The 12 Days of Downtime Prevention

As many plants prepare for the Christmas period, steam systems continue running even when staffing levels drop. With limited personnel on-site, a small issue can quickly grow into an unplanned shutdown and holiday deliveries aren’t always guaranteed.

To help maintenance and reliability teams stay ahead, we’ve created the 12 Days of Downtime Prevention: a practical, no-nonsense checklist of common seasonal risks and the simple actions you can take to prevent disruptions.

Each day highlights a real-world issue our engineers see frequently in December, along with the recommended spares that keep your system protected during low-staff periods.

Let’s get into it.


Day 1 — Steam Trap Freeze Risk
Freezing temperatures can cause traps on exposed pipe runs to ice over, stopping discharge and backing up condensate.

What to look for:
• No discharge at expected intervals
• Excessive condensate build-up

Prevention:
Check insulation along exposed piping. Ensure trap jackets are intact.

Recommended spares: Thermodynamic trap discs & repair kits.



Day 2 — Strainer Blockage from Sludge
Winter increases sludge and debris across steam and condensate lines.

Symptoms:
• Reduced flow
• Control valve hunting

Prevention:
Inspect Y-strainers, especially in cold-end areas.

Recommended spares: Replacement screen elements & gasket sets.



Day 3 — Low Water Level Trips
Seasonal demand changes can make level controls more sensitive.

Symptoms:
• Unexpected boiler shutdowns
• Repeated low-level alarms

Prevention:
Clean level probes and confirm gasket integrity.

Recommended spares: Probe kits & float chamber gaskets.


Day 4 — Waterhammer in Return Lines
Cold condensate, partial blockages and low flow conditions increase the chance of waterhammer.

Symptoms:
• Intermittent banging
• Pipe movement or vibration

Prevention:
Check F&T traps for partial blockages and correct installation.

Recommended spares: F&T internals & check valve components.


Day 5 — Gasket Fatigue at Flange Joints
Metal contraction in cold conditions weakens gaskets and flange seals.

Symptoms:
• Steam leaks
• Hissing noises around joints

Prevention:
Re-torque high-vibration flanges and inspect gasket condition.

Recommended spares: Spiral wound, EPDM or PTFE gasket packs.


Day 6 — Control Valve Drift in Low Usage
Stop/start holiday operation puts strain on valve seats and diaphragms.

Symptoms:
• Temperature drift in controlled processes

Prevention:
Check actuator travel and look for signs of seal wear.

Recommended spares: Seat kits, diaphragms & packing kits.


Day 7 — Feedwater Strainer Fouling
Cold months bring rust flakes, sediment and feedwater impurities.

Symptoms:
• Slow boiler response
• Poor firing characteristics

Prevention:
Check feedline filters before shift changes.

Recommended spares: Feedwater strainer screens.


Day 8 — Clean Steam Gasket Failure
Sanitary gaskets become brittle in low temperatures risking compliance issues.

Symptoms:
• Product contamination risk
• Aroma or taste variations

Prevention:
Inspect hygienic connections and seals.

Recommended spares: EPDM/PTFE hygienic gasket kits.


Day 9 — Trap Blow-Through
Continuous discharge wastes energy and hides deeper issues.

Symptoms:
• High steam consumption
• Hot return lines

Prevention:
Listen for traps discharging continuously.

Recommended spares: Replacement seats and discs.


Day 10 — Condensate Lift Failure
Colder condensate increases the workload on pump traps and lift stations.

Symptoms:
• Backed-up condensate
• High backpressure

Prevention:
Check check-valve functionality and inspect lift performance.

Recommended spares: Check valve internals.



Day 11 — Heat Exchanger Fouling

Seasonal load changes create pockets of fouling and slow warm-up times.

Symptoms:
• Poor throughput
• Delayed heating cycles

Prevention:
Inspect traps on exchanger outlets and check for subcooling.

Recommended spares: Thermostatic trap elements.


Day 12 — “Just-In-Case” Stock Buffer
Even the best-run facilities face unexpected issues especially with skeleton staff.

Symptoms:
None… until they’re urgent.

Prevention:
Hold a +1 buffer of your high-risk, long-lead and fast-moving spares.

Recommended spares: Mixed “Just-In-Case” stocking bundles.

Each point above is based on thousands of real customer interactions across winter periods. The combination of reduced staffing, colder weather and holiday delivery delays means December is the riskiest month for unplanned downtime in steam systems. A few low-cost spares often less than the price of a service call are all it takes to keep your system stable during the holiday window.

Ready to Protect Your Plant This Holiday Season?
Spirax Sarco has critical spares in stock now, with guaranteed pre-31 December delivery on available items.

Choose your next step:

👉 Book a 10-Minute Peace-of-Mind Stock Check
A Spirax Sarco engineer will help identify stocking gaps based on your plant.

👉 Build your Year-End Spares Bundles
Based on your needs and site requirements.

👉 Ask for Recommended Stock Levels
Get tailored advice for your systems, load profile and industry.