Running a compressed-air leak survey programme
A compressed-air leak survey programme uses ultrasonic detection to find, tag and repair leaks across a plant's air system on a recurring schedule. Because compressed air is expensive to make and leaks are inaudible over plant noise, a systematic survey is the fastest, highest-return way to cut air-system energy.
What it is
Compressed air leaks through fittings, hoses, couplings and valves that no one can hear. A survey programme walks the system with an ultrasonic detector, tags each leak, estimates its cost, and feeds prioritised repairs into maintenance — then repeats, because new leaks appear constantly.
Why it is done
Only a fraction of a compressor's electricity ends up as useful work; the rest is heat and leakage. Leaks force compressors to run longer and at higher pressure, so finding and fixing them cuts energy directly. Because leaks recur, a one-time fix decays — the programme is what holds the savings.
How it is done
An ultrasonic detector is used to sweep the distribution system during normal operation, locating the high-frequency hiss of each leak. Leaks are tagged, logged with an estimated flow and cost, and ranked. Repairs are scheduled, verified, and the survey is repeated on a cycle. System pressure is then reviewed downward once the worst leaks are gone.
- Ultrasonic sweep
- Tag leaks
- Estimate cost
- Prioritise repairs
- Verify fixes
- Lower set pressure
What to watch for
Tagging leaks without closing the repair loop is the commonest failure — the survey becomes a wall of unactioned tags. Lowering system pressure before fixing leaks risks starving end uses.
Related practices
Retrofitting waste-heat recovery
Retrofitting variable-speed drives
Sequencing and controlling multiple compressors
Related topics
Compressed Air Efficiency: Leaks, Pressure and Cost · Compressed Air System · Specific Energy Consumption (SEC)
Common in: Food Processing · Brewing & Beverage · Dairy · Chemicals · Pharmaceuticals · Paper & Packaging