Compressed air leak detection-commercial compressors are frequently put up in facilities around the United States, and they may quickly become expensive pieces of equipment to run. About 19% of the total power consumed in a compressed air system is turned into clean, tight airflow. The remaining 81 percent is wasted as heat. As a result, compressed air is more expensive than other utilities such as electricity, natural gas, and water. In addition, when you combine it with compressed air leaks, your energy efficiency may suffer. Thus, compressed air leak detection is extremely essential.
A quick walkthrough with a decent pair of ears may reveal some serious leaks. You may also notice a shift in equipment productivity. However, if you can discover problems in this manner, the situation has already become quite expensive.
Specialized equipment and a professional expert should be used for accurate compressed air leak detection, especially in noisy surroundings. Ultrasonic leak detection systems are the most effective instrument for detecting leaks. Their frequent use can aid in a compressed air system’s consistent and high functioning. In addition, regular leak audits decrease lost energy costs, and excessive wear on air compressors, and assist prevent air compressor downtime.
Manufacturing companies that want to save production costs and enhance energy efficiency should monitor their compressed air leak detection system. According to conservative estimates, such systems consume 10% of all energy consumed in the global industry, with 10–30% lost due to leakage. This waste may be highly costly since even a 3mm leak can cost over £2000 per year, with an energy loss equal to 16 tonnes of CO2 emissions.
Despite this, compressed air leak detection audits are not as common as they could be. Some customers are unaware of the degree of any onsite leakage, let alone its expense; others are apprehensive that any audit will be disruptive and time-consuming. However, when done right, audits may be efficient, quick, and painless, exposing the potential for energy savings and process improvements.
The first steps may be taken with little or no technology. For example, a compressor can be run without any associated equipment to reduce background noise. Some leaks in compressed air leak detection can thus be discovered simply by listening. However, bigger ones may be inaudible or occur only at specific pressures. Others may be out of reach.
The first steps may be taken with little or no technology. For example, a compressor can be run without any associated equipment to reduce background noise. Some leaks can thus be discovered simply by listening. However, bigger ones may be inaudible or occur only at specific pressures. Others may be out of reach.
The concept of compressed air leak detection is easy a turbulent flow is created when air travels from high to low pressure via a leak site. This turbulence has discernible ultrasonic components. In general, the higher the ultrasonic level, the larger the leak. Background sounds in the audible range are largely unaffected by ultrasonic detectors since they are filtered away. As a result, leakage may be heard even in the noisiest situations.
Several hand-held, battery-powered probe devices are available that may be pointed towards the pipes under inspection. One kind electronically transforms high-frequency emissions into lower-frequency counterparts that may be heard via a headset. Another is built as a camera that displays photographs of the surveyed piping, with any identified leaks shown as bright spots.
The cost-saving benefits of these ultrasonic devices are maximized when they are employed as part of a continuous compressed air leak detection system monitoring plan. This gives survey results to management in a simple, actionable format; moreover, the survey may be repeated at regular intervals – generally every six months or so – to discover new leaks as they emerge.
Atlas Copco conducts ultrasonic leak assessments as part of their AIRScan energy audit service, which evaluates flow, power, air quality, and maintenance levels and leaks.
Each survey report contains, when appropriate, ID images, CFM leak rates in colour-coded schedules, related expenses, and corresponding CO2 emission losses.
Such compressed air leak detection surveys may gain many advantages, including Continuous energy cost reduction.
Load reduction extends the life of the air compressor and treatment equipment while lowering the cost of ownership.
Productivity gains from sustaining greater system pressures.
Compliance with legislation when combined with other rules| compressed air leak detection
A normal AIRScan can result in energy savings of 25-30%. For an instance, in one recent Atlas Copco project, a leakage detection program used across a car manufacturing factory found leaks worth £102,000 per year in wasted energy. A comparable study, executed over three days by Atlas Copco’s AIRScan team at the premises of the UK-based food industry, identified £49,000 in leakage. This demonstrates the value of undertaking this sort of audit. However, there is no fee if the AIRScan engineers do not discover enough leaks to justify the cost of the survey.