Having an air leak in your compressed air system not only affects your company’s performance but can also cost your business thousands of dollars.
Air leaks are a big waste of energy, which couldn't be ignored as it would cause a huge amount on your electricity bill.
Did you know a single quarter-inch air leak at 100 psi can cost as much as $8,000 a year in lost compressed air?
Up to 20% of the compressed air consumption in Compressed air installations of more than 5 years old may be lost through leaks in compressed air systems
What causes compressed air leaks?
- Not closing the Valves
- Poorly fitted connections
- Microscopic fissures in pipes that cant be noticed by your eyes
These Are just a few places where your compressed air can escape out of your system. so Addressing these leaks can save you money and make your production more efficient.
So how do you know if you have a leak?
There are a few signs to look out for. You might have a leak if…
- You can hear it.
Large leaks are audible. Take the time to walk through your system every few months and listen for large leaks. These leaks are less common than inaudible leaks, but they do waste a lot of compressed air and in conjunction, a lot of money. - You experience unusual pressure losses.
Have you noticed the pressure in your system has gone down? Have you noticed your system has to work harder to supply the same airflow that it used to provide with ease? It could mean you have a leak. This probably means multiple smaller leaks, but it all adds up. - You lose compressed air, even when you are not using it.
If you notice you are using compressed air even when your end uses aren’t, then you have a leak. Any air lost while your compressed air is not in use, means you may have lots of little leaks contributing to your air loss. - Your piping system is more than 5 years old
Systems that are more than five years old have been shown to exhibit leaks of up to 25 percent. If your piping is outdated, consider upgrading to a new, easy to install aluminum system.
How do you detect & fix a compressed air leak?
Ultrasonic leak detection
At the end of the Air Leak. check program, you will receive a detailed report of in-depth evaluation of problems along with recommendations for leak repair, which would save you up to 30% of energy immediately by closing the energy gap.
How to fix leaks
- Leaks occur most often at joints and connections. Stopping leaks can be as simple as tightening a connection or as complex as replacing faulty equipment such as couplings, fittings, pipe sections, hoses, drains and traps.
- In many cases, leaks are caused by bad or improperly applied thread sealant, which can be fixed by properly installing equipment with the appropriate thread sealant.
- Another source of leaks can come from non-operating equipment. Equipment that’s no longer in use should be isolated with a valve in the distribution system.
- Lowering the demand air pressure of the compressed air system can also reduce leaks. The lower the pressure differential across an orifice or leak, the lower the rate of flow, which equals a decreased leakage rate.
Once leaks have been identified and repaired, the compressor control system should be re-evaluated to realize the total savings potential.
Are you interested in establishing a leak prevention program that can save your industrial facility costly repairs?
