 pounds of steam, this would result in an annual cost of $25 for just one small leak. Multiply that by dozens or even hundreds of leaks, and the cost quickly adds up. This is an example of a small steam leak. Most industrial facilities have much larger diameter steam piping.
In addition to the cost savings achieved through reduced energy consumption, repairing steam leaks can also lead to increased efficiency and capacity within the steam system. By maintaining proper pressure levels and preventing damage to equipment, the system can operate more smoothly and effectively, reducing the likelihood of downtime and costly repairs.
Consider Investing In Repairs
Overall, repairing steam leaks is a simple and cost-effective way for industrial manufacturing facilities to reduce their operating costs, improve their overall efficiency, and keep their team members safe. By investing in regular maintenance and internal pipe repair of their steam systems, these facilities can realize significant cost savings over time, allowing them to remain competitive and profitable in a challenging economic environment.
Contact RAK today to see how we can help make your company more efficient and cost-effective.
