Compressed air leaks and their financial impact

In the industrial landscape, efficient compressed air systems play a pivotal role in enhancing productivity and cost management. However, the presence of compressed air leaks can significantly impact both financial performance and workplace safety. In this guide, we'll explore the dangers of compressed air leaks and provide actionable strategies to identify, minimize, and quantify their financial impact.

Transportation of compressed air to the user is an expensive process that requires expensive equipment which consumes large amounts of electricity and requires regular maintenance. Users often don’t realize how high are the annual costs of operating the system and how much you can save by improving the impact of these systems.

Identifying Compressed Air Leaks

Detecting compressed air leaks promptly is key to minimizing their impact. Common signs include hissing sounds, pressure drops, and visual inspections of connections and equipment. Utilizing advanced tools, such as ultrasonic leak detectors and thermal imaging cameras, can enhance the accuracy and efficiency of leak detection processes.

Anyone who has been in production after work heard the sound of a leak in the installation of compressed air. Leaks in the system with compressed air can cause significant costs. These losses can reach 25% or more of the total supply of air. They can occur due to a leak of valve joints, welded places, corroded pipes, the leak in the rubber hose and coupling element, failures on automatic condensate drain, a leak in the filter or regulator, leakage, quick couplers, nonfunctioning safety valve failure, pneumatic cylinder, ...

Leaks behave as a nozzle from which the air is the expiry of a very high speed. Such points leaks 24 hours per day, 365 days per year. As a result, the pressure is reduced, the compressor is repeatedly switched on despite the inaction of consumers, while consuming valuable energy and reduces costefficiency of the energy system.

Leaks in compressed air systems can cause thousands of Euros losses. The detection of leaks is an important maintenance requirement which traditionally can be done by soap water, but now by an Ultra Sound detector. When gases are leaking through tubes and tanks an ultrasonic sound is produced which can be detected by detector even from several meter distance.

Minimizing Compressed Air Leaks

Preventing and fixing leaks requires a proactive approach. Regular maintenance schedules, employee training and the use of quality components are integral to reducing the occurrence of leaks.?

The Cost of Compressed Air Leaks

Understanding the financial impact involves calculating the cost associated with system leakage during compressor on periods. This method allows us to quantify the volume of lost air and its corresponding power consumption. Let's dive into an example calculation to illustrate the potential annual savings:

Calculation of system leakage based on compressor starts

If there is no air consumption in the system (consumers are not operating), you can measure the amount of leaking air in the system by following the automatic compressor start-ups. Since the system is not emptied, the pressure in it drops, so the compressor turns on at the set pressure and fills the system up to the maximum pressure.

EXAMPLE:

Vp = volume flow of air leakage in m3/h

Vk = compressor volume flow (capacity) in m3/h

t = sum of operating times of the compressor during the measurement (t = t1 + t2 + t3 + t4 +…)

T = total measurement time

Vp=?

The power of our compressor = 37 kW

Vk= 5,3 m3/h

t = t1 + t2 + t3 + t4 + t5 = 150 s

T = 900 s

Vp = (Vk x t) / T

Vp = (85,3 x 150) / 900

Vp = 0,883 m3/h = 16,6% air lost due to leakage!

In our example, 6,1 kW of power (37 x 0.166) is used every hour to cover losses. When the compressor is connected to the network all the time, this leakage occurs 24 hours a day, 365 days a year, which amounts to:

6,1 kW x 24 h x 365 days = 53436 kW annually.

Now multiply this amount by the cost of a kilowatt hour and you will get the cost of a compressed air system leak. If the price is?0,15 EUR/kWh then the cost of air leaks is 8.015,4 € per year.

Efficient compressed air systems are vital for industrial operations, and minimizing leaks is a key aspect of achieving this efficiency. By understanding the dangers, implementing effective detection methods, and proactively addressing leaks, businesses can enhance both their financial bottom line and workplace safety.

Solution: OMEGA AIR products for system leakage detection

When gases are leaking through tubes and tanks an ultrasonic sound is produced which can be detected by OS 530 even from several meter distance. OS 530 transforms these inaudible signals into a frequency which can be easily heard by using the supplied noise-isolated headset.

The integrated laser pointer helps to spot the leak from a distance. In unpressurized systems, an ultrasonic tone generator can be used whose sound will leak through small openings.

Contact us today for professional assistance in identifying and addressing compressed air leaks in your facility: https://www.omega-air.si/contact-us