Don’t Overlook These Causes of Leaks

Estimated reading time: 2 minutes

Leaks are little problems that can add up to big financial losses. A leak of just 3/8-inch operating at 100 psig can cost an operator upwards of $36,000 per year. But leaks don’t have to break your compressed air budget. By preventing leaks before they start, you can save your operation money in the long run. Take a look at these common—yet often overlooked—causes of leaks.

Installation and sealing: Leaks can form even before compressed air is flowing through the system. Pipe fittings may develop leaks due to poor sealing, and air cylinders may leak around the rod seals or piston packing if improperly installed.

Materials: You know the saying—buy cheap, buy twice. The same goes for piping system materials. While low-quality materials may save money initially, they are more susceptible to damage from external or internal forces. (Think accidental bumps or corrosion from condensation build-up.) Cheap can cost you more in the end.

External damage: Air compressors are often housed in busy spaces. Lift trucks, pallet jacks and other material-handling equipment may bump a pipe connection occasionally, causing the fittings to crack. If your air system is in a high-traffic area, be sure to check often for external damage.

Human error: We’ve all forgotten to turn something off. Maybe it was the television, or the sink, or, *gulp* the oven. But when it comes to pneumatic applications, failing to shut-off leaking tools or neglecting to close valves can pose a hazard to workers and to your wallet. Following standard protocols is an easy way to remove human error from the leak equation.

 Don’t forget that at the end of the day, air equals money; if you spend a little time checking your system now, you might find large savings later.

Valves that don’t close all the way, poorly fitted connections, microscopic fissures in pipes…these are just a few places compressed air can sneak out of your system. And while it may not look like much, escaping air can add up. Just one quarter-inch air leak at 100 psi could cost more than $2,500 a year.

Addressing leaks is a great way to save money, and who doesn’t want to do that? No one, that’s who. In order to fix air system leakage with minimum costs, it is vitally important to detect the problem as soon as possible. But how do you know if you’re facility has air leaks? There are a few telltale signs to look out for. You might have an air leak if…

When you walk through your system, large air leaks are audible. These types of leaks are less common than smaller, inaudible leaks, but they do waste lots of compressed air. Take the time to walk through your system every few months to make sure large leaks aren’t costing you money.

If you’re using compressed air even when your end uses aren’t, you have a leak. Any air lost when compressed air isn’t in use is solely feeding the leaks. If this happens, you most likely have lots of little leaks contributing to your air loss.

Has the pressure in your system gone down? Is your compressor working harder to supply the same pressure and airflow that it used to provide with ease? Well, that could be a leak. Again, this is probably the compounding of multiple smaller leaks, but it can add up.

Piping systems more than five years old have been shown to exhibit leaks of up to 25 percent. If your piping is outdated, consider upgrading to a new, easy to install aluminum system.

Operators may notice these symptoms and attribute them to poor compressor performance, but leaks are the most likely culprit. Because most leaks cannot be heard without assistance, ultrasonic leak detection is required. By locating and fixing small leaks, facilities can save thousands in costs each year. 

Schedule a compressed air audit today to end leaks and start saving money.