Tag: Ultrasonic Leak Detector

The Cost of Compressed Air Leaks and How to Find Them.

Published on by John BallLeave a comment

As margins get tighter and the cost of manufacturing climbs, industries are looking for ways to be more economical.  A big focus is on the compressed air system.  Compressed air is considered to be the “fourth utility” behind gas, water, and electricity.  Air compressors are necessary to run pneumatic systems, but they are the least efficient of the utilities.  For every $1.00 that is put into making compressed air, you only get roughly 5¢ of work from it.  So, it is very important to use this utility as efficiently as possible. 

One of the biggest problems affecting compressed air systems is leaks.  That quiet sound coming from the pipelines is costing your company a lot of money.  A study was conducted by a university to determine the percentage of air leaks in a typical manufacturing plant.  In a poorly maintained system, they found that 30% of the compressor’s capacity is lost through air leaks on average.  Just to let you know, the majority of companies do not have a leak prevention program, so they will fall into the “poorly maintained” category.  The chart below shows the amount of money that can be wasted by the size of the hole for larger leaks. Unlike a hydraulic system, compressed air is clean, so leaks will not be visible at the source.  You have to find them by other means.  There are four main methods to test your system for leaks.

Ultrasonic Leak Detector:  When you have small air leaks, the turbulent flow will emit an ultrasonic sound.  This method is the most direct way to find leaks in your system.  With the EXAIR Ultrasonic Leak Detector, it can pick up these high frequencies in the range of 20 kHz to 100 kHz, above human hearing.  This device makes the inaudible leaks audible.  Some other features of the model 9207 are a sensitivity adjustment button, a signal strength display, and a headphone volume button.  It has two attachments; the parabola attachment to locate leaks up to 20 feet (6.1 meters) away, and the tube attachment to define the exact location of the leaks. 

EXAIR’s Digital Flowmeter w/ USB Data Logger

Digital Flowmeters:  With Digital Flowmeters, you can continuously watch for waste.  Air leaks can occur at any time within any section of your pneumatic system.  You can do systematic checks by isolating sections with the Digital Flowmeter and watching for a flow reading.  Another way to monitor your system would be to compare the results over time.  With the Digital Flowmeters, we have a couple of options for recording the air flow data.  We have a USB Datalogger for setting certain time increments to record the air flows.  Once the information is recorded, you can connect the USB to your computer, and with the downloadable software, you can view the information and export it into an Excel spreadsheet.  Once the information starts trending upward for the same process, you can focus your attention on finding the leak.  It can also serve as a preventive measure if a pneumatic system is starting to fail.

Pressure difference:  There are some equations that can be helpful in determining how severe the leaks are in the system.  One method would be to look at a pressure gauge.  For this method to work, you will have to estimate the total system volume, comprising secondary air receiver, piping, and air mains. After the compressor runs for a while to build to an operating pressure (P1).  Then, you have to block the system off and measure the time.  When it reaches a stopping point at pressure (P2), mark that time.  Use Equation 1 to measure the leakage rate, Q in CFM.  If the flow is more 10%

Equation 1:

Q = (V x (P1-P2)/T x 14.7) x 1.25

V = Volume (Ft3)

P1- Starting pressure (psig)

P2 = Ending pressure (psig)

T = Time (Minutes)

Compressor cycling time:  First start by shutting off all the points of use of 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, causing a pressure drop from air escaping. The percentage of total leakage can be calculated by Equation 2.  The leakage rate will be given as a percentage of total compressor capacity lost. This value should be less than 10% for a well-maintained system.

Equation 2:

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

Where:

T = loaded time (seconds)

t = unloaded time (seconds)

Compressed air leaks will rob you of performance, compressor life, and electrical cost.  It is important to have a leak prevention program to check for leaks periodically, as they can happen at any time.  I added some tips and tricks to help determine the severity of the leaks in your system.  The EXAIR Digital Flowmeters and Ultrasonic Leak Detector will help you accomplish this and optimize your compressed air system.  If you need more information, you can contact an Application Engineer at EXAIR.  Once you find and fix all your leaks, you can then focus on improving the efficiency of your blow-off devices with EXAIR products.  It will save you even more money. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Photo: Soap bubbles and pencils by Carola68.  Pixabay license. 

