Leakage monitoring of compressed air is an important factor in reducing energy loss in industrial compressed air systems. These energy losses can sometimes account for up to 20–30 percent of the compressor's total output. Additionally, compressed air leaks in the system cause other issues, such as pressure drops, which force the compressor to operate more than necessary, leading to unnecessary wear and increased energy consumption.
Traditional methods for leak detection
A common method for detecting leaks in compressed air or gas systems is to spray pipes and fittings with soapy water. Leaks are identified by the formation of bubbles at the leakage points. However, this method is time-consuming and inefficient compared to modern technology, making it unsuitable for today's advanced industrial environments.
Where can leaks occur?
Hidden leaks are one of the most common maintenance issues and can occur in any part of the system. Addressing such leaks requires identifying their location and repairing them.
- Fittings, pipes, hoses, and connections
- Common problems include fittings that do not seal properly and damaged hoses.
- Open condensate traps
- Dirty seals or malfunctioning drain valves can cause significant air losses
- Regulators, mist lubricators, and filters
- Incorrect or careless installation can contribute to leakage
- Connections
- Worn O-rings in valves and other process equipment
- Shut-off and control valves
- Worn seals on the valve stem are a common cause of leakage
- Usage points
- Poorly maintained or old, worn-out tools
- Thread sealing
- Incorrect application or use of an unsuitable sealant may result in leakage
- Flanges
- Substandard welds are a common problem. Use materials of the highest quality and follow the installation instructions carefully
- Pipe joints
- Poor welding work can also lead to leakage
Genom att känna till dessa vanliga problemområden kan man bättre förebygga och åtgärda läckage i tryckluftssystem, vilket bidrar till ökad energieffektivitet och minskade kostnader.
What is the cost of a compressed air leak?
Below is a table that illustrates how different leakage sizes affect energy consumption and annual costs, based on a system pressure of 7 bar and an energy cost of 0.60 SEK per kWh:
| Hole diameter (mm) | Leakage (m³/min) | Energy consumption (kWh/year) | Cost (SEK/year) |
| 1 | 0,07 | 3 600 | 3 600 |
| 3 | 0,65 | 32 000 | 32 000 |
| 5 | 1,8 | 90 000 | 90 000 |
| 10 | 7,3 | 365 000 | 365 000 |
The calculation is based on a pressure of 7 bar, continuous operation (8,760 hours/year), and an energy price of 1 SEK/kWh
