Compressed air systems are a mainstay across a multitude of industrial landscapes, owing to their unparalleled efficiency and adaptability. However, in a compressed air system, leaks are inevitable.
Indeed, a well-installed system will allow for the fact that a perfectly sealed system is impossible. However, when more leaks develop, leak detection becomes essential. Understanding what leaks are, what causes them, and how you can find them will help ensure your system runs as efficiently as possible.
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What are compressed air leaks?
Compressed air leaks are unintended releases of air or gases from a system, often through faulty joints, fittings, or worn components in compressed air piping. Even small leaks can lead to significant energy loss, with leak rates as small as a 3mm hole wasting over 30 cubic metres of air per hour.
Common Causes of Leaks
- Improper installation: poorly installed compressed air systems or air distribution components can cause leaks early on. Skilled installation is crucial to prevent these issues.
- Wear and tear: seals and gaskets deteriorate over time, causing air leaks. Regular maintenance, including tests while equipment is running, can help detect these issues before they become costly.
- Vibration and movement: constant vibration in compressed air systems can loosen fittings, leading to leaks that are difficult to detect by ear.
- Corrosion: moisture or contaminants in the compressed airflow can corrode pipes and condensate traps, causing leaks in any part of the system.
- Physical damage: accidental impacts or mishandling during repairs can result in damage that leads to leaks. Effective leak detection and repair are essential to avoid long-term energy loss.
Detection Methods
Advanced leak detection methods, such as ultrasonic detectors, help pinpoint leaks that would go unnoticed. Ultrasonic leak detectors for compressed air systems can quickly locate even small leaks, reducing energy wastage and improving overall efficiency.
Do leaks matter?
Given that leaks are inevitable, do they matter? The short answer is yes, and you will pay a very real price if you fail to address them.
Air leaks cost money
Your compressed air system must maintain the pressure required by your production and use requirements. A leaky system often loses as much as 20% to 30% of the output to leaks. That means the compressor has to work harder to compensate. This results in higher energy costs and more wear and tear on your system.
Failure to address leaks can result in a downward spiral and, therefore, performance as your compressor struggles to maintain pressure, and your processes suffer as a result.
Air leaks have an environmental impact
While the leaks are simply air – and in some cases very pure and dry air — because your compressor is working harder, it is using more energy, increasing your carbon emissions. The impact goes beyond the compressor. For example, if you have driers, they will need to be powered to dry air that is simply escaping.
Without air leak testing, your first sign of a problem might be escalating bills and increasing difficulties in meeting your environmental goals.
Air leaks reduce your operational efficiency
Leaks within your compressed air system can quickly impact your operations. How this happens will depend on your specific processes, but lower pressure might impact the performance of pneumatic tools and slow production. Alternatively, it can result in inconsistent pressures, increasing costly production failures.
At its worst, the pressure lost to air leaks can result in expensive downtime if your entire operation must be halted while you conduct extensive maintenance on your system.
How are compressed air leaks detected?
If you have ever repaired a cycle inner tube using soapy water, you are already familiar with the basic concept behind air leak detection. Escaping air creates bubbles in the soapy water, indicating the leak’s location and size. Fortunately, more modern techniques work in much the same way, such as using technology to identify the leak’s effects.
Using flow meters at various points in your system is one method. These take precise airflow measurements, allowing you to identify drops caused by a leak. Thermal imaging can also be used to spot the temperature difference between the escaping compressed air and the ambient air. However, these methods have drawbacks. Flow meters cannot precisely identify a location, just narrow it down to a section, and thermal imaging requires line-of-sight, which may be impossible for some installations.
Ultrasonic detection has become the gold standard of leak detection.
Why ultrasonic leak detection is the best way to find leaks
Ultrasonic detection works by tracking the inaudible, high-frequency sounds created by escaping air. Because it works at a high frequency, it can be used even with background noise, meaning that detection can take place without affecting operations.
It is incredibly precise, allowing pinpoint accuracy in locating the leak and assessing the leak’s volume – detectors even have lasers to target the leakage. Due to ultrasonic leak detectors working on sound and being small, they are effective for leak detection even in complex systems where pipes might be hidden or obscured.
The result is that ultrasonic detection can quickly provide a comprehensive and prioritised list of leaks within a system, all without disrupting day-to-day operations.
How can you prevent and manage leaks?
Preventing and managing leaks in compressed air systems is essential for reducing energy loss and operational costs.
Prevention Strategies
- Proper installation:
Utilising skilled engineers and quality materials helps prevent leaks, ensuring consistent air pressure and system durability. - Routine maintenance:
Regular inspections and leak detection in compressed air systems help catch issues early. Performing tests while equipment is running can quickly identify leaks. - Monitoring system health:
Implementing cloud-based software to monitor leaks tracks airflow and generates reports for improved energy management.
Managing Leaks
- Leak detection and audits:
Ultrasonic leak detectors can locate leaks that are undetectable to the human ear, pinpointing the issue’s exact location. - Prioritising repairs:
Addressing larger leaks first helps prevent significant energy loss and further damage.
Value of Leak Management
Effective leak detection saves energy, reduces costs, and extends the lifespan of your system. A well-maintained system minimises waste and ensures operational efficiency.
Getting started with leak detection
One of the great advantages of air compressors is that they are hard-working and robust machines, but like any other equipment, you must take care of them.
Understanding how your machine performs and investigating any change is important. However, combining your understanding of your system with best practices in regular leak detection will ensure that your compressor works as efficiently and cost-effectively as possible. Many of our clients find that the energy savings quickly recoup the cost of leak detection. So, if you want to check your compressed air system’s health, just call us.
FAQ
What is the best method for compressed air leak detection?
The most effective method for detecting compressed air leaks is ultrasonic leakage detection. This technology identifies inaudible high-frequency sounds caused by escaping air, allowing it to pinpoint leaks that cannot be detected by the human ear. It accurately locates leaks without interrupting operations, making it a preferred solution within the industry.
How do leaks in compressed air systems affect energy costs?
Leaks in compressed air and gas systems result in significant energy loss, as a large proportion of electrical energy is wasted due to compressors working harder to maintain pressure. Addressing leaks promptly through regular leak detection can prevent the loss of thousands of pounds annually in wasted energy.
How can monitoring systems help with leak management?
Cloud-based software systems for monitoring leaks provide real-time airflow and energy usage tracking in compressed air systems. These systems offer detailed audit reports for better energy management, helping businesses reduce energy wastage and improve overall efficiency.
