Compressed air is a widely used utility in various industries, powering tools, machinery, and processes. However, it’s also one of the costliest utilities due to the energy required to generate and maintain compressed air systems. A significant portion of this cost is attributed to leaks within these systems, which can result in substantial energy and financial losses. Implementing effective leak management practices is crucial to minimize compressed air waste and maximize operational efficiency. In this article, we will explore four best practices for leak detection and repair.
The cost of compressed air leaks
The cost of compressed air leaks can be significant. A small leak, the size of a pinhole, can waste up to 10 cubic feet of air per minute. Over the course of a year, this can add up to thousands of dollars in wasted energy.
Calculation example:
Installed power 1 screw:100 kW
Annual operating time:8760 h
Average electrical power of CAS:80 kW
Energy costs: 8760 [h/ a] x 80 [kW] x 0.10 [$/kWh] = 70,080.00 $ per year
Leakage rate: approx. 20 to 30% of total consumption, typical for old plant
17,520.00 $ per year savings potential (25%)
In addition to the cost of wasted energy, compressed air leaks can also cause other problems. They can lead to decreased air quality, increased noise levels, and even safety hazards.
How to detect compressed air leaks
1. Regular Audits and Inspections:
Performing routine audits and inspections of your compressed air system is the foundation of effective leak management. These audits should involve a comprehensive examination of all components, including pipes, fittings, valves, and connections. Regular inspections not only help identify existing leaks but also prevent potential leaks from escalating into major issues.
2. Utilize Ultrasonic Leak Detection:
Ultrasonic leak detection technology has proven to be highly effective in identifying compressed air leaks that are often imperceptible to the human ear. Ultrasonic leak detectors are designed to detect the high-frequency sounds produced by escaping air. This method enables quick and accurate pinpointing of leaks, minimizing downtime and unnecessary repairs. Technicians equipped with ultrasonic detection tools can swiftly locate leaks, making the repair process more efficient.
Other ways include listening for the sound of escaping air. Another way is to use a soap solution to create bubbles at the site of a leak. The last two ways are not very accurate as most leaks are inaudible to the human ear.
How to repair compressed air leaks
Creating a standardized protocol for addressing leaks is essential. This protocol should include steps for reporting leaks, prioritizing repairs based on severity, and documenting the repair process.
Once a compressed air leak has been detected, it is important to repair it as quickly as possible. The best way to repair a leak will depend on the size and location of the leak. However, in most cases, the leak can be repaired by tightening connections, replacing seals, or patching holes.
Additionally, tracking and analyzing data related to leak detection and repair can provide valuable insights into patterns and trends, helping to prevent future leaks.
Preventing compressed air leaks
The best way to stop compressed air leaks is to prevent them from happening in the first place. Here are a few tips for preventing compressed air leaks:
- Use high-quality components and materials.
- Install proper filtration and lubrication systems.
- Inspect your system regularly for signs of wear and damage.
- Keep your system clean and free of debris.
In addition to the tips mentioned above, here are a few other things you can do to prevent compressed air leaks:
- Use quick connect couplings instead of threaded connections.
- Use aluminium or stainless-steel pipes instead of galvanized pipes.
- Install air dryers to remove moisture from the air.
- Use a pressure regulator to maintain a constant pressure in the system.
By following these tips, you can help to keep your compressed air system running smoothly and prevent leaks.
Employee Training and Awareness:
Well-trained employees are your first line of defense against compressed air leaks. Educate your workforce about the importance of leak detection and the impact of leaks on energy consumption and operational costs. Provide training on how to use leak detection equipment and encourage employees to report any suspected leaks promptly. Fostering a culture of leak awareness can significantly contribute to the success of your leak management efforts.
Lorna Olum
Application Engineer,
REN Engineering Solutions
T +254 715 833 628