5 Common Air Leakage Problems in Compressed Air Systems & How to Fix Them
Air leakage in compressed air systems is a hidden issue that can have a significant impact on industrial efficiency. Leaks contribute to major losses in compressed air. We see that around 20% of the compressed air which is produced gets lost along the way due to leakages in the piping system. They are, however, easy to trace and repair but it requires continuous analysis to control the leaks. Even small leaks can lead to substantial energy losses, increased operational costs, and reduced system performance. Addressing these leaks is crucial for maximizing efficiency and maintaining optimal system performance. In this blog, we’ll explore seven common air leakage problems and offer solutions to help you improve your system’s efficiency.
Problem 1: Leaking Hoses and Tubing
Causes:
Hoses and tubing are particularly susceptible to leaks due to constant pressure and exposure to harsh conditions. Over time, they can develop cracks or splits, leading to air leakage.
Identification:
Inspect hoses and tubing for visible signs of wear, such as cracks or bulges. But be aware that most of the leakages are not easy to find, however will have a significant impact. A plant inspection with the use of an acoustic camera is adviced.
Solution:
Fixing these leaks is essential to keep production running in the most efficient way possible.
By using the Atlas Copco RePress solution, leaks are fixed while the distribution net is under pressure, and without dismantling pipes or couplings.
Problem 2: Inadequate Pipework
Impact:
Improperly installed or ageing pipework can lead to air leakage problems in compressed air systems. Misaligned or corroded pipes can result in loss of compressed air, decrease in compressed air quality and increased pressure drop.
Assessment:
Regularly assess the condition of your pipework for signs of wear, corrosion, or improper installation. Address any issues promptly to prevent leaks.
Solution:
Upgrade to modern, high-quality piping materials fitting to your needs, which are resistant to corrosion. Ensure proper installation to minimize the risk of leaks.
Problem 3: Pressure Drop Issues
Signs:
Pressure losses themselves will not be the root cause but losing pressure throughout the network is a clear sign of air leakages. When air escapes, the pressure drop will increase, leading to inefficiencies and increased energy costs. When the compressor generates air with a pressure level of 7 bar but you only see the pressure levels at point of use are about 6 bar, this means 1 bar gets lost along the way. This is a clear indicator of something being wrong throughout the network, and most probably this will be leaks.
Root Causes:
Pressure drops can be caused by leaks, blockages, or improperly sized components. Identifying and resolving the root cause is essential to restoring system efficiency.
Solution:
Monitoring your equipment is essential, this can be done remotely with SMARTLINK. Also regular maintenance can help prevent pressure-related issues and improve overall efficiency.
Problem 4: Saturated Air
Impact:
Saturated air, if untreated, can enter the compressor and eventually the complete network and damage internal pipe surfaces, leading to decreased compressor efficiency, corrosion and air leaks.
Detection:
Know the ambient conditions is a first step in identifying the humidity level at the air intake. If required. Throughout the compressed air network, you will see signs of moisture damage, such as rust or water accumulation in the system.
Solution:
Implement proper air treatment methods, such as using dryers and line filters, to remove moisture before the compressed air is being put in use. Regular maintenance of these components is crucial to preventing moisture-related leaks.
Problem 5: Incorrect piping material
Impact:
Using the wrong materials for your piping system can lead to premature wear, corrosion and end of use pollution.
Solution:
Choose materials that are resistant and suitable for your specific environment. Stainless steel or aluminum pipes are better options for preventing corrosion and ensuring long-term durability.
Leaks might be small but can cause major issues & losses
As you’ve see, even small, undetected leaks in compressed air systems can lead to significant energy waste and increased operational costs. These leaks are often hard to identify without specialized equipment, making it challenging to maintain system efficiency.
One of the best ways to detect hidden leaks is by using advanced ultrasonic technology, which can identify leaks that are not easily visible or audible. Regular air audits can help pinpoint these leaks before they become costly problems. Consider using Atlas Copco’s AIRScan service, which offers a comprehensive audit of your compressed air system. AIRScan uses state-of-the-art technology to detect even the smallest leaks, providing you with a detailed report and actionable recommendations to improve system performance.
Air leakage is a common issue that can have a significant impact on your compressed air system’s efficiency. By addressing these five common problems, you can improve system performance, reduce energy costs, and extend the life of your equipment.
If you suspect your compressed air system has leaks, don’t wait until it becomes a costly problem. Contact our experts today for a thorough assessment and discover high-quality replacement parts and maintenance tools to keep your system running efficiently.
