How Much $$$ are Compressed Air Leaks Costing You?!

All compressed air systems will have some amount of leakage. It is a good idea to set up a Leak Prevention Program.  Keeping the leakage losses to a minimum will save on compressed air generation costs, and reduce compressor operation time which can extend its life and lower maintenance costs.

The Compressed Air Challenge estimates an individual compressed air leak can cost thousands of dollars per year when using $0.07/kWh.

  • 1/16″ diameter hole in excess of $700/year
  • 1/8″ hole in excess of $2900/year
  • 1/4″ hole in excess of $11,735 per year

There are generally two types of leak prevention programs:

  • Leak Tag type programs
  • Seek-and-Repair type programs

If you walk through your facility, how many leaks can you hear? These are only the REALLY bad ones!!  So if we know that a large amount of compressed air is leaking, what do we do about it? ? A proper leak prevention plan is the key to success. Since these leaks are impossible to see and some cannot even be heard, you need a tool to help assist you. EXAIR’s model 9061 Ultrasonic Leak Detector is the right tool for the job. When compressed air leaks through a pipe, it creates an ultrasonic signature due to turbulence. While this sound is not always detectable by the human ear, this meter will allow you to locate leaks up to 20’ away by converting the ultrasonic signature into an audible sound.

The first step will be locating the leaks using an Ultrasonic Leak Detector and tagging them throughout the facility. Don’t let this overwhelm you!! If you have a larger facility, break it up into sections that can be completed in 1 day. This will allow you to decide which areas of the plant should be looked at first. Once you’ve located and tagged all of the leaks, rate them under two separate criteria so that you can prioritize what to fix first. Rate them based on the difficulty that it will take to fix them and also by the severity of the leak. Those that are severe yet easy to fix would make sense to begin fixing first. Those that may require a period of shutdown can be planned to fix at a more appropriate time.

9061 ULD

When you’ve had the opportunity to fix them, don’t just forget about it. When new piping is installed, new lines are added, or anything involving compressed air is installed there is the potential for new leaks to develop. Set this as one of your regular PM activities and complete your own compressed air audit once a year. Implementing the process and maintaining it are the keys to your success.

If you have questions about developing a leak program or how to use the Ultrasonic Leak Detector, give us a call. An Application Engineer will be happy to help with the process and recommend some other methods to save on your compressed air supply.

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Find Compressed Air Leaks with an Ultrasonic Leak Detector

The Ultrasonic Leak Detector (ULD) is a hand-held, high quality instrument that can locate costly leaks in a compressed air system. The definition of Ultrasonic as defined by Merriam-Webster is: “having a frequency above the human ear’s audibility limit of about 20,000 hertz —used of waves and vibrations.” The human hearing range depends on pitch and sound. Sound is a measure of how low or high the volume of loudness in terms of decibels (dBA) and “Pitch” is measured in Hertz (Hz).The overall spectra of the emitted ultrasonic sound is “white noise”, white noise is the broad band emission of sound.

Humans can detect sounds in a frequency range from about 20 Hz to 20 kHz. (Human infants can actually hear frequencies slightly higher than 20 kHz, but lose some high-frequency sensitivity as they mature; the upper limit in average adults is often closer to 15–17 kHz.)

The Model 9061 ULD is designed to locate the source of ultrasonic sound emissions and is used to find compressed air leaks. These ultrasonic sound emissions are converted by the ULD to a range that can be heard by humans. All this being said, the EXAIR ULD makes finding your air leaks fast and efficient.

The Model 9061 comes complete with with a hard shell plastic case, headphones, parabola, tubular adapter, tubular extension and a 9 volt battery. The ULD can be adjusted to filter out background noise typically heard in manufacturing environments by using the X1, X10 and X100 sensitivity settings. The “on/off” thumb wheel can be used for sensitivity adjustment within each of theses settings. The parabola or tubular extension can be attached to the ULD masking out background noise and finding the ultrasonic sounds being generated from the leaks.

Compressed air is an expensive cost center so using the ULD to detect and fix air leaks can not only be fun but also show a payback on investment with just one leak detection. The illustration below demonstrates just how a payback occurs.

EXAIR has many tools and accessories for your intelligent air needs and want to hear from you as we have Application engineers ready to assist your projects and compressed air challenges.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

Save $$$ by Finding and Fixing Compressed Air Leaks

SBMart_pipe900

The generation of compressed air accounts for approximately 1/3 of all energy costs in an industrial facility. According to the Compressed Air Challenge, about 30% of that compressed air is lost through leaks. This means nearly 10% of your facilities energy costs are simply wasted through poor connections, faulty air valves, improper installation, etc. In addition to simply wasting money, compressed air leaks can also contribute to a variety of other operating losses. A leak can cause a drop in system pressure. When this occurs, end users may not operate as efficiently and has an adverse effect on production. This same drop in system pressure will also cause the equipment to cycle on/off more often, shortening the life of your compressor and other equipment. If the leaks cause an issue in supply volume, it may lead to the belief that more compressor capacity is necessary, further increasing your operating costs.

To put leaks in perspective (assuming energy costs of .10/ kWh), the folks at Compressed Air Challenge put it this way:

  • A $200/year leak cannot be felt or heard
  • A $800/year leak can be felt, but not heard
  • A $1,400/year leak can be felt and heard.

If you walk through your facility, how many leaks can you hear? These are only the REALLY bad ones!!  So if we know that a large amount of compressed air is leaking, what do we do about it? ? A proper leak prevention plan is the key to success. Since these leaks are impossible to see and some cannot even be heard, you need a tool to help assist you. EXAIR’s model 9061 Ultrasonic Leak Detector is the right tool for the job. When compressed air leaks through a pipe, it creates an ultrasonic signature due to turbulence. While this sound is not always detectable by the human ear, this meter will allow you to locate leaks up to 20’ away by converting the ultrasonic signature into an audible sound.

The first step will be locating the leaks using an Ultrasonic Leak Detector and tagging them throughout the facility. Don’t let this overwhelm you!! If you have a larger facility, break it up into sections that can be completed in 1 day. This will allow you to decide which areas of the plant should be looked at first. Once you’ve located and tagged all of the leaks, rate them under two separate criteria so that you can prioritize what to fix first. Rate them based on the difficulty that it will take to fix them and also by the severity of the leak. Those that are severe yet easy to fix would make sense to begin fixing first. Those that may require a period of shutdown can be planned to fix at a more appropriate time.

ULD_Kit

When you’ve had the opportunity to fix them, don’t just forget about it. When new piping is installed, new lines are added, or anything involving compressed air is installed there is the potential for new leaks to develop. Set this as one of your regular PM activities and complete your own compressed air audit once a year. Implementing the process and maintaining it are the keys to your success.

If you have questions about developing a leak program or how to use the Ultrasonic Leak Detector, give us a call. An Application Engineer will be happy to help with the process and recommend some other methods to save on your compressed air supply.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Why Start a Leak Prevention Program?

All compressed air systems will have some amount of leakage. It is a good idea to set up a Leak Prevention Program.  Keeping the leakage losses to a minimum will save on compressed air generation costs, and reduce compressor operation time which can extend its life and lower maintenance costs.

The Compressed Air Challenge estimates an individual compressed air leak can cost thousands of dollars per year when using $0.07/kWh.

  • 1/16″ diameter hole in excess of $700/year
  • 1/8″ hole in excess of $2900/year
  • 1/4″ hole in excess of $11,735 per year

There are generally two types of leak prevention programs:

  • Leak Tag type programs
  • Seek-and-Repair type programs

Of the two types, the easiest would be the Seek-and-Repair method.  It involves finding leaks and then repairing them immediately. For the Leak Tag method, a leak is identified, tagged, and then logged for repair at the next opportune time.

A successful Leak Prevention Program consists of several important components:

  • Document your Starting Compressed Air Use – knowing the initial compressed air usage will allow for comparison after the program has been followed for measured improvement.
  • Establishment of initial leak loss – See this blog for more details.
  • Determine the cost of air leaks – One of the most important components of the program. The cost of leaks can be used to track the savings as well as promote the importance of the program. Also a tool to obtain the needed resources to perform the program.
  • Find the leaks – Leaks can be found using many methods.  Most common is the use of an Ultrasonic Leak Detector, like the EXAIR Model 9061.  See this blog for more details. An inexpensive handheld meter will locate a leak and indicate the size of the leak.

    Model 9061
    Model 9061
  • Record the leaks – Note the location and type, its size, and estimated cost. Leak tags can be used, but a master leak list is best.  Under Seek-and-Repair type, leaks should still be noted in order to track the number and effectiveness of the program.
  • Plan to repairs leaks – Make this a priority and prioritize the leaks. Typically fix the biggest leaks first, unless operations prevent access to these leaks until a suitable time.
  • Record the repairs – By putting a cost with each leak and keeping track of the total savings, it is possible to provide proof of the program effectiveness and garner additional support for keeping the program going. Also, it is possible to find trends and recurring problems that will need a more permanent solution.
  • Compare and publish results – Comparing the original baseline to the current system results will provide a measure of the effectiveness of the program and the calculate a cost savings. The results are to be shared with management to validate the program and ensure the program will continue.
  • Repeat As Needed – If the results are not satisfactory, perform the process again. Also, new leaks can develop, so a periodic review should be performed to achieve and maintain maximum system efficiency.

An effective compressed air system leak prevention and repair program is critical in sustaining the efficiency, reliability, and cost effectiveness of an compressed air system.

If you have questions about a Leak Prevention Program or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer
Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS