Are you looking for ways to reduce your operating costs? One of the most effective and impactful ways to do this is by managing your compressed air system's leaks.
When operating a compressed air system, it's common for up to 30% of your energy costs to be wasted on leaks. With just one leaky fitting, you could rack up $600 a year of wasted air!
In this article, we outline the various strategies for detecting leaks, including ultrasonic leak detection and regular air audits. We also share the best methods for fixing leaks, including simple connection repairs, press-fit piping, high-quality piping materials, leak detection programs, and full-scale system redesigns.
Air compressor leaks occur when compressed air escapes from the pressurised piping system, fittings, or connected equipment. These leaks often go unnoticed in industrial settings, impacting energy efficiency, operational costs, and overall productivity.
By proactively managing the leaks in your compressed air system, you can reduce leaks to less than 5% of the compressor’s output. Over time, this equates to massive cost savings and improvements in operational efficiency.
Fortunately, there are several steps you can take to prevent and minimise air leaks. Firstly, be proactive about identifying air leaks in your system as they can only be found using specialised equipment. When you have found the leaks, there are also several ways to repair the leaks and prevent them from manifesting again in the future.
The first step to improving system efficiency is by monitoring and identifying air leaks. This should be done regularly, allowing you to pinpoint leaks before they become a major issue.
By running your hands around the joins in your system, you may be able to feel air escaping. This is most likely to happen along joins, air hoses, valves, and other fittings.
In some quieter areas, you can also listen for audible air leaks within your system. If you hear a small hissing or whistling sound, book a leak detection service or full air audit immediately.
Ultrasonic leak detection uses specialised equipment to detect the high-frequency sound waves produced by escaping air. While these sounds are inaudible to the human ear, the equipment picks it up quickly and accurately, allowing you to find small and hidden leaks.
This is one of the most effective leak detection methods, working in noisy industrial environments and allowing a high level of precision, even in complex systems.
Conducting routine system audits ensures leaks are found as early as possible. During these inspections, we recommend focusing on high-risk areas like joints, valves, and hoses where leaks are most common.
By assessing and documenting air leaks regularly, you can identify problem areas. This helps you to track recurring issues and prioritise repairs for the most impact. Over time, you will build a comprehensive history of your system, informing any decisions about the design and layout.
Once you’ve identified the leaks in your system, there are several options to reduce or eliminate them.
The first step is to make a few simple fixes to your system, such as tightening all the connections and fittings. In industrial settings, it is common for connections to loosen up due to equipment vibrations so it pays to monitor this regularly. By replacing faulty seals, valves, or hoses, you can reduce costs and boost efficiency in the process.
Maintaining a compressed air system can be costly and time-consuming, especially if you’re dealing with welded joins. That’s why we recommend the Pneupress range of press-fit piping. It’s quick and easy to maintain, with no need for hot works permits. The press-fit tool makes installation and repairs quick and cost-effective — and it’s completely leak-free!
When choosing the pipes, seals, and fittings for your compressed air system, quality counts for a lot. High-quality materials like stainless steel and aluminium offer exceptional durability, reducing the risk of corrosion or physical damage. These metals are also more hygienic than plastic air piping, making them ideal for high-purity compressed air systems.
Implementing an ongoing leak prevention program will ensure you identify any future leaks before they become a problem. We recommend setting up a systematic leak management routine, assigning responsibility and booking regular inspections. This also involves training your staff to check for leaks periodically and use equipment correctly.
For best results, book a regular leak detection check or air audit with our specialised technicians. We will ensure these are booked at the right times depending on your operations.
If your system is prone to leaks or experiences recurring leaks in the same places, it may be worth redesigning the system. This also enables you to optimise the new system with a more efficient layout, suitable pressurisation, and higher-quality materials.
At Industrial Air Systems, we can work with your people to design the best system for your requirements and project-manage the entire installation. When your new system is up and running, we’ll also be available 24/7 365 days a year for servicing support and spare parts. You can find more information about our services on our website.
To get started, try out our online piping calculator to determine the best piping specifications for your needs. Alternatively, contact our team of experts today to discuss your requirements.