Why leaks matter
Every leak runs all the time, including when production stops. In many plants leakage is a large share of air production, and it also reduces the pressure available at the point of use.
How to find leaks
Common methods:
- Ultrasonic leak detection during production
- Listening and soapy-water checks for accessible joints
- Measuring the load on the compressor when production is stopped
- Tagging and recording every leak found
Typical leak points
Look at:
- Hose connections, couplings and quick-release fittings
- Threaded joints and flanges
- Regulators, lubricators and filters
- Valves, drains and condensate traps left open
- Old or damaged hoses and tools
Repair and sustain
Repair, record, and re-survey on a schedule. Leaks return unless there are routines to find them and a way to report them. Compare the baseline before and after to see the result.
Starting data
To start, it helps to have:
- Compressor make, model, rated power and controls
- Operating pressure settings and the lowest pressure the processes need
- Operating hours and shift pattern
- Any existing power, flow or pressure records
Frequently asked questions
How much leakage is acceptable?
Less is better, and the level that is practical depends on the plant. We measure the current level and set a target together.
Can leaks be found while the plant is running?
Yes. Ultrasonic detectors work in noisy plants.
Do I need to stop production to measure leakage?
One way to estimate it is to measure compressor load with consumption stopped, but other methods avoid a stop.
Field guide
Leak reduction: often the cheapest air you can buy
Leaks are compressed air you pay for and never use. In many plants they account for a large share of compressor output, and they run 24 hours a day whenever the system is pressurised.
Find them
- Weekend or shutdown test: with production stopped, note how often the compressor loads, or how fast receiver pressure falls. What it delivers then is mostly leakage.
- Ultrasonic detector: finds leaks you cannot hear in a noisy plant.
- Soap solution on accessible fittings.
Where they usually are
Quick couplings, hose connections, filter-regulator-lubricator units, drain valves stuck open, pipe threads, worn cylinder seals and tools left connected.
Make it stick
- Tag each leak, record its size estimate and location.
- Fix the biggest first; many need only a new fitting or seal.
- Re-test after repair and record the drop in demand.
- Repeat the survey regularly, because leaks return.
- Isolate idle areas and machines with valves when they are not working.
Use the leak cost calculator to put a figure on what your leaks cost each year.
What to send for a quotation
- Compressor make, model and rated power of each machine.
- Electricity tariff and annual running hours.
- Typical pressure at the compressor and at the furthest user.
- Any measurements you already have (power, flow, loaded hours).
Send it through find my part or the spare parts enquiry, or call +91 99590 60718 or +91 92468 88812.