Addressing Compressed Air Leaks
The largest source of energy loss in any compressed air system is through air leaks. The U.S. Department of Energy estimates that 20-30% of consumed energy is lost to air leaks. Often hard to spot, leaks allow the compressed air to escape, wasting energy and money. Air leaks decrease production capacity and lessen equipment lifespan. To keep systems running their best, follow these tips on leak detection, fixes, and prevention.
Detecting Air Leaks:
Because air is invisible, spotting leaks can sometimes be difficult. However, the following three methods each allow for air leak detection.
Feel and listen
This technique involves traveling the entire length of the system and carefully listening for disturbances. If this method is employed, often the system has to be down. Hearing leaks over the noise of production can be difficult. Because of human hearing limitations, this method typically only detects large leaks.
Soapy Water
This method involves brushing soapy water over the pipes of a system. Any area with a leak will cause the soapy water to bubble. Though very reliable, this method can be time consuming. It also will not provide much detailed information on the leak besides the location.
Ultrasonic
Specialized leak detector equipment pieces pick up the ultrasonic noise associated with the release of compressed air. This method is fast and accurate and can even detect very small leaks. Due to its increased sensitivity, most leak detection programs will employ this method.
Fixing Air Leaks
Once the leaks have been identified, the challenge is to fix it appropriately. Depending on where the leak is, the solution will vary. The most common places for leaks are around connections and equipment. Often times, the piping simply needs to be tightened to increase the seal. Incorrect use of threaded sealant can also be a large area of leakage. If a leak is caused by old or damaged equipment such as a coupling, tube, or fitting, the old version should be replaced as soon as possible.
Prevention/Maintenance
Though leaks in a compressed air system may seem inevitable, preventive measures still exist to decrease leak impact. The best way to prevent future air leaks is to establish a regular leak detection and repair program. This program should involve identification, tracking, repair, and verification, of leaks.
The most important aspect of a successful leak maintenance program is the integration of employees into every step. They are the ones who work with the system on a daily basis. They know the air system better than most people and can more easily spot where problems are. Making sure that employees look out for the system, is the best way to catch and fix leaks before they become too much of an issue.
Merely detecting leaks is not enough for a successful leak prevention program; the leaks actually need to be fixed. Though it seems obvious, many companies spend money on detecting leaks, but never move forward to fix the problems. Generally, the largest leaks should be addressed first in order to see the greatest energy savings.
Effective leak prevention is not just one and done. Instead, facilities should use ongoing efforts to spot problem areas. Compressed air systems run often and undergo constant change, which could lead to new leaks. The best way to stay on top of these changes are to be regularly monitoring the system, and fix leaks before they become too large.
If an energy efficient, cost-effective compressed air system seems like the right direction for your plant, addressing air leaks is a good place to start.
Looking for help in leak detection? Contact a CASCO USA specialist. To learn more about other ways to save money in your compressed air system, read our Energy Rebates blog.
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