From Survey to Savings – 4 Steps in a Steam Trap Survey

Steam traps are small but mighty components in your facility’s steam system. When they fail, they can quietly drain energy, disrupt production, and rack up costs. If left unchecked, a single failed trap can waste thousands of dollars in energy each year. That’s where a steam trap survey comes in.

That’s why a steam trap survey isn’t just a maintenance task, it’s a smart investment in your operation’s efficiency and reliability.

What is a Steam Trap?

A steam trap survey is a comprehensive inspection of your facility’s steam traps to identify failures, inefficiencies, and opportunities for improvement. In 2024 alone, our team checked just under 20,000 steam traps, helping facilities across industries reduce waste and improve performance.

The Survey Process: Step-by-Step

We don’t just show up with a clipboard. A steam trap survey is a structured, data-driven service designed to uncover inefficiencies and help you fix them fast.

1. Pre-Survey Planning

It starts with a quote and estimated trap count based on your facility’s size and layout. This helps scope the work and ensures we’re aligned from the start.

You’ll designate someone familiar with your steam system to guide our team on-site. This step is key to navigating your facility efficiently and safely.

2. On-site Kickoff

Once we arrive, we begin with a brief introduction and overview of the UMT (Ultrasonic Measurement Tool), a non-invasive device used to assess trap performance. We also walk through how the survey will be conducted and confirm the scope of work using the Kendall service app.

3. Trap-by-Trap Inspection

Each steam trap is inspected and logged into the Sage program, including:

• Trap type and condition
• Location and what it services
• Photos (if permitted)

This detailed data collection ensures nothing is missed and sets the stage for actionable insights.

4. Reporting & Recommendations

After the survey, you’ll receive a comprehensive report—either printed or on a USB drive the we will review with you. It includes:

• A list of failed traps
• Replacement recommendations
• Notes on other system issues or inefficiencies observed during the survey

Why It’s Worth It: The Benefits

Steam trap surveys aren’t just about fixing what’s broken, they’re about optimizing your entire steam system.

Boost Productivity & Reliability

Failed traps can cause temperature inconsistencies, damage equipment and slow production. In industries like food processing or pharmaceuticals, this can mean batches that don’t meet spec.

Cut Energy Costs

A single small failed trap can leak up to 75.8 lbs of steam per hour, costing $6,640 annually at $10 per 1,000 lbs of steam. Multiply that across dozens or hundreds of traps, and the savings become substantial.

Optimize System Efficiency

Healthy traps mean smoother operations, fewer interruptions, and better steam quality—leading to more consistent output and reduced wear on equipment.

Industry Insights

Steam trap failure is more common than many facilities realize. In systems without regular maintenance, studies show that 15–30% of steam traps may be failed at any given time. These failures can lead to significant energy loss, especially in facilities with hundreds of traps. Facilities that implement proactive steam trap surveys and maintenance programs can reduce failure rates to under 5%, dramatically improving system efficiency and lowering operational costs. Facilities with over 500 traps often see significant steam losses—and savings—after a survey.

Ready to take action? If you’re looking to improve energy efficiency, reduce costs, and protect your equipment, a steam trap survey is a smart first step.  Reach out to a Merlo Energy expert to schedule a survey or explore smart monitoring tools.