As much as 30% of a company's energy usage is used by your air compressors. Typically, on older pipework systems, between 20% and 30% of the compressed air generated is wasted through leaks in pipework and tool connections.
To see how 'leaky' you factory is, just wander around in the evening when everyone has gone home. What do you hear? Air leaks!
These leaks result in totally unnecessarily high electricity bills. With power prices rapidly increasing, fixing leaks is a rapid fire way of reducing power bills.
The benefits of fixing leaks are:
- No large upfront capital investments.
- Benefits are seen immediately on the repair being carried out.
- The return on investment is very clear and is usually measured in weeks
- Repairs can be scheduled to fit with normal operations
The first step to fixing leaks is to survey the pipework and connections. The survey identifies the location of leaks, the scale of the leak and the likely root cause of the leak.
Martin Baker from Air Equipment says 'once an air leak survey has been completed you can easily plan your repairs, allowing you focus on the ones that will have the biggest benefits, optimising your repair effectiveness'
Our ultrasonic air leak detector works based on the in-audible ultrasonic sound created by an air leak. This is accurate at a distance of several meters, in high background noise environments and even works through some materials such as thin metal.
How does an air leak survey work?
When compressed air escapes through a hole in pipework, as well as an audible hissing noise it creates a much louder un-audible ultrasonic 'noise'. Our ultrasonic tester picks up this ultrasonic noise. This works effectively from several meters away and even when there is significant ambient noise. The ultrasonic noise also gives the meter a good estimate of the size of the leak based on working pressure, and its location.
After we have completed the survey we put together a report detailing for each leak identified, the leak location, including a photo of the area, the size of the leak along with other specific details.
Find out more about the Air Equipment leak survey process and report here.