Why does compressed air leak detection matter?

Manufacturing businesses aiming to cut costs and enhance energy efficiency can benefit by examining their compressed air systems. These systems are estimated to consume 10% of global industrial energy, with 10-30% wasted on leaks. Detecting and fixing these leaks is crucial, as even a small 3mm leak can cost around a lose of $3,300 NZD of kwh and generates CO2 emission of 2600kg over a year. 

Despite the potential savings, some businesses are not aware of their onsite leaks or are concerned about the disruption caused by energy audits. However, efficient and non-disruptive audits can identify energy-saving opportunities.

Various methods can be used for compressed air leak detection, starting with simple approaches like listening for leaks and using soapy water solutions to identify bubbles. However, the most effective and widely used method is ultrasonic detection equipment. This method operates without interrupting plant operation, reaches inaccessible areas, and detects all leaks by capturing ultrasonic components generated by turbulent air flow through leak sites. These devices are like super-sensitive ears that can pick up sounds we can't hear. They work even in noisy environments and don't disrupt the regular operation of a factory.

Here's how it works: when air escapes through a leak, it creates a kind of noise that these detectors can pick up. The bigger the leak, the louder the sound. Imagine it like a detective listening for clues!

There are different tools available, like handheld devices and cameras, that help point out where the leaks are. Some of them even turn the noise into a sound we can hear with headphones. Using these tools regularly, maybe every six months, helps save money by finding and fixing new leaks before they become a big problem.

Atlas Copco provides ultrasonic leak detection as part of the AIRScan energy audit, where they check different aspects like air quality and maintenance levels in addition to finding leaks incorporates ultrasonic leak surveys.

By doing these surveys, businesses can enjoy benefits such as:

• continuous energy cost reduction
• increased equipment life
• productivity improvements
• compliance with regulations.

In a recent project, an Atlas Copco AIRScan survey identified leaks costing $18,226 NZD annually at a NZ food manufacturing plant, demonstrating the potential savings. This illustrates the benefit of conducting this type of audit.

Discover how to minimize compressed air wastage – typically ranging from 20-40%. We can guide you through the process!