Why you shouldn't delay getting an air leak survey

Carrying out an air leak survey is an effective way of preventing large amounts of energy from being wasted during the operation of a compressed air generator. 

Energy costs have only gotten higher over the years, which means that air leak surveys hold more value than ever before. In this article we will be going over how an air leak survey can help to significantly reduce costs industries that utilise an air compressor, as well as how the process itself is carried out. 

The change in energy over the years

As it currently stands in the UK, the price for electricity currently stands at 24.86p per kw/hr with gas standing at 6.34p hw/hr. The scale of energy waste via an air leak depends on the diameter of the damaged area. The table below outlines the potential amount of energy that would be lost in the case of different air leak incidences with the energy cost being around 30p per kw/hr:

This is only expected to get higher, and since compressed air can account for up to 15% of total on-site energy costs, it is our responsibility to advise our clients on best practices to prevent this. 

Why are air leak surveys important?

Air leak surveys are included as part of the compressed air energy audits that we provide for our clients. These surveys are important to carry out as air leaks can go undetected if an audit comes back with pressure readings that seem fairly standard.

As evidenced by the table above, even a very small undetected leak can lead to large amounts of wasted energy. If an air leak survey is carried out on a regular basis, it becomes easier to determine and maintain what the ideal system pressure should be. This not only improves overall productivity but also ensures a continuous reduction in energy costs and greatly reduces the risk of further air leaks. 

It is worth noting that some air leaks only occur at certain pressures, and without regular air leak surveys it would difficult to determine what pressure is responsible. 

What can cause an air compressor to leak?

As important as it is to know about the significance and benefits of an air leak survey, it is equally important to know what can cause an air leak. Below are some potential causes of finding an air leak in your air compressor:

•    Installation and sealing: Poor pipe fittings with weak sealings can cause air to leak before it even starts to flow through the air compressor system 
•    External damage: Pipe fittings can be more susceptible to damage if the air compressor is located in a busy environment surrounded by heavy material-handling equipment.
•    Pipe material: If the air compressor pipes are made from cheap material, it increases the risk of damage to the pipe at higher pressures, from external forces and even from corrosion. All it takes is a microscopic fissure for an air leak to start which can incur huge costs in the long run.  

How is an air leak survey carried out?

When carrying out an air leak survey, we use ultrasonic leak detection equipment. This state-of-the-art equipment has the ability to identify air leaks that may not be audible or in hard-to-access areas. The principle behind this equipment is simple:

•    Air travels from an area of high pressure to low pressure in the case of a leak and this creates a flow. 
•    This turbulence has ultrasonic components which can be detected by the equipment and a location can be identified. 
•    The size of the leak can also be determined using ultrasonic leak detection equipment as the larger the leak, the greater the ultrasound reading. 

Every leak that we detect is tagged with colour label and given a unique reference number and then finally graded for priority. At the end of the survey, we compile a report with an estimation of the total number of leaks found, including high-priority leaks, energy cost of the leaks and an approximate repairs cost. 

What happens after an air leak survey?

Once all identified air leaks have been fixed, we recommend an air leak survey be carried out again to see if there is an expected change in pressure, and find any outstanding leaks that might have gone unnoticed. 
We will always advise as to whether or not we think a piping system might need changing. If an air leak survey comes back showing a significant number of leaks, and if this has been the case for previous air leak surveys, it might be an indication that the piping system needs changing, especially if the piping system is over 5 years old.

If you have been noticing unusual drops in pressure or think you might be hearing an air leak, get in touch with us today to book an air leak survey. Our experts are always ready to help you save on your energy and money.