An air leak survey is the easiest way to save money 

Compressed air can be responsible for as much as 30% of a factory’s energy consumption. Wasting part of this energy simply means throwing money away. Analysis your compressed air system is an excellent way to start the optimisation of your plant or manufacturing facility.

One of the simplest and most effective checks to make on your compressed air system is an air leak survey. Unfortunately, traditional galvanised steel compressed air pipework is prone to leak after a period of time. From surveys most older pipework systems leak on average 20% – 30% of produced compressed air, so it is clear potential savings are significant. One of the most common causes of air leaks in galv pipework is corrosion. This normally occurs in the threads at the joints. The corrosion causes the pipe to expand creating a leak. Other common causes of faults in all types of pipework are faulty valves, mechanical damage, leaky hoses, leaking connections to plant etc etc.

Four simple checks to see if you are leaking

There are four simple checks that you can do to check how big a problem you have with leaking pipework.

When the factory is quiet (weekend, night time or shut down), can you hear the hiss of compressed air?

When you are not in production is your compressor still running?

Is the pressure reading in the compressor house higher than the pressure reading at the furthest point of use in the factory?

What pressures do your processes require versus the pressure that is generated?

These are easy checks that you can perform yourself. However, when it comes to properly working out the size and scale of the leaks you have in your pipework system it is best to call in the experts with the correct equipment and experience to carry out the task quickly and efficiently.

Air Equipment we use ultrasonic testers to detect even the smallest leaks. The equipment is so sensitive that even tiny leaks can be detected from many meters away. The equipment is also able to give a good estimation of the size of the leak so we can calculate for each particular leak how much money is being wasted and what the saving would be if the leak was fixed – giving a great payback estimation.

The Air Equipment Air Leak survey process

During our leak detection survey process we go round your pipework with the leak detector, identify and tag each leak, giving it a unique reference, location and scale of leak. In most cases we also photograph the problem area. We then write all this information into a report which we present back to the customer. Normally we also make recommendations as to which leaks we feel should be carried out and the cost to carry out these repairs.

The customer can follow our recommendations or come up with their own, but always knowing how much its going to cost for the repair and how much energy they will save.

We recommend an annual survey with an ongoing programme of repairs, picking off the top 80% of leak volume every year. Payback on this process is typically measured in a few months rather than years. Air leak surveys / repairs are one of the most effective and quickest payback solutions to improving compressed air efficiency.

Call us to arrange a air leak survey for your plant. We normally a charge a nominal fee for the initial survey which is credited against repairs you implement.

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Air Equipment can support you and your compressed air system throughout its life. We will monitor your system to ensure it remains reliable, efficient and operating correctly. We will service your compressors, filters and air dryers to schedule, to ensure they continue to operate correctly. We can also help and guide you through changes to your air system as your company changes and grows.

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