Compressed air leak detection and surveys

Compressed air leaks are usually invisible, and often inaudible once machinery is running, so they go unnoticed while they keep adding to your costs.

Small leaks, big costs

Unlike oil or water leaks, compressed air leaks leave no visible trace. Even small leaks can increase annual operating costs by thousands of pounds through wasted energy and reduced productivity. On some sites, up to 40% of the compressed air produced is lost through leaks.

Producing compressed air requires significant amounts of electricity. Guidance from the US Department of Energy puts the overall efficiency of a typical system at only 10–15%. The Carbon Trust reports that compressed air accounts for around 10% of UK industry’s electricity use.

Is a survey worth it?

Removing every leak is rarely realistic, but with energy prices where they are, a survey can pay for itself quickly. A 30kW compressor running all year can cost over £80,000 to run, so even a modest share lost to leakage is a significant sum.

The Carbon Trust points out that a 3 mm hole can waste over £1,000 of energy a year. Guidance from the US Department of Energy says a poorly maintained system can lose 20% to 30% of compressor output. As leaks grow, compressors run longer, and in time may struggle to keep up with demand.

Why leaks happen

Leaks mostly come from wear and tear: couplings, hoses, fittings, valves and condensate drains that loosen, crack or stick open over time. They build up slowly and rarely stop production, so they go unnoticed.

How EcoAir finds leaks

Escaping compressed air makes a high-frequency ultrasonic sound that the human ear can't pick up. EcoAir engineers use specialist ultrasonic detection equipment to pinpoint each leak and judge its size.

Every leak is tagged and photographed on site, and its location, estimated leak rate and annual energy cost are recorded. EcoAir then produces a detailed survey report covering all the equipment tested, with leaks ranked by severity so the most serious are repaired first, along with clear recommendations for remedial work. Repairs can then be approved and the savings checked afterwards.

Estimated costs are based on measured leak rate, operating hours and the customer’s electricity cost.

Benefits of a leak survey

• Shows where and how energy is being wasted in your compressed air system
• Carried out while equipment is running, with no shutdown or downtime
• Reaches leaks in awkward or hard-to-access places

Supporting BRCGS-certified sites

EcoAir understands the hygiene, safety and documentation requirements of food and beverage production environments. Surveys and repairs are completed using site-specific working procedures, contamination controls and traceable reporting. More for food and drink sites.

• Site-specific RAMS and safe systems of work
• Hygiene, PPE and contamination-control procedures
• Calibrated detection equipment
• Photographic and traceable leak reports
• Work planned around production requirements

Questions

Find out what your leaks are really costing you

Requesting a quotation is free. Surveys are quoted individually before work begins.