Industrial Steam Trap Survey Services — Stop Energy Waste Before It Costs You Thousands
A single failed steam trap can waste $5,000–$10,000 in energy per year. Most facilities have dozens. Newton Industrial Solutions conducts comprehensive steam trap surveys using ultrasonic detection technology to identify every failed, leaking, and bypassed trap in your plant — before your next utility bill forces the conversation.
We serve manufacturing, food & beverage, pharmaceutical, pulp & paper, chemical, and healthcare facilities across South Carolina, North Carolina, and Georgia.
30%+ Average energy savings from steam trap survey | 2–3× Typical ROI in year one | 100% Of facilities have at least one failed trap |
What Is a Steam Trap Survey?
A steam trap survey (also called a steam trap audit or steam trap inspection) is a systematic evaluation of every steam trap in your facility. Our technicians use ultrasonic testing equipment and temperature measurement to determine whether each trap is:
- Operating correctly (passing steam and blocking condensate)
- Failed open — blowing live steam directly to condensate return, wasting energy continuously
- Failed closed — blocking condensate flow, causing water hammer, corrosion, and process problems
- Bypassed or isolated — hiding a problem that will resurface later
- Blowing through — partially failed, wasting steam intermittently
Every trap is logged, photographed, and documented in a detailed report with failure mode, energy loss estimate, repair priority, and cost-benefit analysis.
Our Steam Trap Survey Process
Step 1: Pre-survey planning
Before we arrive, we gather your steam system drawings, trap inventory (if available), and operating pressures. If no trap inventory exists, we build one as part of the survey. We coordinate with your maintenance team to ensure safe access to all trap locations.
Step 2: Ultrasonic and thermal testing
Our technicians use ultrasonic detection equipment combined with infrared temperature measurement on every trap in your system. Ultrasonic technology detects steam blow-through that visual inspection completely misses. We test every trap under normal operating conditions — no shutdowns required.
Step 3: Failure classification and energy loss calculation
Each failed trap is classified by failure mode and assigned an energy loss value based on your steam pressure, trap orifice size, and fuel cost. This gives you a dollar-per-year figure for every failed trap — not just a list of problems.
Step 4: Prioritized repair report
You receive a comprehensive report including: full trap inventory with GPS/location tagging, test results for every trap, failure classification, energy loss estimate per failed trap, total facility energy loss, repair recommendations ranked by ROI, and an executive summary suitable for capital budget requests.
Step 5: Optional follow-up verification survey
After repairs are completed, we offer a follow-up verification survey to confirm repaired traps are operating correctly and calculate your actual energy savings versus projected — giving you a documented ROI for your records.
Industries We Serve
Steam systems are used across a wide range of industrial and commercial facilities. Newton Industrial Solutions has direct experience conducting steam trap surveys in:
- Manufacturing plants — automotive, aerospace, rubber, plastics, metal forming
- Food & beverage facilities — cooking, sterilization, pasteurization, CIP systems
- Pharmaceutical and biotech — process steam, clean steam, autoclaves, HVAC
- Pulp & paper mills — digesters, dryers, evaporators, black liquor systems
- Chemical plants — reactors, distillation, heat exchangers
- Healthcare and hospitals — sterilization, laundry, HVAC steam systems
- Commercial and institutional — universities, government facilities, large campuses
Each industry has unique steam system requirements, regulatory considerations, and failure consequences. Our team understands those differences and tailors every survey report to your specific operational context.
Why Ultrasonic Steam Trap Testing vs. Visual Inspection
Many facilities rely on temperature guns or simple visual checks to assess steam traps. This misses the majority of failures. Here is why ultrasonic testing is the professional standard:
Method | What it detects | Failure rate missed |
Visual inspection | Obvious leaks only | Up to 80% |
Temperature gun only | Cold traps (failed closed) | 50–60% |
Ultrasonic testing (Newton) | Open, closed, blowthrough, cycling failures | Minimal |
Service Areas — Steam Trap Survey
Newton Industrial Solutions provides on-site steam trap surveys throughout the Southeast United States. Our primary service territory includes:
South Carolina
Greenville · Spartanburg · Columbia · Charleston · Rock Hill · Anderson · Florence · Myrtle Beach · Sumter · Aiken
North Carolina
Charlotte · Raleigh · Greensboro · Durham · Winston-Salem · Asheville · Wilmington · Fayetteville · High Point · Gastonia
Georgia
Atlanta · Savannah · Augusta · Columbus · Macon · Albany · Rome · Dalton · Brunswick
Outside these areas? Contact us — we travel for larger facilities and multi-site contracts.
Frequently Asked Questions
How long does a steam trap survey take?
Survey duration depends on the number of steam traps in your facility. A typical industrial plant with 50–150 traps takes one to two days on-site. Larger facilities with 300+ traps may require two to three days. We schedule around your production to minimize disruption.
Do we need to shut down to do the survey?
No. Our ultrasonic testing is conducted under normal operating conditions. No shutdowns, no process interruptions. We test traps while your system is running — this actually produces more accurate results since we can observe each trap’s normal operating cycle.
What does a steam trap survey typically cost?
Survey cost varies based on facility size, number of traps, and location. Most industrial clients see full ROI within three to six months from energy savings alone — before accounting for avoided repairs and reduced downtime. Contact us for a facility-specific quote.
We don’t have a steam trap inventory. Can you still do the survey?
Yes — and this is more common than you might think. If you don’t have a trap inventory, we build one as part of the survey. Every trap is documented with location, manufacturer, type, and size. You receive a complete trap inventory as part of your survey deliverables.
How often should we do a steam trap survey?
Most industrial facilities should survey their steam traps every 12–18 months. Facilities with older or high-pressure systems, or those with poor historical maintenance records, may benefit from surveys every 6–12 months. After an initial survey and repair program, many clients maintain an annual inspection cadence.
Do you repair steam traps as well as survey them?
Our primary service is the survey, testing, and reporting. We provide detailed repair specifications and can connect you with qualified contractors. Some clients prefer to complete repairs with their in-house maintenance team using our prioritized repair report as a work order list.
What is the typical failure rate found in a steam trap survey?
Industry data consistently shows 15–25% of steam traps in an untested facility are in some state of failure. In facilities that have never had a formal survey, we commonly find failure rates of 20–30%. Even a single large failed trap can justify the entire cost of a survey.
Ready to Find Out What Your Failed Steam Traps Are Costing You? |
Newton Industrial Solutions provides expert steam trap surveys across South Carolina, North Carolina, and Georgia. Our team has experience in food & beverage, pharmaceutical, pulp & paper, manufacturing, and chemical industries.
Call us: 1-864-432-3510
Email: info@newtoninds.com
Or use our contact form at newtoninds.com/contact-us
Our Services
Newton Industrial Solutions conducts
professional steam trap surveys across South Carolina, North Carolina, and
Georgia. Our Greenville, SC-based team serves the full Southeast — from
automotive plants in Upstate SC to paper mills in Savannah to pharmaceutical
facilities in Raleigh. Select your state below for city coverage, industry
experience, and location-specific information.