When looking at compressed air systems we can spend a lot of time on the larger more expensive items like compressors and vacuum pumps. What we can forget is that the connections between these units are at least as vital to the efficient running of the system as the pumps and compressors themselves.
Leaks can be a significant source of wasted energy in a compressed air system, wasting anything up to 20-30% of a compressor’s output. A system that has not been properly maintained will possibly have a leak rate equal to 20% of total compressed air production capacity. Taking a proactive approach to leak detection and repair can cut that to less than 10% of compressor output. Leaks can also cause a drop in system pressure, making air tools function less efficiently, once again slowing production. By forcing the equipment to cycle more frequently, leaks shorten the life of almost all system components as well as leading to increased maintenance requirements.
All pneumatic systems have some air leakage designed into them as part of the production process. The unexpected leaks that are the ongoing maintenance issues can appear in any part of the system and require an ongoing air leak detection and repair program. Most of the problems come from relatively small and inexpensive components. Couplings, hoses, and fittings are some of the most common problems. Push fit fittings incorrectly located, O-rings missing or damaged, or simple items like thread sealants improperly applied can all contribute to leaks.
An efficient leak prevention program will include identification and tagging of problems, tracking, repair, and retesting. Leak prevention should be part of an overall service programme aimed at improving the performance of compressed air systems. A good compressed air system leak repair program is important to maintain the efficiency, reliability, stability and cost effectiveness of any compressed air system.
Harrier Pneumatics carry out full air audits and leak detection services. These are designed to achieve the lowest operating cost for the compressed air system and a fast return on any investment. Breakdown prevention is always much less painful, disruptive and expensive than any cure. Regular servicing from Harrier Engineers can be a major asset when it comes to controlling production downtime. Get in touch to learn more about our services.
This post was written by Harrier Pneumatics