Spirax Sarco Steam Audit

Steam systems can deliver large amounts of energy with remarkable efficiency, making steam boilers the heart of any plant's energy infrastructure — yet maintenance and energy optimization of these systems are frequently overlooked. Steam traps, while small in size, play a vital role in maintaining system efficiency by removing condensate and preventing the loss of live steam. When failed traps go unnoticed, the impact can be significant energy losses and reduced reliability of the whole system.

Through Intrepid Group's partnership with Spirax Sarco, our Steam Trap Survey program helps customers uncover these hidden inefficiencies and turn them into measurable savings.

What we find in the field

Industry data shows that 10–30% of steam traps in unmanaged systems fail during normal operation, often without visible signs. A recent survey conducted at a customer facility identified a 43% failure rate due to long-overdue testing.

While these numbers may seem small relative to the total population, the impact was substantial:

• $270,000 annually in steam losses
• 11,360+ tons of steam wasted per year
• 2,440+ tons of associated CO₂ emissions

Even a single failed trap can waste thousands of dollars per year. Multiplied across a plant, the opportunity becomes impossible to ignore.

What the survey delivers

Intrepid's Steam Trap Surveys go beyond simple inspection. Using proven, third-party validated methods, our technicians:

• Inspect and test every trap for performance and proper installation
• Document each asset including tag, location, size, and condition
• Analyze energy loss with quantified cost, steam loss and emissions impact
• Prioritize actions based on ROI and operational risk

It's a comprehensive, plant-wide report that provides clear, actionable insights, not just data.

Why it matters

A properly functioning steam system:

• Reduces fuel consumption and operating costs
• Prevents water hammer and equipment damage
• Improves system reliability and uptime
• Supports emissions reduction and sustainability targets

In contrast, failed traps quietly drain energy, increase maintenance costs and reduce overall system performance.

Start seeing your steam system differently

Steam trap failures are often invisible, but their impact isn't. A targeted survey provides one of the fastest and most cost-effective ways to improve plant efficiency and recover lost energy.