“Did You Hear That!?”- EXAIR’s Ultrasonic Leak Detector

Published on by jasonkirbyLeave a comment

The production of compressed air represents roughly one-third of the total energy expenses in an industrial setting. The Compressed Air Challenge indicates that approximately 30% of this compressed air is lost due to leaks. Consequently, nearly 10% of the energy costs incurred by the facility are squandered because of inadequate connections, malfunctioning air valves, and improper installations. Beyond financial waste, these leaks can lead to various operational inefficiencies. A reduction in system pressure can hinder the performance of end users, negatively impacting production efficiency. Additionally, this pressure drop may result in more frequent cycling of equipment, which can diminish the lifespan of compressors and other machinery. If leaks compromise the supply volume, it may create a false impression that additional compressor capacity is required, thereby escalating operating expenses.

When a leak occurs, it generates ultrasonic noise due to turbulence, often at frequencies above 20 kHz, which are inaudible to the human ear. The EXAIR Ultrasonic Leak Detector, model 9207, is designed to detect these frequencies and convert them into audible sounds through a technique known as “heterodyning.” This device features a signal strength indicator and a bar graph display, enabling the identification of even the smallest leaks. It includes two attachments: a parabolic microphone for detecting leaks from distances of up to 20 feet, and a tube attachment for pinpointing the exact location of a leak among multiple connections within a pipe. Once a leak is identified, it can be marked for repair.

The ULD is equipped with attachments designed to minimize background noise commonly encountered in industrial settings, featuring “+” and “-” buttons for precise adjustments to the meter’s sensitivity. This latest model enhances leak detection capabilities in difficult-to-access locations and adheres to the IEC 61326-1 standard, ensuring its functionality in the typical electromagnetic environments present in industrial facilities.

In most industrial facilities, huge amounts of savings can be realized rather easily by implementing a leak protection program. If you have questions about introducing the Ultrasonic Leak Detector to your leak protection program, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Environmental Impacts: Be Efficient. 

Published on by John BallLeave a comment

Since the establishment of EXAIR in 1983, customer satisfaction has always been the cornerstone of our business model.   This may seem like common practice, but here at EXAIR, we like to go the extra mile.  We have over a 99.9% on-time delivery with thousands of products in stock.  We offer free expert technical help from our Application Engineers, as well as within EXAIR Blog writings and application search library.  We have an Efficiency Lab to report on comparison results with safety and compressed air saving.  We also offer a 30-day unconditional guarantee on our cataloged products for you to try.   So, what more can EXAIR do for you?

Compressors use large amounts of electricity to produce compressed air and are considered the fourth utility in most manufacturing plants.  EXAIR manufactures engineered products that can save compressed air and increase energy savings.  With that, EXAIR was able to partner with Energy Star.  “Energy Star is a government-backed symbol of energy efficiency, helping to save money and to protect the environment through energy-efficient products and practices.” This commitment by EXAIR to reducing energy, increasing safety for workers, and protecting the environment for future generations are effective ways to sustain a business value.

When large amounts of energy can be saved, electricity-producing companies take notice.  Electrical suppliers started a rebate program for using engineered nozzles in their facilities.  Similar to other energy-saving rebates, like LED light bulbs and high-efficiency furnaces, the EXAIR engineered nozzles now fall into that same category.  If your electrical provider supports this program, the total cost to purchase and implement the EXAIR Super Air Nozzles is greatly reduced.  Even if a rebate program has not yet been implemented in your area, the idea of saving energy makes it very practical and environmentally sound.

The NC Clean Energy Technology Center created a website to consolidate all the electrical companies that offer rebates for efficient products and programs.  The website is www.dsireusa.org.  “DSIRE is the most comprehensive source of information on incentives and policies that support renewable and energy efficiency in the United States.”  EXAIR engineered products fall into this category, so if a rebate can be applied to our products, it will be located on that site.

Another energy-saving tip from Energy Star refers to waste from leaks.  They recommend a leak prevention program to help improve energy savings.  As part of that program, EXAIR does offer an Ultrasonic Leak Detector.  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.  They thought that they would need to buy a larger air compressor to keep the plant running.  In discussing that a company without a leak prevention program could have as much as 30% waste, they decided to purchase an Ultrasonic Leak Detector.  They checked every fitting and connection in the facility.  When they finished checking the compressed air system, they found a total of 91 leaks.  Not only did this save on energy waste, but it also saved money by fixing the leaks and not expanding the capital expenses in the company.

With EXAIR being backed by Energy Star, EPA, and rebate programs, together, we can save energy, improve the environment, and reduce compressed air usage.  If you would like to discuss how EXAIR can work for you, you can contact an EXAIR Application Engineer.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Photo: Lightbulb by TheDigitalArtist.  Pixabay Content License

Maintaining Your Compressed Air System

Published on by Jordan T ShouseLeave a comment

A poorly maintained compressed air system wastes energy, increases operational costs, and risks unexpected failures. Common issues include leaks, pressure loss, contamination (like moisture or oil). Studies suggest that up to 30% of compressed air is lost to leaks in an average system, while contaminants can damage downstream equipment or spoil products. Routine maintenance tackles these problems head-on, ensuring reliability and cost-effectiveness.

