Compressed Air Leak Detection

Compressed air systems are a vital component of many businesses and must offer efficient running hours, especially when you need to reduce energy costs and improve production.

One of the most common problem areas is leakage in the system, slowing the production process and increasing costs. Leaking air reduces system pressure, leading to slower equipment operation, decreased output, and potentially even production downtime. This can result in lost revenue, missed deadlines, and frustrated customers.

Compressed air leak detection is the best method of dealing with this issue and allows you to detect leaks before they negatively impact your business.

This article will delve deeper into the problem of compressed air leaks, exploring common leak areas, the financial impact of leaks, and the benefits of implementing effective leak detection strategies.

Understanding Compressed Air System Leaks

In compressed air systems, a leak occurs when compressed air unintentionally escapes into the atmosphere. Common causes of leaks include:

• Vibration: Constant movement can loosen fittings and connections.
• Corrosion: Rust and degradation can weaken seals and joints.
• Material Failure: Components can wear out or become damaged over time.

Compressed air systems are significant energy users, and leaks significantly degrade their efficiency.  While some minimal leakage (up to 10%) may be considered normal, noticeable leaks often indicate a 40-50%  loss – a major drain on your energy costs. The solution is to invest in an ultrasonic leak detector, which offers a highly accurate and non-invasive way to pinpoint and repair these costly leaks, enhancing both energy efficiency and production reliability.

Impact of Compressed Air Leaks

Ignoring compressed air leaks isn’t just inconvenient, it’s a costly gamble with your bottom line and equipment safety. Think of it like a thief silently draining your profits and putting your machinery at risk, day after day. Here’s why regular leak detection is the ultimate defence against this invisible threat:

1. Leaky Profits: Every leak translates to wasted energy and skyrocketing costs. Even a small leak can waste thousands of dollars annually.
2. The Cost of Delay: Unrepaired leaks worsen over time, leading to bigger problems and higher repair bills. Early detection saves you money in the long run.
3. Compressor Overdrive: Leaks force compressors to work harder, causing premature wear and tear. Leak detection helps protect your compressors and prolong their lifespan.
4. Safety Concerns: Pressurised air leaks can create projectile and spark hazards. Proactive leak detection promotes a safer work environment.

Investing in regular leak detection isn’t just about plugging holes; it’s about safeguarding your profits, protecting your equipment, and prioritising the safety of your workforce. Don’t let silent leaks devalue your business – implement a proactive leak detection strategy and watch your compressed air system transform from a hidden drain into a reliable asset.

Methods of Compressed Air Leak Detection

If you are keen to get to work on your leak detection, there are two main leak detection methods to choose from, traditional or ultrasonic:

Tradition Leak Detection

Traditional leak detection works to detect leaks by using soap and water mixed together and poured over joints to check for bubbles and leakage. When the solution is poured and settled, air leaks flow into the solution and create bubbles at the leak location.

Further leaks can be found by listening for hissing sounds escaping from the equipment, highlighting the areas that may have unexpected airflow as a result of leakage.

The issue with this method is that it requires a quiet environment to locate leaks and can be incredibly time-consuming, reducing your production process and halting work as the equipment is properly checked. Modern solutions like ultrasonic leak detectors are recommended to save time and improve accuracy, especially in noisy industrial environments. If you want to estimate the leak load, you can install a pressure gauge downstream from the volume to get an accurate sense of operating pressure problems.

These traditional methods of managing the leak detection process are really best when you already know which valves are leaking, and you only want to confirm this before paying for a repair.

Ultrasonic Leak Detectors 

Ultrasonic leak detection uses a microphone that is highly sensitive and can pick up the harmonics that are produced by leakage. The system then converts the signal frequency into an audio signal that can be heard through the ultrasonic detector’s headphones, allowing you to pinpoint leaks intuitively.

Even the noisiest environments can benefit from ultrasonic leak detectors, and this method of leak finding will help you keep your equipment working for the longest possible time, reducing costs and ensuring production is at the best level possible.

One of the greatest benefits of an ultrasonic acoustic detector is that it can reach areas in your system that cannot be accessed by other equipment or methods. Plus, with 8m of range, your compressed air system can be assessed at speed, helping you return to normal operating pressure, and reduce leakage, in next to no time.

Another benefit of this leak detection survey is that you will get a leak detection report to work from, allowing you to reduce your leak rate in a more cost-efficient way.

Choosing the Right Leak Detector

If you think that you may have a leakage that needs to be addressed, or you are looking for the best compressed air leak detection system to help avoid a reduction in your air pressure, it is important to pick the right system for you.

Take a look at some of these key factors to help you decide which leak detection survey or system you should opt for:

Sensitivity

The first thing that you will need to consider is how sensitive you need your leak detection survey to be. If you have large compressors, or several systems to check, then using a high-sensitivity solution will allow you to find the widest range of leaks.  If you have large compressors or several systems to check, a high-sensitivity solution will enable you to identify a wider range of leaks, even those that may be less obvious.

Range

Again, when you need a quick and precise air leak detection solution, opting for one with the biggest audible range will allow you to check for air leaks more quickly, and on a larger scale. Ultrasonic detectors with extended ranges are highly recommended for complex systems to save time and improve coverage.

Cost

When you notice low pressure in your system, finding new leaks is always going to be a priority. However, fixing leaks can be expensive so it is important to consider the cost of finding leaks in your compressed air system when you are picking the best leakage detector for your needs.

Implementing a Leak Detection Programme

Are you ready to implement an effective leak detection programme for your compressed air system? Take a look below at the steps you need to follow:

• Choose Your Leak Detection Solution – This means picking between traditional and more modern options, such as ultrasonic detectors.
• Agree on a Leak Detection Plan – This involves scheduling regular checks of critical areas, including your distribution system, valves, flow, and pressure, to detect and address leaks promptly.
• Decide Who Will Implement – Appoint the people responsible for your compressed air system units and ensure they follow a comprehensive maintenance plan.
• Undertake Regular Repairs – Ensure identified leaks are promptly repaired to maintain efficiency and system reliability.
• Monitor Costs – Track system pressure, energy costs, and flow metrics to ensure costs remain within optimal ranges and detect inefficiencies early.

Best Practices for Leak Prevention and Maintenance

Compressed air leaks may seem inevitable, but proactive strategies can significantly minimise their impact on your system and your bottom line. By implementing smart practices for both leak prevention and regular maintenance, you can turn the tide on wasted energy, equipment strain, and costly repairs. Let’s explore some key tactics to keep your compressed air system running smoothly and efficiently.

Leak Prevention:

• Invest in Quality: Choose durable components, like pipes, coupling, and fittings from reputable brands. These minimise the risk of premature wear and reduce long-term maintenance costs.
• Mind the Connections: Proper installation and tightening of all connections are crucial. Leaky joints and couplings often stem from inadequate assembly or loose fittings. Regularly inspect these points and ensure snug connections to prevent air from escaping.  Ensure proper assembly and regular inspection of all fittings to prevent air from escaping through loose or inadequately installed connections.
• Routine Inspections: Don’t wait for trouble to find you. Schedule regular visual inspections of your entire compressed air system, paying close attention to potential leak hotspots like connections, hoses, and valves. Conduct scheduled visual checks for leak-prone areas, including connections, hoses, and valves. This proactive approach helps identify and resolve issues early.
• Embrace Automation: Consider implementing an automatic leak detection system. Advanced ultrasonic systems offer precise and efficient leak detection, saving time and manual effort.

Maintenance is the hard work behind prevention and it matters a lot. Here’s how you can maintain your air compressors to avoid the big consequences due to leaks.

• Drain It Regularly: Moisture buildup within the system can corrode components and contribute to leaks. Ensure proper drainage of condensate traps and separators at regular intervals to keep the system dry and healthy. Condensate traps and separators should be drained frequently to prevent corrosion and system damage.
• Filter Power: Replace air filters periodically to avoid restricted airflow and strain on compressors. Clogged filters restrict airflow and put additional strain on compressors, potentially leading to leaks and breakdowns.
• Keep it Lubricated: Follow manufacturer recommendations for lubrication to minimise wear and prevent leaks.
• Professional Expertise:  Periodic system tune-ups by professionals can identify hidden inefficiencies, optimise system performance, and prevent costly breakdowns. They can identify potential issues before they turn into leaks, optimise system performance, and ensure your compressed air system operates at peak efficiency.

These leak prevention and maintenance practices can significantly reduce the impact of leaks on your compressed air system. Remember, a proactive approach not only saves money but also safeguards equipment, optimises performance, and ultimately strengthens your bottom line.

Let Control Gear Support

It’s clear that investing in a leak detection survey or process is a great way to keep your compressed air system in perfect working order. However, knowing what to choose or how to proceed can be difficult.

At Control Gear, we provide expertise to help you understand everything from CFM (free air) calculations to pinpointing each leak site confidently. If you are ready to reduce costs and repair requirements, contact us today for professional guidance.

If you are ready to find out more and want to keep your cost and repair requirements low, then we’d love to help. Reach out today to find out more!