New Research Unveils the Importance of Frequent Air Leakage Maintenance Checks

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Compressed air systems are beneficial in a variety of fields. Air leaks may be costing a company each year due to needless energy losses, even though they are an unavoidable business expenditure. Because compressed air is among the most expensive — and necessary — services in many sectors, even a minor leak may be a financial loss.

According to research from Direct Air, companies lose about £100 million each year due to air leakage. Wasted energy costs the company money, contributes to carbon emissions and has a detrimental influence on the environment. A 3mm hole in equipment might result in a loss of £600 and upwards per year for one company alone.

Why Is It So Important to Find Air Leaks?

Air leaks might cause equipment to underperform and even disrupt industrial operations. Converting electrical horsepower to compressed air power sometimes necessitates a significant increase in electrical horsepower. To generate 1 HP of compressed air power, a compressor needs about 7 to 8 HP of electrical power. This is a relatively costly conversion rate, and so any leakage is expensive.

They can also cause tools and equipment to fail abruptly, putting the user and others around them at risk. While the air may not appear to be a threat, leaking compressed air can endanger employees’ health.

How Much Money Could Your Company Lose Due to Air Leakage?

Air leaks cost the UK £100 million each year, which businesses can better spend on other aspects of their operation. The direct air research estimates that air leaks waste 20 – 40% of produced air in a manufacturing plant. Additionally, it discovered that even a modest air system that is not maintained correctly could cost a firm £2-£7 daily. Many companies may be surprised at the amount of money they could save by repairing air leaks.

Furthermore, compressed air leakage may have a detrimental impact on the performance of other parts of your system. Leakage can disrupt a system’s performance in a variety of ways. If the overall device pressure decreases, downstream processes can be disturbed, and measurements are thrown off. Pressure and varied fluctuations are not taken into consideration during the design of many equipment.

How to Discover Air Leaks

Ultrasonic Detector

When it comes to detecting air leaks, using an ultrasonic detector is one of the best options. Even during business hours, you may buy or hire specialists to check for air leaks. Although the sensor may be operated by in-house personnel, employing an expert is preferable.

As previously stated, ultrasonic detectors are effective even during working hours. It finds the least damaged areas every time, and production continues.

Keep an Ear Out for Leaky Noise.

Air leaks may be detected using your hearing, although the accuracy is limited. Run each piece of equipment independently, come closer, and listen for leaking noise. Unfortunately, it does not operate during working hours, and you would waste more time unsuccessfully listening for air leaks. Finding major leaks is more straightforward; the issue is the minor breaches that go unnoticed.

Inspect Pipes

To begin, make a lather by combining water and soap. Soak a sponge in the liquid and apply it to all of the machines’ piping. Compared to what professional air compressor services have to offer, this approach takes time and is inaccurate. The lather will produce bubbles on the leaking location if there are air leaks.

Take a Look Around

By checking around the machinery, you can detect air leaks. Mixing water and soap to make lather is one of the methods. Apply the mixture to the piping with a sponge to examine where the lather bubbles up, including the valves, flanges, and joints. The challenge with this approach is that it is time-consuming and inaccurate.

Air Leak Prevention

To guarantee optimum efficiency and safety for equipment, the best course of action is prevention. Companies can prevent air leaks by:

  • Scheduling frequent equipment maintenance checks and teaching all floor workers how to spot air leaks.
  • Replacing worn components as soon as possible, even if they appear to be in good working order.
  • Promptly replacing damaged pipes.
  • Keeping an eye out for rubber components. They wear down faster than others, though they are usually concealed.
  • Frequently tightening them lose connections. They make it easy for air to leak and are the simplest approach to fix a leak.

In Summary

If you don’t see any air leaks, it doesn’t imply there aren’t any; nevertheless, if you notice any, have them fixed by an expert to avoid wasting money. Furthermore, minor leaks may be indicative of more significant breaches.

Use routine servicing to guarantee optimal performance. Most current air leak service companies provide adaptable and customizable solutions to meet your company’s needs. To save money, promote safety, and prevent downtime tomorrow, combat compressor air leaks today.

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