As margins get tighter and cost of manufacturing climbs, industries are looking into different areas to be more efficient. A big focus nowadays is in their compressed air system. Why is this? Manufacturers are starting to realize that it takes an abundant amount of electricity to make compressed air. That is why EXAIR manufactures compressed air products for optimization to get the best efficiency. But what many manufacturers don’t realize is that quiet little hissing sound from there compressed air lines is costing them much money. That is why EXAIR has the Ultrasonic Leak Detector.
Energy Star, a federal voluntary program ran by the Environmental Protection Agency, offers energy-efficient solutions. EXAIR has partnered with Energy Star because it underscores our commitment to improve energy savings. They even wrote an excerpt about compressed air leaks here: Energy Tips: Minimize Compressed Air Leaks. With compressed air leaks, it can be as much as 30% of your compressed air usage.
When a leak occurs, it emits an ultrasonic noise. The EXAIR Ultrasonic Leak Detector can pick this up. It has a frequency range from 20 KHz to 100 KHz, above human hearing, so it can make the inaudible leaks, audible. With three sensitivity ranges and LED display, you can find very minute leaks. It comes with headphones and two attachments; the parabola attachment to find leaks up to 20 feet (6 meters) away, and the tube attachment for local proximity to define the exact location of the leak.
In the Energy Tips from Energy Star, they reference estimated leak rates and costs associated with these leaks. They also recommend a leak prevention program with reference materials to help improve energy savings. As part of that program, an Ultrasonic Leak Detector is the best way to begin.
To tell a common success story about the Ultrasonic Leak Detector, an EXAIR customer had a 50-horsepower air compressor. It started to overwork, overheat, and occasionally shut down. He thought that he would need to buy a larger air compressor to keep his plant running. In discussing his problems and requirements, he decided to purchase an Ultrasonic Leak Detector from EXAIR to check for leaks as a possible cause. He checked every fitting and connection in his facility. When he finished checking the compressed air system, he found 91 leaks. (You will be surprised with your system if it is not well maintained).
If we look at a very small 1/16” (1.6mm) diameter hole at 80 PSIG (5.5 bar), it will cost you $360 a year per leak (based on 6000 working hours per year). Thus, 91 leaks at $360/year will equal $32,760 per year. After the fittings were reworked with piping compound, the compressor was back operating in a normal range. There was no need to buy a larger air compressor with capital funds, and he was able to save $32,760 a year by finding and fixing the leaks.
As a little secret with the Ultrasonic Leak Detector, it can do more than find compressed air leaks. Any issue that creates an ultrasonic noise, the Ultrasonic Leak Detector can find it. This will include air damper seals, circuit breakers, cracked rubber belts, gas burner leaks, refrigerant leaks, worn bearings, and air brake systems on trucks. It is a handy tool to find potential issues or problems in other areas other than compressed air systems.
For optimization of your compressed air system, it is very important to find and correct leaks in your piping system. The Ultrasonic Leak Detector can help you do that. It is an inexpensive way to solve an expensive problem, compressed air leaks. If you would like to discuss the features and benefits in more detail, you can contact an Application Engineer at EXAIR. We will be glad to help you.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb
