Stop Wasting Money on Compressed Air System Leaks
That hissing sound coming from the leak in your compressed air system is the sound of money and productivity being wasted. Don’t let air leaks drain your profits when you can rely on the compressed air experts at JHFOSTER to help solve this costly problem.
Why Your Industrial Compressed Air System Is Leaking
Compressed air leaks are common, but they waste resources and negatively impact the performance of your pneumatic tools and machinery.
Common causes of air leaks include:
● Loose fittings and connections: Vibration, expansion and contraction that occurs with normal operation can loosen fittings and connections.
● Worn seals and gaskets: O-rings, seals and gaskets degrade over time and require replacement.
● Damaged hoses or piping: Cracks or punctures in air lines are frequent sources of leaks.
● Malfunctioning valves: Issues with drain valves, check valves, pneumatic control valves and pressure relief valves may be responsible for air leaks.
● Corrosion: Corrosion associated with damaged or degrading pipes can create pinhole air leaks.
● Pneumatic actuators: Periodic replacement or repair is necessary to alleviate leak losses.
The Hidden Costs of Leaks in Your Compressed Air System
Compressed air leaks cause pressure drops that adversely impact the performance and reliability of pneumatic equipment, reducing productivity and uptime. And, because leaks force the air compressor to work harder, the system consumes excess electricity and experiences unnecessary wear and tear, making this a costly problem for manufacturers.
Finding and fixing compressed air system leaks is critical to avoid:
Excessive energy costs: Air system leaks force the compressor to compensate for the loss of pressure, significantly increasing electric bills. According to Compressed Air Best Practices, air compressor leaks can waste 20 to 30% of a compressor’s output and a plant that has not been well maintained may have a leak rate equal to 20% of its total compressed air production. For the average facility, 20 to 30% of the electric bill is attributed to operating the compressed air system, and when you consider that the average facility loses 20 to 30% of its energy consumption to compressed air leaks, it’s easy to see how air compressor leaks can waste thousands of dollars each year.
Lost productivity: Pressure drop caused by air leaks can reduce the performance of pneumatic equipment, drastically slowing down productivity.
Equipment failure: When leaks force the air compressor to work harder to deliver the required pressure, it causes wear and tear on the compressor and system components, resulting in equipment failure, costly repairs and, ultimately, a reduced lifespan for the equipment.
How to Find and Fix Compressed Air System Leaks
While many leaks can be detected and remedied by in-house technicians using basic leak detection and repair methods, a professional service provider like JHFOSTER may provide a better remedy for industrial-scale issues.
Here are three steps to finding and fix leaks in the compressed air system:
Step 1: Basic leak detection methods: Listening for hissing sounds coming from compressed air lines can help technicians find leaks. However, if there is no audible sound, but a leak is suspected, applying soapy water to connections, joints or pipes can pinpoint the source because bubbles will form where there is a leak.
Step 2: Professional-grade leak detection for complete accuracy: Ultrasonic leak detection is the most reliable way to find leaks. This method is used by the professionals at JHFOSTER to detect leaks, even those that are inaudible due to a noisy environment, without shutting down operations.
Step 3: Fixing the leak: Tightening loose fittings and connections will remedy some problems. Using an appropriate sealant such as Teflon tape on pipe threads can provide a fix for minor leaks. Pneumatic components such as control valves, actuators and tubing may need repair or replacement. For a reliable, long-term solution, its best to use correct, industrial-grade parts when making the repairs.
Your Partner in Air System Reliability
JHFOSTER’s services provide a complete solution to finding compressed air system leaks, minimizing costs and waste and maximizing efficiency and productivity. Our audit team specializes in evaluating your full system and recommending efficiency improvements.
Our solutions include:
Expert Diagnosis: Our audit department has many years of experience and uses the latest technology assuring accurate compressed air leak detection. Leaks are tagged for easy identification by factory maintenance personnel.
No interruptions: In most cases, our auditor can perform leak checks throughout the plant while production continues.
Unregulated-Poorly Regulated: All industrial manufacturing plants have leaks in the compressed air system which makes identifying and repairing them an ongoing battle. Our auditor will also identify areas that would benefit from proper pressure regulation. When possible, reducing pressure is one of the quickest most cost effective ways to reduce leak losses.
Leak Report: When the survey is complete our auditor will provide a report including a leak log, leak map, average kW saved, electrical cost savings, repair cost, any potential rebates, in an estimated ROI.
Don’t Let Air Leaks Drain Your Profits. Contact Us Today
Don’t waste another cent on compressed air leaks. Contact JHFOSTER today to schedule a professional leak detection survey. We’ll help you improve efficiency, reduce downtime and start saving money.
