Why compressed air leak detection is important

Compressed air systems form the backbone of many industrial operations. However, unnoticed leaks in these systems lead to significant losses. They affect your productivity, drain your resources, and can cost you hundreds of thousands of dollars annually. That makes compressed air leak detection and repair crucial for any business using these systems.

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In this article, you’ll learn:

• Why air leaks are bad for business and how to calculate what they cost you
• Signs of a compressed air leak
• Types of leak detection systems and their benefits

Compressed air leaks: A costly problem in industrial settings

Wasting air is a considerable energy cost in industrial settings. Losses from compressed air leaks don’t just stem from the direct wastage of the compressed air. There's also the additional energy required to compensate for the pressure drops caused by these leaks.

According to recent research, 25 to 40 percent of the world's industrial energy is lost due to leaks in compressed air systems. Globally, that adds up to billions of dollars in losses from poorly-maintained equipment.

That's anywhere from a few thousand to nearly a million dollars in annual losses for an individual plant, brewery, or other production setting,

How to calculate air leakage

One straightforward method of calculating air leakage involves observing pressure drops.

By measuring the flow into the distribution system when the plant isn't running until there's a 14.5 psi drop in pressure, industries can gain a realistic estimate of leakage levels.

Comparing these pressure drops to standard operating levels reveals the degree of leakage.

Next, you can calculate your individual losses using your operating costs. We’ll use the low estimate that 25 percent of operating costs stem from compressed air leakage.

Start by multiplying the number of compressors in operation by the amount of Kw each uses. Multiply your result by the total operating hours per year, then by the cost per kilowatt. This is assuming all the compressors run concurrently.

The full formula looks like this:

(number of compressors) x (amount of kW each uses) x (total operating hours) x (cost per kWh)= operating cost

Now, simply multiply that by .25 for 25 percent of your operating cost. The result is a low-end estimate of annual money wasted due to air leakage.

Signs of a compressed air leak

A compressed air leak can go overlooked in a noisy industrial environment. Problem signs to watch for are:

• Audible hissing or whistling
• Decreased equipment performance
• Unexpected rise in energy bills
• Frequent system downtimes

Let's explore each one in detail:

• Audible hissing or whistling: As air escaping from the system often produces hissing or whistling. But, smaller leaks might produce sounds below our hearing threshold. And, you may not notice audible sounds in an otherwise loud environment. So, the absence of a hissing sound doesn't indicate no leakage.
• Decreased equipment performance: Compressed air systems with leaks won’t perform as well as ones that are better-maintained. This results in decreased productivity and output.
• Unexpected rise in energy bills: An undetected air leak could be the silent culprit behind a sudden spike in your energy cost. As the system compensates for the lost air, it consumes more energy. This results in higher bills.
• Frequent system downtimes: A leaky system suffers from excess wear and tear as it works harder to compensate for pressure loss. This leads to more frequent system downtimes.

Fixing leaks is often a time-consuming process, especially when they've gone undetected for long. There’s also the time necessary to repair related damage.

Benefits of compressed air leak detection

Identifying and addressing air leaks promptly can save industrial setups from wasting air and escalating energy costs. It also optimizes the system's efficiency, ensures the longevity of equipment, and reduces the carbon footprint of the plant.

Air leak detection methods

Four ways to find leaks in industrial settings are:

• Soapy water
• Ultrasonic leak detectors
• Air flow meters
• Thermal imaging

Let's see how these work: 

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• Soapy water: Apply soapy water to suspected problem spots. The formation of bubbles indicates a leak. However, this simple, yet effective method for locating leaks isn’t effective in a large-scale industrial setting.
• Ultrasonic leak detectors: Ultrasonic detectors pick up the high frequency sounds produced by leaks, which are often inaudible to the human ear. These ultrasonic acoustic detectors transform those frequencies into audible sounds that allow operators to locate even the smallest of leaks.
• Air flow meters: Installing air flow meters at strategic points in the system alerts you to pressure drops as they occur. Meters that use IO-Link technology can provide real-time reporting. This allows you to address even the smallest problem before it becomes larger and more costly to repair.
• Thermal imaging: Thermal imaging cameras detect the temperature changes caused by air leaks, visualizing them for operators to identify and address.

Compressed air leak detectors: find the right tools

The best air leak detector depends on your specific application and the size of your operation. When selecting one, ensure it aligns with your plant's needs and has a good range.

Compressed air leak detection FAQs

How do I find out where an air leak is coming from?

Ultrasonic detectors, air flow meters and thermal imaging can determine where an air leak is coming from in large industrial environments. Visual checks, applying soapy water to suspected problem spots, and listening for hissing are useful in smaller settings.

