Air Leak Detection
The main purpose of an air leak detection test is to build a profile of the energy wasted through air leakage within your compressed air system. By finding, logging, quantifying and costing air leaks you can prioritise the remedial work required to reduce your energy costs.
The best, and most widely used approach is to use ultrasonic leak detection equipment. It operates without interrupting plant operation, reaches system areas that are hard to access, and locates all air leaks.
I have been carrying out compressed air leak detection audits for over 18 years and have never come across a site which didn’t have any savings to be realised!
I have been at a London power station carrying out a leak detection test that I recommended to the customer. There were lots of leaks adding up to thousands of pounds in costs. The new ultrasonic leak detection camera that we use at Atlas Copco is accurate and easy to use, also giving the customer a picture to locate the leaks for repair.
What can I expect from a leak detection test?
We will arrange for a fully qualified engineer to visit your site with our state-of-the art acoustic leak detection camera. Even though the air leakage detection has to be done on a live system there will be no interruption to your production. Every leak found will be tagged and logged by our engineer. Afterwards you will receive an itemised, written report which shows the results in a clearly understood and actionable format.
Atlas Copco always carries out risk assessments and method statements prior to a site visit and our engineers are equipped with the appropriate PPE. Read more about safety.
Our step by step leak detection process
Step 1: Assess the air network
Walk the line to understand the distribution of the compressed air pipework network and usage.Step 2: Audit the air network Take an ultrasonic leak detection test. It not only recognises the compressed air leaks, it carries out on-board analysis to pinpoint the exact source of leak and size of leak in litres/minute. Step 3: Identify and tag the leaks Each individual weatherproof tag will carry an identification number stating the date and severity of the leak in l/min. Step 4: Report the results The report will list the leaks and show: • Site location • Photographs of leak• Tag ID • Severity of leak (l/min) • Cost of leak £’s • Position of leak • Cost to repair Step 5: Prevent future leaks Take a proactive approach to monitoring and controlling leaks on an ongoing basis.
Guaranteed results: We will reimburse the cost of the leak detection survey if we don’t find any leaks that would cover the cost of the test once they're fixed!
What will happen after the leak detection test?
Once you have had time to read and digest the findings in the report, we will send a quotation to repair the air leaks. Atlas Copco can also, if required, develop a monitoring and control programme to suit your individual needs. Our aim is to offer a solution that will reduce the cost of generating compressed air and therefore lead to a direct increase in your company’s profits.
How does Atlas Copco’s leak detection kit compare to others?
The cost of air leaks
All compressed air systems have leaks. These have several causes, including corrosion holes, poor pipe connections and bad seals. According to the British Compressed Air Society, the average leakage rate is 25% but some plants lose as much as 80% of their compressed air due to leaks. Just imagine filling up your car and then watching a quarter of your fuel drip on to the road through a leaky fuel line as soon as you start driving!
Generating compressed air only to lose it to leaks is of course is a waste of money. The Carbon Trust estimates that a hole of just 3mm in diameter in a compressed air pipe can create a leak that costs up to £1,000 per year in wasted electricity costs. The benefit of fixing leaks will be a lower energy cost and it may also reduce the running hours of your compressors, which may in turn also reduce maintenance costs. It is unfortunately almost impossible to guarantee that all leaks can be repaired, and it is inevitable that over time, new leaks will occur.
Best practice advice is that the percentage of compressed air lost to leakage should be less than 10% of your total compressed air production. We therefore recommend that your system is checked for leaks at least once a year. This proactive approach should enable you to keep a tighter control of the system and potential energy wastage.
Read more in our article Why compressed air leak detection matters – and how to maximise its benefits
Some users are simply not aware of the extent of any onsite leakage, or the associated cost; others are concerned that any audit will be disruptive and time-consuming. Yet, when done correctly, auditing can be efficient, fast and hassle-free, while highlighting opportunities for energy-saving and process improvements.
Examples of companies who have reduced their energy bill after detecting and fixing their compressed air leaks
- A global manufacturer of connectors and sensors saved £48,000
- A producer of health, hygiene and home products saved £40,000
- A leading multinational automotive manufacturer saved £22,000
- One of the UK’s largest food companies saved £45,000
The leak detection report was attached to a site layout plan, marking where each leak was. This showed us where to carry out the remedial work. The Atlas Copco engineer was a star and is more than welcome on site anytime.
Watch our 'Which compressed air audit is right for your production facility?' webinar:
This webinar is presented by Energy Efficiency Manager, Neil Frater.
On average 20-40% of compressed air produced is lost to leaks. Let us show you how to reduce this!
This webinar looks at why most compressed air systems have leaks, explains the different air audits and leak detection possibilities, and will help you discover which one is right for your production facility.
Terms and Conditions of the Money Back Guarantee
The money back guarantee is valid if you book and pay for a leak detection test directly from Atlas Copco Compressors. The money back guarantee only applies if we do not find any energy savings following the leak detection test.
