Up to 40% of your generated compressed air could be being lost due to leaks…
How leak detection can save your compressor and your wallet.
Yes, you heard that right!
A whopping 40% of all the compressed air that your systems are producing could be being lost as we speak.
And the worst thing?
You might not even know this is happening.
Leakage is the single largest cause of wasted air within a compressed air system and this is pretty bad news all round for a number of reasons.
Not only does this mean a larger environmental strain due to increased energy usage, but it also results in you needing more services AND more often to reflect the increased hours of usage needed to get the same results.
And that is not even mentioning that compressed air leaks will also burn a massive hole in your wallet. We estimate (with electricity figures of £0.34p/kWh3) that a hole as small as 1.5mm will cost you £2,000 a year, a 4.0mm hole jumps up to £14,000, and a 6.0mm hole will cost you a whopping £30,000 a year. And this estimate is even a little low compared to current energy prices if you can believe it!
So for less than a cm of damage you could be losing the salary of a full time member of staff per year!
It is somewhat inevitable that leaks will occur in compressed air or vacuum pipework systems naturally over time. So with this type of problem, it is less of a case of if it will happen, and more a case of when.
So with that sense impending doom on your mind, how do we actually go about solving this problem if it does arise?
Is there an easy way to spot leaks?
The good news is that compressed air leaks tend to form in a handful of places making it a bit easier to catch. Compressed air leaks tend to happen in areas such as:
Couplings, hoses, tubes and fittings
- Valves that don’t completely close
- Point of use of devices
- Pipe joints from above
Another way of realising you have a potential leak is in your actual machine usage. If you’ve noticed a noticeable increase in usage and spend, this could be a sign that there is a compressed air leak afoot. However, there is the potential of misdiagnosing the jump in usage for another problem within your machinery here.
And for this reason we recommend our fool-proof methods for leak detection in your compressed air systems!
The fool-proof method for detecting leaks.
At J&J there are actually 2 options for leak detection.
- A complete ultrasonic leak detectors with leak analysis software
- Our on site leak analysis audit service.
Both technologies work to accurately identify leaks, but they both work in very different ways.
The complete ultrasonic leak detector works by sensing the high-frequency ultrasonic sound created when compressed air or gas escapes through a leak. By using sensitive microphones, we are able to filter the ultrasonic noise from background sounds, and this then converts into an audible or visual signal therefore allowing us to quickly pinpoint the precise leak source. Not only does this work out exactly where the leak is coming from, but also to see how much wastage this may actually be causing your company.
The onsite leak analysis audit service works a little differently. By installing sensitive flow monitoring equipment onto your compressed air supply, over the course of a week (or potentially longer), we are able to ascertain the minimum flow rate of your machinery. The minimum flow rate of your compressor is essentially the rate of flow when no equipment is running. From this point we can then work out the total volume of the current leaks in your system.
Both of these technologies allow us to not only see exactly how much a leak is costing in terms of volume of air, and of course in cold hard cash, but they also help to show us the priority level of the repair.
These reports will also help to implement a best practice strategy for how to move forward.
*Please note, we also carry out free data-logging at every service which could also indicate the first sign that something may be wrong within your system, such as a leak.*
How does our free data-logging at service work?
At J&J Air Systems we use state of the art data-logging technology during our services to make sure that we know exactly where any discrepancies may be occurring.
During our data-logging effort, we will monitor your compressed air systems 24/7 for an entire week to see how efficiently your compressed air system is running. Our technology helps find any weak spots in your systems including, but not limited to, demand inconsistencies, pressure drops, air use and power use which could be caused by a number of issues, including leaks.
How do we fix leaks?
Now it goes without saying that fixing leaks will cost you money, however with our efficiency report sent to you after our leak audit we will be able to say exactly how much money your leak repair will save you per year.
Don’t believe how much a saving you could make? Check out our graph below!
So now you know how much money you will be saving by fixing your leak, it is time to take the plunge and let our service team take over.
Our service staff are absolute experts in compressor repairs, so all that’s left for you to do is just pick a time and date that works best and we will be out to see you to tighten and replace those fittings in no time at all!
How often should you get checked for leaks
At J&J we would strongly recommend at least keeping up with your normal servicing schedule to not only ensure your warranty, but for early detection of any anomalies that may be occurring, such as leaks.
However, if you have noticed increased usage, cost or reduced output we would absolutely recommend giving us a call so we can come over to see exactly what might be happening within your systems.
With leaks it really is a case of better safe than sorry when looking at sunk cost that happenswith large undetected holes, so if in doubt make sure to give us a call today!
Your next steps:
So if you’ve noticed any changes then make sure to get in touch with our expert team today on 0800 0278 442 or send us over an email to [email protected].
And lastly, if you would like to learn more about leak detection today then check out our handy PDF here.
With leaks prevention and repair there really is nothing to lose, so don’t delay, act today.
And, of course, if you have enjoyed this blog today then make sure to check out our other posts here.
J&J- Compressed Air Made Simple.
CompAir Kit-Spare Parts (Separator)