A good leak prevention programme will include identification, tracking, repair, verification, and employee involvement and use of one an ultrasonic acoustic detector set
Since air leaks are almost impossible to see, the best way to detect leaks is to use an ultrasonic acoustic detector, which can recognise the high frequency hissing sounds associated with air leaks.
These portable units consist of directional microphones, amplifiers, and audio filters, and have visual indicators and/or earphones to detect leaks.
How to fix leaks.
Leaks occur most often at joints and connections.
Stopping leaks can be as simple as tightening a connection or as complex as replacing faulty equipment such as couplings, fittings, pipe sections, hoses, joints, drains, and traps.
In many cases leaks are caused by bad or improperly applied thread sealant.
Select high quality fittings, disconnects, hose, tubing, and install them properly with appropriate thread sealant.
Non-operating equipment can be another additional source of leaks.
Equipment no longer in use should be isolated with a valve in the distribution system. Another way to reduce leaks is to lower the demand air pressure of the system.
The lower the pressure differential across an orifice or leak, the lower the rate of flow, so reduced system pressure will result in reduced leakage rates.
Stabilising the system header pressure at its lowest practical range will minimise the leakage rate for the system.
Once leaks have been repaired, the compressor control system should be re-evaluated to realise the total savings potential.
A leak prevention programme. A good leak prevention programme will include the following components: identification (including tagging), tracking, repair, verification, and employee involvement and use of one of the EP range of ultrasonic acoustic detector sets.
The Logis-Tech EP542A and EP2400 detector sets are ideal instruments.
All facilities with compressed air systems should establish an aggressive leak program.
A cross-cutting team involving decision-making representatives from production should be formed.
A leak prevention program should be part of an overall program aimed at improving the performance of compressed air systems.
Once the leaks are found and repaired, the systems throughout the plant should all be re-evaluated.
