A steam trap survey is an audit of all steam traps in a facility to determine their operating condition and efficiency. Steam traps are automatic valves that remove condensate (liquid water) and non-condensable gases from steam systems while preventing live steam loss. In an industrial plant, hundreds or thousands of steam traps help ensure steam is used effectively for heating or process needs.
Over time, however, steam traps can fail open (leaking steam constantly) or fail closed (blocking condensate discharge). Either failure mode wastes energy, impacts productivity, and can even create safety hazards like water hammer. A steam trap survey finds these failed traps so they can be repaired or replaced. This is critical, as even a single failed trap can waste thousands of dollars in energy per year. In this guide, we’ll explain what a steam trap survey involves, why it’s so important, recent statistics on energy losses from failed traps and best practices.
What is a Steam Trap Survey?
A steam trap survey is essentially a health check and evaluation for your steam system’s traps. It involves inspecting each steam trap in the facility to verify if it is operating properly. Trained technicians use specialized tools to test trap performance under normal operating conditions. Each trap is typically checked for signs of failure. A leaking trap will blow live steam (often detected by ultrasound or thermal imaging), whereas a failed-closed trap will be cold and prevent condensate flow.
The survey usually includes documenting each trap’s location, type, model, operating pressure, and condition in a report or database. Importantly, a steam trap survey is not just a one-time check, but part of an ongoing steam trap management program.
The U.S. Department of Energy (DOE) emphasizes that implementing almost any type of proactive steam trap maintenance program is beneficial and highly cost-effective. Regular surveys help catch failures early, reducing energy waste and preventing problems from compounding.
Why Are Steam Trap Surveys Critical?
When steam traps fail, they can leak a surprising amount of steam. Recent data shows that the energy losses due to failed traps are enormous across U.S. industry. According to the Federal Energy Management Program (FEMP), roughly 20% of the steam leaving a boiler in a typical space heating system is lost through leaking traps if no proactive maintenance program is in place. In other words, without regular trap surveys and fixes, you could be losing one-fifth of your steam production straight through failed traps. This represents wasted fuel, wasted money, and unnecessary carbon emissions.
The U.S. Department of Energy estimates 15% to 30% of steam traps in a system will fail within 3-5 years if they are not regularly inspected and maintained, impacting customers significantly. Even in systems that are maintained, industry data shows an annual failure rate of about 5% to 10% of traps. If surveys are neglected for multiple years, these failures accumulate, underscoring the importance of conducting surveys on a regular basis.
The cost impact of these failed traps is significant. A single leaking steam trap can hemorrhage steam 24/7. One analysis estimated that a moderately sized trap (1″, at ~160 psig steam) leaking just 48lbs of steam per hour will waste about 190 metric tons of steam per year. This equates to roughly $7,000 USD per year in lost energy (assuming typical steam generation costs). In real-world surveys, service providers commonly uncover $50,000 to $250,000 per year in energy losses due to failed traps at a single facility.
There’s also the environmental cost – wasted steam means wasted fuel (natural gas, coal, etc.) burned at the boiler, which results in needless CO2 emissions. Fixing steam leaks is an easy way to cut a site’s carbon footprint.
The payoff is immediate – the DOE observed that replacing failed traps typically pays back in well under a year through energy savings. In the federal sector, it was estimated that a comprehensive trap maintenance program could save $80 million annually with an average payback of less than 6 months.
Pre-Survey Preparation
A proper steam trap survey starts with preparation. The survey team will gather a list of all steam traps in the facility, organizing them in order of their locations, service, and types of traps (thermodynamic, float & thermostatic, inverted bucket, etc.). This serves as a baseline and helps identify areas that may require special attention. Reviewing historical maintenance records and past survey data can help identify recurring issues and prioritize problem areas.
If a current map or database doesn’t exist, part of the survey is to locate and tag each trap with an ID number for record-keeping. This upfront work ensures no trap is overlooked and helps in analyzing results later.
Survey Procedure
Technicians typically follow a route through the plant, ensuring each steam trap is surveyed one by one. For each steam trap, they will:
- Identify the trap and its tag. Note its type and operation (is it cycling on/off or modulating)
- Apply the ultrasonic probe to listen to flow while also measuring temperature.
- Ultrasonic detector – a handheld device (often with headphones and a probe) that “listens” for the high-frequency sound of steam flowing. A good trap operating correctly will have distinct intermittent sounds (for cyclic traps) or a steady condensate flow sound. A trap blowing steam has a high, continuous rushing sound. Ultrasonic testing is considered the industry standard for trap inspection due to its accuracy in detecting even small leaks.
