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Please write me a 5 page report outlining our 5 worst performing steam traps and prioritize their replacements by ROI. Include a full financial analysis with ROI calculations.
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Steam Loss Analysis Report
Executive Summary
Financial Impact Overview
During the 12-month analysis period, SteamIQ monitoring detected $14,929.80 in steam losses across 6 monitored steam traps at your facility. All 6 devices exhibited failure conditions requiring immediate attention, with 61 distinct performance anomalies detected and 213 coordinated operational events identified.
- Total Steam Loss: 1,546,218 lbs (11,545 therms)
- Average Daily Loss: $41.73
- Devices in Failed State: 6 of 6 (100%)
- Highest Loss Device: Acme-60 ($5,748.30 annually)
- Coordinated Plant Events: 213 system-wide disturbances
Worst Performing Devices
| # | Device | Location | Annual Loss | State | Priority |
|---|---|---|---|---|---|
| 1 | Acme-60 | B1B / 117: Load Side Autoclave 2 | $5,748.30 | Failed Open | CRITICAL |
| 2 | Acme-32 | Parking Garage B1 Entrance | $3,703.81 | Failed Open | CRITICAL |
| 3 | Acme-13 | CUP: Back Left Wall Over Railing | $3,653.22 | Failed Open | CRITICAL |
| 4 | Acme-34 | CUP: Far Back Wall Behind HV 1 | $1,034.87 | Failed Open | CRITICAL |
| 5 | Acme-17 | CUP: Behind HEX 2 | $636.75 | Failed Open | HIGH |
| 6 | Acme-16 | CUP: Behind HEX 1 | $152.85 | Failed Open | MEDIUM |
Plant-Level Operational Insights
SteamIQ detected 213 coordinated events affecting multiple traps simultaneously, indicating significant facility-wide operational patterns:
- Frequent System Cycling: 150+ synchronized events where 3-5 traps changed behavior simultaneously
- Seasonal Transitions: Major coordinated drops in late March and September indicating equipment shutdowns
- Temperature Correlation Events: Multiple instances where temperature and cycling patterns changed together
Device-by-Device Analysis
Acme-60 exhibited continuous failed-open operation throughout the entire monitoring period, representing the facility's most severe steam loss.
- February 4-28: Series of 6 complete cycle stops indicating bucket mechanism failure
- Late May: Persistent 7-day cycle failure marking permanent failed-open state
- November-December: Leak percentage oscillated 60-80%
This high-pressure drip leg trap demonstrated severe state instability with 111 state transitions—the highest oscillation rate among monitored devices.
Financial Analysis & ROI
Current State Summary
Return on Investment
Even in worst-case scenario (complications discovered), ROI still exceeds 600% over 3 years.
Each month of delayed action results in $1,244 in continued steam losses and 128,852 lbs of wasted steam.
Recommendations
Priority 1: Critical Safety Repairs (Next 30 Days)
| # | Device | Action | Impact | Payback |
|---|---|---|---|---|
| 1 | Acme-60 | Schedule during autoclave maintenance | $5,748/yr | 40 days |
| 2 | Acme-32 | Immediate repair (high-pressure safety) | $3,704/yr | 74 days |
| 3 | Acme-13 | Coordinate with Acme-17 repair | $3,653/yr | 63 days |
Conclusion
The SteamIQ monitoring system has identified $14,929.80 in annual steam losses across 6 monitored traps at your facility. A comprehensive repair program requiring $3,780 investment will deliver $14,482 in annual savings with payback in just 95 days and 3-year ROI exceeding 1,000%.
Generated in 28 seconds
SteamIQ analyzes your devices, history, and configuration to generate reports
Report Scope
Select assets and devices to include
Acme Industries-32
Acme Industries-60
Acme Industries-13
Acme Industries-34
Acme Industries-17
Acme Industries-16
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SteamIQ understands your facility and writes exactly what you ask for
"Write me a brief 2 page summary of our steam system performance YTD."
"Show me the top 5 steam trap failures in terms of losses in 2025."
"Which are the top 10 traps in terms of fastest ROI for repair?"
"Given you have determined our annual plant shutdowns and have historical natural gas pricing, when is an ideal time to perform these repairs?"
"I need an executive summary for plant management—focus on financial impact and top priorities."
"Generate a quarterly review comparing Q3 to Q2 performance."
Consultant-grade analysis, on demand
Generate any type of report your facility needs
Steam Loss Analysis
Detailed breakdown of losses by device, building, and system. Prioritized repair recommendations with payback calculations.
ROI & Financial Impact
Executive-ready financial summaries. Cost of inaction, repair ROI, budget justification.
Root Cause Analysis
Pattern detection across failures. Coordinated events, systemic issues, upstream problems.
Trend Reports
Performance over time. Quarter-over-quarter comparisons, improvement tracking, seasonal patterns.
Building/Zone Reports
Focused analysis by location. Perfect for building managers or zone-specific maintenance planning.
Compliance & Audit
Documentation for audits, sustainability reporting, and regulatory compliance.
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