Compressed air systems form the backbone of many industrial operations. However, unnoticed leaks in these systems lead to significant losses. They affect your productivity, drain your resources, and can cost you hundreds of thousands of dollars annually. That makes compressed air leak detection and repair crucial for any business using these systems.
In this article, you’ll learn:
Wasting air is a considerable energy cost in industrial settings. Losses from compressed air leaks don’t just stem from the direct wastage of the compressed air. There's also the additional energy required to compensate for the pressure drops caused by these leaks.
According to recent research, 25 to 40 percent of the world's industrial energy is lost due to leaks in compressed air systems. Globally, that adds up to billions of dollars in losses from poorly-maintained equipment.
That's anywhere from a few thousand to nearly a million dollars in annual losses for an individual plant, brewery, or other production setting,
One straightforward method of calculating air leakage involves observing pressure drops.
By measuring the flow into the distribution system when the plant isn't running until there's a 14.5 psi drop in pressure, industries can gain a realistic estimate of leakage levels.
Comparing these pressure drops to standard operating levels reveals the degree of leakage.
Next, you can calculate your individual losses using your operating costs. We’ll use the low estimate that 25 percent of operating costs stem from compressed air leakage.
Start by multiplying the number of compressors in operation by the amount of Kw each uses. Multiply your result by the total operating hours per year, then by the cost per kilowatt. This is assuming all the compressors run concurrently.
The full formula looks like this:
(number of compressors) x (amount of kW each uses) x (total operating hours) x (cost per kWh)= operating cost
Now, simply multiply that by .25 for 25 percent of your operating cost. The result is a low-end estimate of annual money wasted due to air leakage.
A compressed air leak can go overlooked in a noisy industrial environment. Problem signs to watch for are:
As air escaping from the system often produces hissing or whistling. But, smaller leaks might produce sounds below our hearing threshold. And, you may not notice audible sounds in an otherwise loud environment. So, the absence of a hissing sound doesn't indicate no leakage.
Compressed air systems with leaks won’t perform as well as ones that are better-maintained. This results in decreased productivity and output.
An undetected air leak could be the silent culprit behind a sudden spike in your energy cost. As the system compensates for the lost air, it consumes more energy. This results in higher bills.
A leaky system suffers from excess wear and tear as it works harder to compensate for pressure loss. This leads to more frequent system downtimes.
Fixing leaks is often a time-consuming process, especially when they've gone undetected for long. There’s also the time necessary to repair related damage.
Identifying and addressing air leaks promptly can save industrial setups from wasting air and escalating energy costs. It also optimizes the system's efficiency, ensures the longevity of equipment, and reduces the carbon footprint of the plant.
Four ways to find leaks in industrial settings are:
Apply soapy water to suspected problem spots. The formation of bubbles indicates a leak. However, this simple, yet effective method for locating leaks isn’t effective in a large-scale industrial setting.
Ultrasonic detectors pick up the high frequency sounds produced by leaks, which are often inaudible to the human ear. These ultrasonic acoustic detectors transform those frequencies into audible sounds that allow operators to locate even the smallest of leaks.
Installing air flow meters at strategic points in the system alerts you to pressure drops as they occur. Meters that use IO-Link technology can provide real-time reporting. This allows you to address even the smallest problem before it becomes larger and more costly to repair.
Thermal imaging cameras detect the temperature changes caused by air leaks, visualizing them for operators to identify and address.
The best air leak detector depends on your specific application and the size of your operation. When selecting one, ensure it aligns with your plant's needs and has a good range.
Ultrasonic detectors, air flow meters and thermal imaging can determine where an air leak is coming from in large industrial environments. Visual checks, applying soapy water to suspected problem spots, and listening for hissing are useful in smaller settings.
Ultrasonic detection and air flow meters are reliable leak detection methods for compressed gases. However, the “correct,” or best methods depend on the specifics of the gas being used and the system in question.
Testing typically begins with high pressure as these lines are the primary sources of significant leaks. However, the exact pressure depends on the system and the standards it adheres to.
Leak detection for compressed air systems should be conducted quarterly or bi-annually. The frequency varies based on the system's age and usage patterns. Tools such as air flow meters using digital technology can run constantly and provide real-time alerts.