Compressed air is a vital component of most factory environments and its leakage can cause major setbacks to industrial plants. In fact, air compressor leaking can mean 20% to 30% of wasted energy for a plant. This can become a real nightmare as it can also lead to high repair costs and a slowdown in productivity.
Unfortunately, air leaks are actually quite common. Because of this, it is necessary to understand why they occur and how to deal with them when they do. Read on, and we’ll walk you through some helpful information to make sure you’re prepared the next time a problem like this arises.
How to Detect Air Compressor Leaking
The simplest way to spot an air compressor leak is to hear it. At a plant, it would be advised to assign someone to regularly walk around to monitor during a time when production is not occurring. This person should listen for the high-pitched sound of compressed air leaking.
Unfortunately, not all air leaks can be easily heard by human ears. Because of this, it is also helpful to have an ultrasonic leak detector on hand.
This device detects the high-frequency sounds that compressed air leaks make. These tools can even be used while production is going on which makes detecting air leaks even more convenient for the plant and its crew.
How to Fix a Leak
Most of the time, an air leak can be repaired by simply tightening connections in order to stop air from escaping. But sometimes a more complex and costly solution is needed.
If equipment is old or cracked, you may need to replace it in order to stop the leaking. Though newer, high-quality equipment may be more expensive upfront, it is also less likely to break down than older equipment and will also run more efficiently.
How to Prevent a Leak
The best way to ensure that chances of compressed air leaking are low is to use well-made equipment from trusted manufacturers. There is a reason why cheap equipment costs less and it is usually not worth the risk when considering the possible implications.
Another great way to prevent leaks is to lower the air pressure in the system. As air pressure is lowered, the amount of potential compressed air leaking out will also be lowered because the compressed air is not being transferred as powerfully.
It is also important to ensure that all connections in the system are properly sealed. Equipment should be regularly checked and maintained to ensure the chances for leaks are minimized.
Air compressor leaking can result in a big headache and should never be left unattended. That is why it is so vital that you not only be on the lookout for any issues but to make sure that all of your air compressor systems and equipment are well maintained and working properly.
Need more help with your air compressor? Check out the Max-Air blog for more advice and information or give us a call.