Key Maintenance Practices

  1. Monitor and Replace Intake Filters
    The air compressor draws in ambient air, which is often laden with dust, dirt, and water vapor. The intake filter is your first line of defense, protecting the compressor’s internals from wear. Over time, debris buildup increases pressure drop, forcing the compressor to work harder and reducing efficiency. Check the filter regularly—typically monthly—and replace it when the pressure differential exceeds the manufacturer’s recommended limit (often around 5-10 psid) or at least annually.
  2. Manage Moisture with Dryers and Drains
    Water vapor in compressed air condenses as it cools, leading to rust in pipes, damage to pneumatic tools, and quality issues in applications like painting or food processing. A dryer—whether refrigerated, desiccant, or membrane—is crucial. For smaller systems or point-of-use applications, inspect and clean dryer coils or replace desiccants as per the manual (usually every 1–2 years). Automatic drain traps should also be checked quarterly to ensure they’re removing condensate effectively.
  3. Audit for Leaks
    Leaks are silent efficiency killers. Even a small 1/8-inch hole at 100 psig can cost over $1,000 annually in wasted energy. Conduct a leak audit every 6–12 months using an ultrasonic leak detector. Focus on fittings, valves, and older piping sections, where vibration or corrosion often takes a toll. Repairing leaks promptly can save 20-30% on energy costs. EXAIR’s 9207 can help with this task.
  4. Optimize Pressure Settings
    Over-pressurizing the system to compensate for downstream losses wastes energy—every 2 psig increase adds about 1% to power consumption. Use pressure regulators at the point of use to deliver only what’s needed. Monitor system pressure monthly to ensure it aligns with demand, adjusting as equipment or processes change.

How EXAIR Products Enhance Maintenance and Efficiency

EXAIR’s Intelligent Compressed Air Products are engineered to complement these maintenance practices. Here’s how some specific items can help:

  • Ultrasonic Leak Detector (Model 9207)
    Pinpointing leaks in a noisy compressor room can feel like finding a needle in a haystack. EXAIR’s Ultrasonic Leak Detector uses sound wave detection to identify leaks with precision, even in high-decibel environments. Regular use during audits—say, every 6 months—helps maintenance teams catch and fix leaks early, slashing energy waste. Its portability and ease of use make it a must-have for proactive upkeep.
  • Automatic Drain Filter Separators
    Moisture and particulates in the air stream can clog tools or ruin products. EXAIR’s Automatic Drain Filter Separators (available in various port sizes, e.g., 1/4″ to 1-1/2″ NPT) feature a 5-micron filter and centrifugal separation to remove bulk liquids and debris. The auto-drain feature expels collected water without manual intervention, reducing maintenance time. Replace the filter element annually or when the pressure drop hits 10 psid to keep air quality high and downstream equipment safe.
  • Oil Removal Filter
    For applications requiring ultra-clean air—like electronics assembly or pharmaceutical production—the Oil Removal Filter takes filtration further. With a 0.03-micron coalescing element, it traps oil vapor and fine particles, coalescing liquids for gravity drainage. Pair it with a Filter Separator for a two-stage approach, and replace elements yearly to maintain performance. This ensures sensitive equipment stays contaminant-free with minimal upkeep.
  • Pressure Regulators
    Excessive pressure at the point of use is a common efficiency drain. EXAIR’s Pressure Regulators (included in many product kits) let you dial in the exact pressure needed—e.g., dropping from 100 psig to 80 psig can cut air usage by nearly 20%. Install them downstream of filters for accurate control, and check settings quarterly to match evolving process demands. They’re a simple, maintenance-free way to optimize demand-side efficiency.

A well-maintained compressed air system isn’t just about avoiding breakdowns—it’s about maximizing efficiency and minimizing costs. By pairing routine checks with EXAIR’s engineered solutions, you can tackle leaks, contamination, and over-pressurization head-on. The result? A system that runs smoother, lasts longer, and keeps your energy bill in check. Whether you’re blowing off parts, powering tools, or cooling processes, these strategies and tools ensure your compressed air works as hard as you do.

For more insights or help selecting the right EXAIR products for your system, reach out to an Application Engineer. Let’s keep your air flowing intelligently!

Jordan Shouse
Application Engineer

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