Do you let your faucets run? No. Well, the same should apply to your compressed air piping system. However, unlike water or oil leaks, air leaks are invisible and won’t cause damage... but they're just as costly! So what should you do? Be proactive: start a leak detection program and keep it up.
How to Tell When Compressed Air Is Leaking
Can you tell if there are air leaks in your compressed air piping system? If you notice any of the following at your plant, it’s time to take action.
- The compressor starts up even though all tools and equipment are turned off (this is easier to notice at night)
- The system shows pressure loss at various locations or at one specific location in the system
- Pneumatic tools or equipment don’t get enough air while in use
- You hear hissing, which is the sound of air escaping (leaks can be loud enough to hear)
What Leaks Can Cost You
It all starts with one or two tiny leaks that are imperceptible at first. Then more leaks appear, or existing ones get bigger. Finally, the many accumulated leaks not only undermine the efficiency and productivity of the entire system, but also lead to high energy bills.
With compressed air costing close to $0.25/1000 ft3 ($0.08/kWh), an average plant can save plenty just by setting up a leak detection and repair program. Every leak has a cost. That’s why you need to act—and quickly.
Air Leaks and Compressor Power Consumption ($/year)
| Leak diameter (inch) | Pressure | |||
| 90 PSIG | 100 PSIG | 120 PSIG | 150 PSIG | |
| 1/64 | 46 $ | 51 $ | 60 $ | 72 $ |
| 1/32 | 185 $ | 203 $ | 239 $ | 292 $ |
| 1/16 | 742 $ | 814 $ | 955 $ | 1 170 $ |
| 1/8 | 2 970 $ | 3 260 $ | 3 820 $ | 4 670 $ |
| 3/16 | 6 680 $ | 7 320 $ | 8 600 $ | 10 500 $ |
| 1/4 | 11 900 $ | 13 000 $ | 15 300 $ | 18 700 $ |
| 3/8 | 26 700 $ | 29 200 $ | 34 300 $ | 42 000 $ |
| 1/2 | 47 500 $ | 5 2000 $ | 61 200 $ | 748 00 $ |
This table shows how much leaks can cost based on leak diameter and pressure. The calculations are based on 8,760 hours of operation with a 100% effective compressor.
Leak Detection Programs
A leak detection and repair program begins with an audit of your compressed air system. This is the most direct way to determine the status of your system and:
- Get an idea of overall air loss
- Identify critical locations where the air is being lost
- Estimate what the leaks are costing you
- Take the required actions based on your priorities
There are different ways to identify compressed air leaks. Once found, mark each leak with an identification tag. This lets you keep track of their location, monitor them closely, and repair them in a timely manner.
Methods of Leak Detection
1. Ultrasonic Meters
Ultrasonic meters are highly effective for measuring compressed air leaks, especially at heights (up to 20 meters). This method is very accurate and should be favored whenever possible. Hire experts who specialize in leak detection. Contact a Topring Technical Advisor to learn more about this effective method of detecting air leaks. We can help you with the process.
Using an ultrasonic meter to detect compressed air leaks.
2. Inspection Outside Operating Hours
Inspecting a compressed air system outside of operating hours is an effective method for estimating compressed air leak flow in an industrial facility. When the plant is shut down, start the air compressor(s) and allow the system to reach normal operating pressure. Under these conditions, all compressed air consumption can be attributed solely to system leaks.
Allow the compressor to run for a period of one to two hours and accurately record its cumulative run time. For air compressors equipped with a basic start/stop control, a stopwatch is required. Compressors fitted with electronic controllers generally include built-in counters that provide access to detailed operating statistics.
The objective of this off-production inspection is to calculate the compressor run time attributable exclusively to air leaks (for example, 15 minutes over a two-hour period), and then compare this value to the compressor’s run time during a normal production day. This comparison makes it possible to quantify the impact of compressed air leaks on overall energy consumption and operating costs.
According to the Compressed Air and Gas Institute (CAGI), a well-maintained compressed air system should not experience leak losses exceeding 10% of total air consumption, which corresponds to no more than 10% of compressor operating time. Exceeding this threshold typically indicates an inefficient system and significant energy losses.
By conducting a compressed air system inspection outside of operating hours, industrial facilities can assess the true condition of their system, establish a reliable performance baseline, and accurately measure potential energy savings following optimization, maintenance, or a compressed air energy audit.
3. Soapy Water
You've probably heard of using a spray bottle filled with mild soapy water before. It’s a cheap and easy way to find leaks. Just spray soapy water at the system connections. Soap bubbles will form at critical points, showing you where the leaks are.
Caution: Be careful! There are often electrical wires near a compressed air system. For safety reasons, some plants prohibit this method. In this case, choose another way to detect leaks.
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Soapy water is used to identify compressed air leaks, which are then marked with a red tag.
System Maintenance and Repair
You know your compressed air system better than anyone. Regular maintenance of the components in that system will keep it operating efficiently. Maintenance frequency needs to reflect the conditions of use.
Detecting air leaks is an important step in the maintenance process for compressed air systems. And fixing those air leaks is just as important, if not more! Unfortunately, companies often invest in a leak detection program, then never take action. Make a long-term plan and stick to it: repair the most critical points first, followed by the least critical ones.
A few examples of maintenance operations:
- Applying a thread sealant to eliminate leaks
- Replacing filters
- Tightening any loose fittings
- Replacing faulty quick couplers, hoses and air tools
Find out about our free training Compressed Air System Maintenance with Topring Academy. Learn more about how you can improve the efficiency and performance of pneumatic tools and equipment, as well as how you can eliminate compressed air leaks.
A Comprehensive Audit of Your Compressed Air System
To turn observations into measurable results, a comprehensive compressed air system audit conducted by a Topring expert accurately identifies air leaks, system inefficiencies, and safety risks that directly impact operating costs and the reliability of your operations.
This in-depth assessment provides a clear analysis of the actual condition of your compressed air system, along with concrete, quantified, and prioritized recommendations to support informed decision-making and maximize the return on investment of corrective actions.
Take the next step. Schedule a comprehensive audit with a Topring expert today and gain a clear, objective, and actionable view of your compressed air system performance.
Contact a Topring Technical Advisor to start a compressed air leak detection and repair program.
