Tag: air leak

No Matter The Size of The System, Air Leaks Should be Fixed

Published on by Brian FarnoLeave a comment

Just last night I was in my garage tinkering around with a vintage Coleman Camping lantern from 1949 that I am working on refurbishing. I grabbed my parts washing bin (A bread pan my wife let me have because she didn’t like the way it cooked bread) and was reminded that I had been soaking a helmet lock from a friends dirt bike in a penetrating oil. I removed the lock from the pan, wiped it down, then went to my trusty 30 gallon compressor to use a Safety Air Gun to blow the residual oil out of the lock.

When not in use my compressor stays turned off and I modified the factory outlet to include a quarter turn ball valve so that I can retain all air in the receiver tank and not have to charge the tank up every time that I use it. As I turned the valve on I was reminded that I have a rather large air leak that can drain the 30 gallon tank down from 150 psig to 60 psig within a few hours.

While my air system is almost as simple as it can be, single air hose real with an additional quick disconnect before the hose reel for small quick blow offs, it still has over a dozen connections within the system. While my worst offending leak is audible to my slightly aged ears there are other leaks that I cannot see or hear. That is unless I use one of two methods I know to find leaks.

The easiest is right out of our 6 Steps of Compressed Air Optimization, the Ultrasonic Leak Detector (ULD). The ULD is a versatile, low cost, hands free electronic device that will quickly and easily detect the general vicinity of a leak and then easily pinpoint the exact point of the leak. In conducting a test, it took right at twenty minutes to test each of the connections within my system and identify which connections had leaks. The actual repairs of the leaks around an hour. Before fixing though I timed the amount of time it took a friend to use the soapy water method to detect the same leaks.

The soapy water method timed in at around thirty-five minutes for the same number of connections. This was due to a few of the fittings needing to be tested multiple times because of small leaks. It then took an additional fifteen minutes to wipe up all the soapy water that was now dripping down the air line and around the fittings.

While both methods found the same leaks and the ULD performed the task quicker and without any cleanup required, the true focus was on all leaks being repaired. My system has a dozen connection points for a two outlet compressed air system that are regulated and filtered at a single point. This system was draining a 30 gallon tank within a few hours which costs me every time I used my compressor and did not shut off the valve that shuts off the system.

This burden on my electrical bill was removed with less than two hours of labor and I can now leave the compressor fully charged and have air as soon as I need it rather than having to wait for the tank to charge up. Had this been in a production environment the cost could have crippled production resulting in catastrophic.

If you would like to discuss how leaks within your system can easily be found by using the ULD or would like to learn more about the other five steps in our Six Steps To Compressed Air Optimization, contact an Application Engineer.

Brian Farno
Application Engineer
Ph. 1-513-671-3322
BrianFarno@EXAIR.com
@EXAIR_BF

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Starting a Leak Prevention Program

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Since 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.

SBMart_pipe_800x

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.  Instead of a log system, the tag may be a two part tag.  The leak is tagged and one part of the tag stays with the leak, and the other is removed and brought to the maintenance department. This part of the tag has space for information such as the location, size, and description of the leak.

The best approach will depend on factors such as company size and resources, type of business, and the culture and best practices already in place. It is common to utilize both types where each is most appropriate.

A successful Leak Prevention Program consists of several important components:

  • Baseline compressed air usage – 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.
  • Identify 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.

    ULD_Pr
    Using the Model 9061 Ultrasonic Leak Detector to search for leaks in a piping system
  • Document 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.
  • Prioritize and plan the repairs – Typically fix the biggest leaks first, unless operations prevent access to these leaks until a suitable time.
  • Document 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.

In summary – 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.

Brian Bergmann
Application Engineer
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Intelligent Compressed Air: Estimating Your Leakage Rate

Published on by Tyler DanielLeave a comment

waste

The electricity costs associated with the generation of compressed air make it the most expensive utility within an industrial environment. In a   poorly maintained compressor system, up to 30% of the total operational costs can be attributed simply to compressed air leaks. While this wasted energy is much like throwing money into the air, it can also cause your compressed air system to lose pressure. This can reduce the ability of the end use products to function properly, negatively impacting production rates and overall quality. Luckily, it’s quite easy to estimate the leakage rate and is something that you should be including in your regular PM schedule.

