Compressed air, often overlooked, is one of the most expensive utilities in manufacturing. Over 50% of compressed air systems face efficiency issues, with up to 30% of air lost due to leaks. This inefficiency leads to costly solutions, like renting spare compressors or adding new ones, which can run into hundreds of thousands of dollars. Establishing a compressed air leak management program is a cost-effective way to improve efficiency, save energy, and reduce waste.
Ultrasound technology is a powerful tool for detecting compressed air leaks. These leaks occur when pressurized air escapes through small cracks, creating turbulence that emits high-frequency sound beyond human hearing. Ultrasound instruments detect these sounds, helping pinpoint leaks. Advances in this technology allow users to calculate the cost and volume of leaks, making the savings from repairs clear. A comprehensive leak survey includes detection, tracking, repair, and verification, which can reduce energy waste by 10–20%. For instance, a 1/8-inch leak at 100 psi can cost $2,981 annually at $0.22 per kWh.
To use ultrasound effectively, planning is essential. Inspectors should conduct a walk-through to identify zones where compressed air is used, safety hazards, and potential leak sites. Starting at the compressor and moving through distribution lines to usage points ensures thorough coverage. As leaks are detected, tagging systems record their location, pressure, and decibel readings. Apps like UE Systems’ Leak Survey simplify documentation and reporting, estimating costs and leak volume for each site.
Accurate reporting relies on proper decibel readings taken about 15 inches from leaks to avoid overestimation. Studies show ultrasound leak surveys can be within 20% of actual savings, offering quick returns on investment when leaks are repaired.
Compressed air is costly, but managing leaks with ultrasound provides significant energy savings, fast payback, and enhanced system performance.
