Leakage, according to the U.S. Department of Energy (DOE), is one of the largest sources of wasted energy in industrial compressed air systems. A typical plant with outflows in its industrial air compressors can lose 20 to 30 percent of its compressor’s output.
To ensure operational efficiency, DOE’s Office of Energy Efficiency and Renewable Energy (EERE) offers the following tips to prevent leaks in compressed air systems:
Routine maintenance for parts of the system. From couplings and fittings to pipe joints and thread sealants, leaks can come from any parts of an industrial compressor. Hence, it’s essential to do a preventive maintenance at least once a month to make sure everything is intact.
Estimate amount of leakage. There are several methods to estimate the amount of leakage of a system. One of these methods involves starting the system when there are no demands on the system to determine the amount of air escaping from the leaks.
Total leakage can be calculated using this formula:
Leakage (%) = [(T x 100)/(T+t)]Where: T = on-load time (minutes)
t = off-load time (minutes)
Apart from wasted energy, leaks in compressed air system can contribute to other operational losses, such as a significant drop in system pressure and increased unscheduled downtime. It is, therefore, important to prevent leaks as soon as possible.
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