- Temperature measurement – usually an infrared thermometer or thermal imaging camera is used to check the trap’s inlet and outlet temperatures. A significant drop in temperature across a trap can indicate it’s stuck closed (cold outlet). A trap stuck open might show abnormally high outlet temperature or visible steam plumes downstream. Many ultrasonic tools include an IR sensor to capture temperature as well. Temperature alone can be misleading (for example, a trap could be hot but still leaking), so it’s used in conjunction with ultrasound for a reliable diagnosis.
- Classify traps condition as Good, Leaking or Blow-through, Blocked/Cold, or other statuses like inverted (installed wrong) or not in service.
- If a trap is blowing steam, estimate the steam loss rate. This can be done by using diagnostic tools or charts that correlate orifice size and pressure to mass flow of steam. The loss is then converted to an annual energy cost and even CO2 emission equivalent.
- Note any system issues around the trap (e.g. plugged strainers, improper piping, missing insulation, water hammer evidence) so that those contributing factors can be addressed.
- Good reports will highlight the worst offenders – for instance, the top 10 blowing traps and their individual losses – so maintenance can prioritize high-value fixes first.
Industry Best Practices and Guidelines for Steam Trap Surveys
Leading organizations and vendors in steam system management have published best practices that can help facilities optimize their steam trap survey efforts. Here we outline some key guidelines, with references to expert sources:
- Survey Frequency: Perform steam trap surveys at least annually in most plants. High-use or critical process facilities might survey semi-annually or quarterly. The U.S. DOE suggests proactive programs to significantly cut losses.
- Use Proper Testing Methods: Rely on ultrasonic and temperature measurement techniques rather than purely visual or auditory guesses. If your maintenance team performs surveys in-house, ensure they have a quality ultrasonic leak detector and know how to use it.
- Train Personnel or Use Experts: A steam trap survey may sound straightforward, but interpreting the results can be tricky in certain situations. Training is important so that technicians understand different trap types and failure modes. For instance, thermostatic traps behave differently than thermodynamic traps, and an inexperienced person might misjudge normal cycling as a leak or vice versa.
- Data Management: Keeping good records is half the battle – you want to track each trap’s history (when it was last inspected, what its condition was, when it was last replaced, etc.). This data helps in budgeting and planning (e.g. knowing you replaced 50 traps last year might inform how many spares to stock).
- Best-in-Class Goals: Strive for a low trap failure rate as your KPI. Industry experts consider < 5% failure rate to be “best in class” performance for a steam trap population. Armstrong analyzed hundreds of sites and found only about 20% had achieved failure rates below 5% (usually those with comprehensive programs).
Case Studies and Real-World Examples
Real-world results highlight the value of steam trap surveys in reducing energy loss, improving efficiency, and justifying ongoing investment.
- Midwest University: A campus-wide survey revealed a 15% trap failure rate, equating to over $220,000 in annual steam losses. After replacing failed traps and conducting follow-ups, the university saved an additional $120,000 over two years and improved startup times—demonstrating strong ROI and improved steam system performance.
- University of Notre Dame: An initial survey showed a 31.4% failure rate and millions of pounds of wasted steam. After corrective action, the rate dropped to 15.7%, cutting steam loss by 9.6 million lbs, saving over $70,000 annually, and eliminating 3.4 million lbs of CO₂ emissions.
- Hospital System: A trap survey uncovered failed traps causing uneven heating and higher energy use. Replacements improved steam distribution, enhanced patient comfort, and generated tens of thousands in savings—while also reducing boiler chemical costs through better condensate recovery.
These examples show that proactive steam trap management delivers measurable results across diverse industries.
Smart Steam Trap Monitoring vs. Manual Surveys (Automation Trends)
Steam trap surveys have traditionally been manual, with technicians inspecting each trap on a fixed schedule. This method is low-cost, hardware-light, and effective when performed diligently. However, it leaves gaps between inspections where traps can fail and leak steam unnoticed, wasting energy for months. Manual surveys can also be time-consuming and are subject to human error, especially in large facilities.
Smart steam trap monitoring offers a real-time alternative. Using sensors to measure parameters like temperature and ultrasound, automated systems continuously track trap performance and alert maintenance teams to failures immediately. This reduces energy loss, minimizes manual labor, and can bring steam losses below 1%—compared to 20% in facilities with no monitoring program.
While automated systems require upfront investment and setup, they reduce long-term maintenance demands. Many facilities now use a hybrid approach—deploying sensors on critical traps while continuing periodic manual surveys for the rest. This balances cost and coverage, ensuring timely action on the most important parts of the system.
Types of Surveys
Steam trap surveys can be conducted using various methods, each offering unique insights into the performance of your steam traps. The primary types of surveys include visual inspections, ultrasonic testing, and thermal imaging.
Visual Inspections involve a physical examination of the steam trap population to identify visible signs of failure, such as leaks, corrosion, or improper installation. While this method is straightforward, it will not detect all issues, especially those not visible to the naked eye.