What is the correct leak detection method for compressed gases?

Ultrasonic detection and air flow meters are reliable leak detection methods for compressed gases. However, the “correct,” or best methods depend on the specifics of the gas being used and the system in question.

How much air pressure do I need for a leak test?

Testing typically begins with high pressure as these lines are the primary sources of significant leaks. However, the exact pressure depends on the system and the standards it adheres to.

How often should I conduct leak detection?

Leak detection for compressed air systems should be conducted quarterly or bi-annually. The frequency varies based on the system's age and usage patterns. Tools such as air flow meters using digital technology can run constantly and provide real-time alerts.

Dunk testing typically leads to inaccurate results, which is why you should consider pressure decay & mass flow leak testing instead!

There’s absolutely no denying how dunk testing is by far the most basic and simplest kind of leak test. Dunk testing essentially entails connecting a part or product to an air supply, and then holding it underwater in order to look for bubbles. If bubbles do rise up to the surface, it could indicate that the part/product has a leak that needs to be addressed.

It’s also undeniable how dunk testing leads businesses to many different disadvantages, and this is largely due to the simple fact that leak testing technology has skyrocketed throughout recent years—which means more accurate, objective test results are easily accessible.

Although a lot of industries have already invested in more tech-savvy leak testing options, a lot of businesses still frequently conduct dunk tests. Below we’ll be explaining how dunk testing is an outdated practice, as well as why businesses should consider pressure decay and mass flow leak testing to get more reliable and accurate results!

The Problems With “X Bubbles Per Minute” Dunk Testing Specifications

It’s important to note that there are some slight variations that businesses will use when conducting dunk tests, and these variations include using other liquids than water—such as mineral oil or ethylene glycol.

Even today in , we’ll sometimes speak with business leaders who use leak specification techniques like “X bubbles per minute”. Although businesses can subjectively compare leak rates with this type of specification, it’s easy to see how inaccurate and unreliable “X bubbles per minute” can be.

Some of the common problems with “X bubbles per minute” dunk testing specifications include:

• Not accounting for bubble sizes
• The likelihood of incorrect bubble counting
• Possible future damages/corrosion
• Contaminated water disposal
• Risks of slipping

Businesses everywhere simply shouldn’t be dealing with these types of issues while conducting leak tests, and this is why dunk testing has become less appealing throughout the manufacturing world.

Pressure Decay Leak Testing & Mass Flow Testing Options

Pressure decay leak testing utilizes state-of-the-art pressure sensors to measure pressure changes and accurately quantify a leak rate; however, these leak rate measurements aren’t always so straightforward when you’re not using Zaxis products.

There are some instances in which business teams will need to know a part or product’s precise volume, and then program this volume into their leak tester device to subsequently set up correct volumetric leak rate calculations.  

Mass flow leak testing is a little different than pressure decay testing in that volume isn’t as important of a factor, and this is because mass flow leak testers will typically display a product’s flow rate. This leak testing is largely oriented around the molecular measurement of a gas flow rate, and we’ll discuss mass flow leak testing in more detail in the below section!

How Mass Flow Leak Testing Works  

Mass flow leak tests are incredibly efficient when it comes to measuring flow rates throughout products or objects, and this test technically entails attaching a test product to an Isaac HD front port and pressurizing it.

Here’s a basic overview of how mass flow leak testing works while utilizing the Zaxis Isaac HD:

• Attachment: You’ll first connect your product to the Isaac HD’s front test port, which will initiate the testing sequence.
• Pressurization: Air will begin to fill your test part, all while the Isaac HD’s pressure sensors measure the test pressure within your pre-programmed tolerances.
• Flow Measurement: The mass flow leak testing technology will then accurately measure the flow rate that occurs during the testing phase.
• Comparisons & Results: The Isaac HD will automatically compare your mass flow test readings against your preset values, which will ultimately determine whether or not a product passes or fails. These results will be clearly displayed on the tester’s screen.

Zaxis Offers Pressure Decay & Mass Flow Leak Testing Solutions To Get Your Business Away From Outdated Dunk Testing!

There’s absolutely no reason why businesses in should still be dunk testing, because this form of leak testing is incredibly outdated, inaccurate and time-consuming!

The good news is that Zaxis has your team covered when you need to efficiently and reliably leak test parts, components and products. Our industry specialists will let you know whether you’d be better off with pressure decay or mass flow leak testing, and we’re more than confident that you’ll see substantial improvements when utilizing our cutting-edge air leak testers.

Contact us to discuss your requirements of multi channel air leakage tester. Our experienced sales team can help you identify the options that best suit your needs.