Starting a Leak Prevention Program

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.

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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.

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    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: Save $$ With a Leak Prevention Program

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Don’t let leaks drive up your utility bill

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 facility’s 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, having 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 Compressed Air Challenge states this:

  • 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?

We know that a large portion of the compressed air is being wasted, but 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.

 

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Model 9061 with parabola attachment

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.

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Accessories that come with the Ultrasonic Leak Detector

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 additional methods to save on your compressed air supply.

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