According to the Compressed Air Challenge, a well-maintained system should have a leakage rate of less than 5-10% of the average system demand. To estimate what your leakage rate is across the facility, first start by shutting off all of the point of use compressed air products so that there’s no demand on the system. Then, start the compressor and record the average time it takes for the compressor to cycle on/off. The compressor will load and unload as the air leaks cause a pressure drop from air escaping. The percentage of total leakage can be calculated using the following formula:

Leakage % = [(T x 100) / (T + t)]

Where:

T = loaded time (seconds)

T = unloaded time (seconds)

The leakage rate will be given in a percentage of total compressor capacity lost. This value should be less than 10% for a well-maintained system. It is not uncommon within a poorly maintained system to experience losses as high as 20-40% of the total capacity and power.

A leak that is equivalent to the size of a 1/16” diameter hole will consume roughly 3.8 SCFM at a line pressure of 80 PSIG. If you don’t know your company’s air cost, a reasonable average is $0.25 per 1,000 SCF. Let’s calculate what the cost would be for a plant operating 24hrs a day, 7 days a week.

3.8 SCFM x 60 minutes x $0.25/1,000 SCFM =

$0.06/hour

$0.06 x 24 hours =

$1.44/ day

$1.44 x 7 days x 52 weeks =

$524.16 per year

A small leak of just 3.8 SCFM would end up costing $524.16. This is just ONE small leak! Odds are there’s several throughout the facility, quickly escalating your operating costs. If you can hear a leak, it’s a pretty severe one. Most leaks aren’t detectable by the human ear and require a special instrument to convert the ultrasonic sound created into something that we can pick up. For that, EXAIR has our Model 9061 Ultrasonic Leak Detector.

ULD_Pr
Model 9061 ULD w/ parabola attachment checking for compressed air leaks

Implementing a regular procedure to determine your leakage rate in the facility as well as a compressed air audit to locate, tag, and fix any known leaks should be a priority. The savings that you can experience can be quite dramatic, especially if it’s not something that has ever been done before!

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

Ultrasonic Leak Detector: Because Leaks Won’t Find (Or Fix) Themselves

Published on by Russ BowmanLeave a comment

I once worked in an equipment repair shop with a small and simple compressed air system…just a 5HP single acting piston compressor that sat atop a 50 gallon tank, in the corner by “The Big Truck”. The majority of our work was field service, and management was big on maintaining our service trucks, so we checked tire pressures every Monday morning as we rolled out, and kept a tire chuck handy to ensure proper inflation. It was also used to supply a couple of air guns that were used at our drill press and soldering/assembly station. One morning, I noticed the air compressor was running when I arrived…I thought it was odd, because I knew for a fact it hadn’t been used in at least 16 hours, but that compressed air went someplace, right? We had a leak. Well, at least one.

This was mid-December, and the week between Christmas and New Year’s Day was characteristically slow, and typically devoted to a thorough shop cleaning. We also took the opportunity to get some bottles of soapy water and check for leaks at the handful of pipe fittings that comprised the system…for the uninitiated, if you have a leaky fitting, the escaping air blows bubbles in the soapy water (a cheap, messy way in other words). We found some bubbling, undid those fittings, cleaned them, and applied fresh pipe thread sealant (I don’t want to start any arguments, but I was taught that tape is more of a thread protectant than an effective sealing agent) and, in addition to replacing a couple of well-worn hoses, we were up and running.  And we never heard the compressor running first thing in the morning again.

Not all compressed air systems are as simple as that, though.  Many go from a room with several large & sophisticated air compressors, to corners of every building on the grounds.  Through valves & manifolds, to cylinders, machinery and blow offs, with more connections than you could soap-and-water check in a month.

In those cases, the EXAIR Model 9061 Ultrasonic Leak Detector makes short(er) work of finding the leaks.  With both visual (LED’s on the face) and audible (headphones) indications, even very small leaks are easy to detect with the parabola installed.  The precise location can then be found with the tubular extension.

EXAIR Ultrasonic Leak Detector “hones in” on the exact location of a leak in a compressed air line.

You’ll still have to fix the leaks yourself, but finding them is oftentimes more than half the battle.  And, once fixed, it can be worth a million (cubic feet of compressed air, that is.)

EXAIR’s Ultrasonic Leak Detectors are not only useful for finding compressed air leaks; they’re popular in a variety of other areas:

Additionally, they can be used to identify faulty bearings, brake systems, tire & tube leaks, engine seals, radiators, electrical relay arcing…anything that generates an ultrasonic sound wave.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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