Detecting Air Leaks: Optimising Your Compressed Air System

Compressed air systems are vital for many industries, but leaks can significantly reduce their efficiency and lead to unnecessary costs. Studies show that, on average, up to 25% of compressed air is lost through leaks, with some systems experiencing losses of over 80%. Identifying and addressing leaks in your compressed air system is essential for maintaining efficiency and reducing energy expenses.

Regular compressed air leak detection can not only prevent wasted energy but also ensure that your system meets tightness standards. Ultrasonic detection, in particular, offers an advanced solution for finding even the smallest leaks.

Why Do Air Leaks Happen?

Compressed air leaks commonly occur due to:

Wear and tear on system components such as welds, tubes, and fittings.
Poorly maintained or incorrectly installed equipment.
Inadequate filters, regulators, and lubricators (FRLs).

Using high-quality components and performing regular maintenance can help minimise leaks. Cheap or improper equipment, such as low-grade FRLs, can contribute to more frequent and severe leaks.

Selecting reliable, high-grade equipment is critical to maintaining an efficient compressed air system. Learn more about improving your system with quality products here.

What Is Acceptable Leakage in a Compressed Air System?

A well-functioning compressed air system should have less than 10% leakage. However, in systems that are not regularly maintained, leakage rates can reach 20–30%, causing significant losses in air power and increased operational costs.

How to Detect Compressed Air Leaks

Detecting leaks early is essential for reducing energy costs and maintaining system efficiency. There are three primary methods for detecting leaks:

Listening
Listening for hissing sounds is a simple and cost-effective way to detect leaks. However, this method is only suitable for identifying larger leaks and may not work in noisy environments.
Liquid Leak Detector
Pressurising the system and applying an air leak detection fluid to the joints can help visually identify leaks through the formation of bubbles. This method requires access to the entire system, which can be time-consuming.
Ultrasonic Leak Detection
Ultrasonic air leak detection is the most accurate method, particularly in noisy environments. This method uses specialised equipment to detect high-frequency sounds produced by leaks.

Ultrasonic leak detectors work by using microphones, amplifiers, and filters to isolate the distinctive noise generated by air leaks. This method is highly effective at finding even the smallest leaks quickly and accurately.

Find out more about ultrasonic compressed air leak detection here.

The Cost of Compressed Air Leaks

Air leaks can have a significant financial impact. For example, in a recent inspection at a large food processing plant, we found 80 air leaks. One of these leaks resulted in the loss of 128.6 litres per minute, costing the company $1,014 per year. The total loss across the system was 2259.6 litres per minute, equating to $17,863 annually.

By identifying and addressing these leaks, the plant was able to achieve substantial cost savings and improve overall efficiency.

Ultrasonic Compressed Air Leak Detection in Adelaide

At Mobile Compressed Air, we provide industry-leading compressed air testing in Adelaide using ultrasonic air leak detection to help businesses reduce costs and improve system performance. Our testing is conducted while your equipment is operational, ensuring minimal downtime.

We offer a detailed report outlining the location, severity, and cost of each leak, allowing for targeted repairs that can quickly improve efficiency and reduce energy waste.

If you’re looking to optimise your compressed air system, book an ultrasonic leak inspection with our team today. Experience the benefits of reduced energy costs and improved system reliability.