Ultrasonic Testing uses high-frequency sound waves to detect steam leaks and other issues. Technicians use handheld ultrasonic detectors to listen for the distinct sounds of steam flow. This method provides a more accurate assessment of steam trap performance, as it can detect even small leaks that might be missed during a visual inspection.
Thermal Testing employs infrared camera or temperature guns to detect temperature differences across steam traps. By capturing thermal images and temp readings, technicians can identify traps that are stuck open or closed. This method is particularly useful for identifying traps that are not functioning correctly but may not show visible signs of failure.
The choice of survey method depends on the specific needs of the site and the goals of the steam trap management program. Often, a combination of these methods is used to provide a comprehensive understanding of the steam trap population. Regular surveys are an integral part of a proactive steam trap management program, helping to identify and address issues before they lead to significant energy losses.
Analyzing Results
Analyzing steam trap survey results is essential for uncovering energy losses, identifying failed traps, and improving system performance. Reviewing the data reveals trends, common failure points, and high-loss areas, enabling targeted maintenance.
Comparing results to industry benchmarks highlights underperforming zones and helps guide improvements toward best-in-class performance. A thorough analysis can also uncover training or support gaps within the steam trap management program.
Implementing Recommendations
Implementing the recommendations from a steam trap survey is essential to achieving energy savings and improving steam trap management. The recommendations should be prioritized based on their potential impact on energy savings and system efficiency.
Develop a plan to implement the recommendations, including a timeline and budget. This plan should outline the steps needed to address the identified issues, such as replacing failed traps, repairing or modifying existing traps, or installing new traps.
Regular follow-up and monitoring are crucial to ensure that the recommended changes are effective. This ongoing oversight helps verify that the implemented solutions are working as intended and allows for adjustments as needed.
Implementing the recommendations may also involve providing training and support to the steam trap management team. Ensuring that the team has the skills and knowledge needed to maintain and operate the system effectively is vital for long-term success.
By acting on the recommendations from the steam trap survey, the steam trap management team can help reduce energy losses, improve system efficiency, and achieve significant cost savings. Additionally, addressing issues such as water hammer and other operational problems enhances safety and reliability.
The Value of Professional Steam Trap Survey Services
The Value of Professional Steam Trap Survey ServicesWhile some facilities attempt steam trap surveys in-house, using a professional service like ours ensures accurate results, faster execution, and real savings. For more information or assistance, contact our team of experts.
Our trained technicians use advanced diagnostic tools to pinpoint trap failures and quantify energy losses. We collect detailed data on each trap, provide clear reports with cost-saving recommendations, and help you prioritize repairs for maximum impact.
Outsourcing surveys also frees up your team to focus on core tasks while we handle the diagnostics, reporting, and—if needed—the repairs. We can also implement continuous monitoring technology to catch failures as they happen.
It’s Not Flashy But Its Important
Steam trap surveys might not be the flashiest project in an industrial facility, but as we’ve shown, they are one of the most impactful for energy efficiency and reliability. Through regular surveys, engineers and maintenance professionals can reclaim lost steam, saving significant fuel costs and reducing emissions. The process involves methodical checking of each steam trap with the right tools, and when done right, it pays for itself many times over. Ultrasonic testing is considered the industry standard for trap testing due to its accuracy in detecting even small leaks. Industry leaders from the Department of Energy to specialized firms all echo the same message: you need to monitor and maintain your steam traps for a healthy steam system.
If performing a survey yourself, technicians should have the appropriate level of training and certification to accurately interpret survey results. Also ensure the equipment used to survey is from a reputable manufacturer. In addition, considering parameters outside of the steam trap, like bypass valve status can improve the management of steam traps. Healthy steam traps are crucial for ensuring effective operation within various applications, from heating systems to industrial processes.
Conclusion
By implementing routine steam trap surveys – and increasingly, by leveraging smart monitoring for real-time insights – facilities can achieve best-in-class performance, often driving trap failure rates down to 5% or less, and keeping them. The benefits cascade into lower operating costs, fewer breakdowns, improved safety, and progress toward sustainability goals. Meanwhile, engaging professional expertise and modern technology can amplify these gains, ensuring no trap is left behind.
For plant managers and maintenance teams in the U.S. and beyond, the takeaway is clear: a steam trap survey is not an expense, but an investment – one that yields quick returns and ongoing dividends. A well-managed steam system ensures safety and operational efficiency in industrial settings. If your steam system hasn’t had a trap survey in a while, there’s no time like the present to schedule one. The boiler will burn fuel whether or not your traps are working; a proactive approach makes sure that energy is used productively for your process and not wasted. In the age of efficiency and carbon consciousness, something as humble as a steam trap survey turns out to be a smart, strategic move that no steam-intensive facility should overlook. Your bottom line – and your boilers – will thank you for it.