Compressed Gas Leak Survey Services for Industrial Plants
Serving South Carolina, North Carolina & Georgia — Greenville, SC Based
Compressed gas leaks are one of the largest hidden costs in any industrial plant. A single 1/8-inch leak in a compressed gas system can waste thousands of dollars in energy every year — and most plants have dozens. Newton Industrial Solutions conducts professional compressed gas leak surveys using ultrasonic detection technology to locate every leak in your system, quantify the energy loss, and deliver a prioritized repair plan that pays for itself within months.
We serve manufacturing plants, food and beverage facilities, pharmaceutical plants, chemical facilities, and industrial campuses across South Carolina, North Carolina, and Georgia.
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30%+ Average energy savings after compressed gas leak survey |
25–30% Of compressed gas produced is lost to leaks in avg plant |
Fast ROI Most surveys pay for themselves within 60–90 days of repairs |
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WHAT IS A COMPRESSED GAS LEAK SURVEY |
What Is a Compressed Gas Leak Survey?
A compressed gas leak survey is a systematic, plant-wide inspection of your entire compressed gas distribution system — piping, fittings, valves, regulators, couplings, hoses, and end-use connections — using ultrasonic detection equipment that identifies leaks invisible to the naked eye and inaudible in a noisy plant environment.
Every leak is located, tagged, measured, and documented with its estimated energy loss in CFM and dollars per year. You receive a complete report with every leak ranked by severity and repair cost versus savings — giving your maintenance team an immediate, actionable work order list.
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SURVEY PROCESS |
Our Compressed Gas Leak Survey Process
Step 1 — Pre-Survey System Review
Before arriving on site, we review your compressed gas system layout, operating pressures, and compressor capacity. This allows us to benchmark your system efficiency and identify the highest-priority areas to survey first.
Step 2 — Ultrasonic Leak Detection
Our technicians use professional-grade ultrasonic detection equipment to scan every component of your compressed gas system under normal operating pressure. Ultrasonic technology detects the high-frequency sound signature of escaping gas — identifying leaks at fittings, valves, hoses, couplings, and distribution points that visual inspection completely misses.
Step 3 — Leak Quantification and Tagging
Every identified leak is tagged with a numbered marker and logged with its location, component type, estimated leak size in CFM, and calculated annual energy cost. We photograph every tagged leak for inclusion in your report.
Step 4 — Energy Loss Calculation
Using your system pressure, compressor efficiency, and local energy cost, we calculate the exact dollar value of energy lost through every leak — individually and as a total facility figure. This gives you a documented ROI for your repair program before a single repair is made.
Step 5 — Prioritized Repair Report
You receive a complete survey report including: full leak inventory with locations and photos, CFM and annual cost per leak, total facility energy loss, repair priority ranking by ROI, and an executive summary for maintenance management and capital budget requests.
Step 6 — Optional Verification Survey
After repairs are completed, we offer a follow-up verification survey to confirm repaired leaks are sealed, measure actual energy savings versus projected, and identify any new leaks that have developed since the initial survey.
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WHAT YOUR SURVEY INCLUDES |
What Is Included in Every Survey
- Complete plant-wide ultrasonic scan of all compressed gas piping, fittings, and end-use points
- Individual leak identification, tagging, and photo documentation
- CFM measurement and annual energy cost calculation per leak
- Total facility energy loss estimate and repair ROI projection
- Prioritized repair report ranked by cost savings and repair complexity
- Executive summary ready for management review and capital budget requests
- Optional follow-up verification survey after repairs
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INDUSTRIES |
Industries We Serve
Compressed gas systems are used across virtually every industrial sector. Newton Industrial Solutions has experience conducting gas leak surveys in:
- Manufacturing plants — automotive, aerospace, rubber, plastics, fabrication
- Food and beverage facilities — process lines, pneumatic conveyors, packaging equipment
- Pharmaceutical and biotech — clean dry air systems, nitrogen, process gas
- Chemical plants — specialty gas distribution, process gas systems
- Pulp and paper mills — large compressed air systems, pneumatic controls
- Textile and carpet manufacturing — high-volume compressed air users
- Healthcare and institutional — compressed medical air, nitrogen systems
- Metal forming and fabrication — plasma cutting, pneumatic tooling
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SERVICE AREAS |
Service Areas — Compressed Gas Leak Survey
We provide on-site compressed gas leak surveys throughout the Southeast United States:
South Carolina
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Greenville SC |
Spartanburg SC |
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Columbia SC |
Charleston SC |
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Rock Hill SC |
Anderson SC |
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Florence SC |
Aiken SC |
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Myrtle Beach SC |
Sumter SC |
North Carolina
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Charlotte NC |
Raleigh NC |
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Greensboro NC |
Durham NC |
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Winston-Salem NC |
Asheville NC |
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Wilmington NC |
Fayetteville NC |
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High Point NC |
Gastonia NC |
Georgia
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Atlanta GA |
Savannah GA |
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Augusta GA |
Columbus GA |
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Macon GA |
Albany GA |
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Rome GA |
Dalton GA |
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Brunswick GA |
Warner Robins GA |
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FAQ SECTION |
Frequently Asked Questions
How do you detect leaks in a noisy plant environment?
We use ultrasonic detection equipment that operates in a frequency range well above typical plant noise. The technology picks up the specific high-frequency acoustic signature of escaping gas — making it highly effective even in loud manufacturing environments where audible leak detection is impossible.
Do we need to shut down to conduct the survey?
No. Compressed gas leak surveys are performed under normal operating pressure with the system running. A shutdown would actually make detection impossible since there would be no pressure driving gas through the leaks. We survey your system during normal production hours with zero process interruption.
How much energy do most plants waste from compressed gas leaks?
Industry data consistently shows that 25 to 30 percent of all compressed gas produced in a typical industrial plant is lost to leaks. In older facilities or those that have never had a formal survey, this figure can exceed 40 percent. Even a 10 percent reduction in leak losses typically yields significant annual energy savings.
How quickly can we schedule a survey in South Carolina, North Carolina, or Georgia?
Being based in Greenville, SC, we can typically schedule surveys within one to two weeks across all three states. For Upstate SC facilities near Greenville, scheduling is often faster. Contact us with your facility details and we will confirm availability promptly.
What is the typical ROI on a compressed gas leak repair program?
Most facilities achieve full payback on both the survey cost and repair costs within 60 to 90 days purely from energy savings. The survey itself typically costs far less than the annual energy value of the leaks we find. We document projected savings in the report so you can calculate ROI before approving any repairs.
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Reach Out Us |
Stop Paying for Compressed Gas That Never Reaches Your Equipment
Newton Industrial Solutions provides professional compressed gas leak surveys for industrial plants across South Carolina, North Carolina, and Georgia. Based in Greenville, SC — we travel to your facility and deliver results your maintenance team can act on immediately.
Call: 864-432-3510
Email: info@newtoninds.com