Executive Summary

Your 90-device fleet generated $9,163 in steam losses over this reporting period, with 97.8% of devices reporting. The financial story, however, is one of sharp escalation: monthly losses climbed from $273 in December to over $3,100 in February before easing slightly to $2,914 in March. Five failed open devices and two leaking traps are driving the bulk of this exposure, and the losses are heavily concentrated — Extrusion Line 2 holds 31% of your devices but drives 68% of total losses. A previous repair on Cascade-24 in July 2025 demonstrated clear results — a $1,200 investment delivered 11.4× ROI before a second failure emerged in March.

The most urgent opportunity is Extrusion Line 2, where four devices — Cascade-51 and Cascade-58 (failed open) and Cascade-33 and Cascade-47 (leaking) — are simultaneously degraded, with Cascade-24 on the Steam Header adding the single largest daily loss at $37.56/day. Industry best practices indicate that clustered failures on a single process line often share a systemic root cause — condensate return conditions, supply pressure, or upstream factors — and replacing individual traps without investigating the shared condition risks recurrence. With Washington natural gas prices currently at $14.22/MCF and the fleet still in a seasonal low-demand window, this is the optimal time to schedule a coordinated maintenance visit before steam loads increase.

Fleet Health Overview

State Distribution

State	Count	Score
Good	18	100
Reduced Activity	56	90
Average	4	75
Leaking	2	50
Failed Open	5	0
Not Reporting	5	20

Note: The 56 devices in reduced activity are operating normally at low load — this is a healthy state, not a concern. Two of the 5 failed open devices (Cascade-72 and Cascade-77) are also not reporting due to the Cascade Enterprise 3 gateway outage.

Health Trajectory

The fleet health score opened the period at 90.4 and closed at 86.3, a net decline of 4.1 points. The trajectory tells a more nuanced story: a late-January dip coincided with new devices coming online and the first detection of open failures. A brief recovery to 92.4 in mid-February gave way to a sustained decline through March as the Extrusion Line 2 cluster emerged and Cascade-24 failed for the second time. The Cascade Enterprise 3 gateway outage in mid-March further depressed the score by taking 9 Building C devices offline. The unresolved failed open and leaking devices continue to pull the fleet score down.

Financial Impact

Monthly Loss Trend

Month	Loss	Change
Dec 2025	$273	—
Jan 2026	$2,828	+937%
Feb 2026	$3,149	+11.3%
Mar 2026 *	$2,914	−7.4%

* March includes 28 of 31 days (90.3% of month).

The December baseline was unusually low at $273, reflecting a period before the current failures were detected. Losses jumped sharply in January as the failed open traps came online, then plateaued in the $2,800–$3,100 range through February and March. The slight March decline coincides with seasonal load changes, but the five failed open devices and two leaking traps are sustaining the elevated loss level. Cascade-24 alone contributes $38/day — nearly a third of current daily fleet losses.

Asset Concentration

Top 5 Device Offenders

Device	Asset	State	Daily Loss	Period Loss
Cascade-24	Steam Header	Failed Open	$38/day	$563
Cascade-51	Extrusion Line 2	Failed Open	$12/day	$136
Cascade-58	Extrusion Line 2	Failed Open	$10/day	$88
Cascade-33	Extrusion Line 2	Leaking	$6/day	$62
Cascade-47	Extrusion Line 2	Leaking	$5/day	$44

Losses are sharply concentrated. Extrusion Line 2 holds 31% of your devices but drives 68% of total losses — 3.8× the fleet average per device. Four problem devices on this line (Cascade-51, Cascade-58, Cascade-33, and Cascade-47) account for the bulk of the exposure. Steam Header runs below fleet average overall, but Cascade-24 alone is losing $38/day — the single worst device in the fleet. The takeaway: addressing Extrusion Line 2 and repairing Cascade-24 would eliminate the majority of your fleet's financial exposure.

ROI Spotlight

Outstanding repair opportunities: Five devices offer strong financial payback — Cascade-24 at $38/day (32-day payback), Cascade-51 at $12/day, Cascade-58 at $10/day, Cascade-33 at $6/day, and Cascade-47 at $5/day. Combined addressable daily loss from the top 5 offenders: $71/day.

Energy Cost Context

Industrial gas prices in Washington have historically peaked in November and reached their lowest in September — a 65% swing that directly impacts the cost of every therm of wasted steam. Your reporting period (January–March) falls squarely in the high-cost winter window, meaning the current failures are occurring when fuel is most expensive. December 2025 pricing of $14.22/MCF is 21.5% higher than December 2024, adding year-over-year cost pressure on top of the seasonal pattern.

Your currently failed traps are losing 11.6 therms per day. Based on the historical pricing pattern for the next six months, leaving these traps unrepaired would cost an estimated $2,941. The monthly cost would range from $543 in April down to $397 in September as prices follow their seasonal decline — but every month of deferral adds to the cumulative total. Repairing now, while the fleet is in a low-demand period and maintenance access is easier, captures the savings during the months when each therm costs the most.

The pricing trend also reinforces the urgency of the Extrusion Line 2 cluster repair: with gas prices 23% above the national average in Washington, every hour of steam loss through a failed or leaking trap carries a premium cost compared to facilities in lower-cost regions.

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