Compressed Air Leak Detection

Compressed Air Leak Detection

Compressed air is one of the most expensive utilities on an industrial site, and leakage is the single largest source of waste within most compressed air systems. Leaks run constantly, including overnight and at weekends when nothing is in production, and the majority are too small to hear over normal factory noise.

IATT carry out compressed air leak detection surveys throughout the UK using the UE Ultraprobe 9000. We locate each leak, label it, and provide a detailed report showing the cost of the leakage in pounds. We are then able to quote for the repair work and prioritise it so that the savings begin as soon as possible.

The Cost of Compressed Air Leaks

The British Compressed Air Society puts average system leakage at around 25%, and rates considerably higher than this are common on older installations. A well managed system, surveyed and repaired regularly, can be brought below 10%.

Leakage does not only waste the air itself. It also increases compressor running hours, which raises energy consumption, shortens service intervals and brings forward the cost of maintenance. Leaks can also cause pressure to fluctuate, which affects the performance of tools and equipment downstream.

What Our Compressed Air Leak Detection Survey Includes

• An ultrasonic survey of your compressed air system using the UE Ultraprobe 9000
• Surveying carried out on a live system, with no interruption to production
• Detection of leaks in noisy environments and in areas that are difficult to access
• Every leak located and labelled on site
• A detailed report giving the cost of each leak in pounds
• A quotation for the repair work, prioritised so the largest savings are addressed first
• Repairs carried out by our own engineers

How the Survey Works

• Walking the system – Our engineer reviews the layout of your compressed air pipework and how the system is used, so that the survey covers the distribution network as well as the plant room.
• Surveying with ultrasound – Compressed air escaping through a small opening produces ultrasonic sound that is inaudible to the human ear but detectable with the correct equipment. The Ultraprobe 9000 identifies these leaks while the system remains under pressure and in normal use, which means production does not need to stop.
• Labelling each leak – Every leak found is labelled where it is located, so your maintenance team can find it again without needing to repeat the survey.
• Reporting and costing – The report sets out each leak, its location and what it is costing you annually, alongside the cost to repair it.
• Repair and review – We quote for the remedial work and can carry it out. New leaks develop over time, so a repeat survey is worth scheduling as part of ongoing maintenance.

Where Leaks Commonly Occur

• Couplings, hoses, tubing and quick release fittings
• Valves that are not closing fully
• Pipe joints, particularly on older or extended pipework
• Filters, regulators and lubricators
• Condensate drains and drain traps
• Point of use equipment and disconnected drops that have been left live

Redundant pipework is worth mentioning separately. Where a line once served equipment that has since been removed, it often remains pressurised and continues to leak, with nobody responsible for it.

Ongoing Leak Management

A single survey deals with the leaks present on the day. Because new leaks develop through vibration, wear and general use, leakage will gradually return to its previous level unless the system is surveyed again.

We recommend including a compressed air leak survey in your planned maintenance schedule so that leakage is kept under control rather than allowed to build back up. This can be arranged alongside our service plans and our other compressed air services.

Why Choose IATT for Leak Detection

• A dedicated team of factory trained engineers strategically located throughout the UK
• Surveys carried out with the UE Ultraprobe 9000
• Costed reporting, so the findings can be presented as a business case rather than a list of faults
• Repairs quoted and carried out by the same company that surveyed the system
• Compressed air treatment, filtration, dryers and air quality testing all available from one supplier

Get in touch today to chat to one of our experienced and knowledgeable staff who can help with any technical or other queries you might have. Request a free quote – we’re happy to help.

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Compressed Air Leak Detection FAQs