Compressed air leak detection

Detection of compressed air leaks

Compressed air leaks within production sites cause enormous energy waste in pneumatic systems, consequently generating large financial losses measured in thousands of euros per year. 

In industrial plants, compressed air generation systems are widely used and critical in production processes. Compressed air systems are large users of electricity and can be a significant part of a company's overall electricity consumption. It is generally acknowledged that a perfect seal is unlikely to be maintained in pneumatic systems; although losses as low as 10 percent may be considered acceptable, the figure is often much higher, and figures as high as 40 or 50 percent are not unusual.

Leaks can result from corrosion, vibration, or material failure of joints and components in the pneumatic circuit. Because of such leaks, compressors are forced to operate at peak performance at all times, resulting in higher energy costs and increased wear and tear on their components.

By successfully detecting and eliminating leaks, it is possible to have an average savings of 12 percent in energy costs, while also reducing compressor runtimes and extending their service life.
It is therefore evident how critically important it is, in terms of plant efficiency, to be able to detect and repair leaks, through regular audits and inspections.

Where the leaks are hiding

  • Hoses
  • Tubes
  • Fittings
  • Threaded joints
  • Quick releases
  • Condensate separators
  • Valves
  • Flanges
  • Seals
  • Pneumatic containment tanks

The AESSE Measures Solution

At the level of operation, these devices receive the sound waves generated by the leaks, which are inaudible to the human ear, and convert them into a color graphic image that allows easy identification of the point of emission.It is important to emphasize that the measurement in the ultrasound field is extremely reliable because it is immune to the hostile environmental conditions and noise normally present in the plant.

This solution is able to identify another phenomenon that occurs in the vicinity of all electrical installations:
partial discharges. Read the article onidentifying partial discharges


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