November 2020

Focus on: Compressed Air Process, Controls & Plant Considerations must also be made to determine the type of leaks that are to be detected with ultrasound such as pressure leaks in compressed air or compressed gas systems, vacuum leaks, or refrigerant leaks. After the initial walk through, select one area or zone to test at a time. For consistency, it is recommended to begin at the compressor, or supply side, and then move to the distribution lines, and then areas where the compressed air is being used. As the compressed air leaks are found with the ultrasound instrument, a tagging system should be in place to tag the leak at its site. The tag should have places to record the leak number, the pressure, type of compressed gas, a brief description of the leak location, and decibel level of the leak that was indicated on the ultrasound instrument once the leak location was confirmed. An estimated cost of the leak may also be helpful in creating awareness of the expense of compressed air or compressed gas leaks. Documentation and reporting Besides repairing the compressed air leaks, the success of the compressed air leak survey largely relies on the reporting and documentation of our findings. For documentation purposes, there is a Leak Survey App by UE Systems, available for iOS and Android. The app allows the inspector to easily document the compressed air and compressed gas leaks, along with the associated costs. When reporting the cost and CFM (cubic feet per minute) loss of compressed air or compressed gas leaks, it’s important to remember that it is an estimated cost. The cost of a leak is based off of the decibel level once the leak has been located, the cost per kilowatt hour of electricity, and the pressure at the leak site. Ideally, the pressure at the leak site is best. For example, the compressed air may start at the compressor at 120psi, but where the air is actually being used it may be regulated down to 75psi. Look for the nearest pressure gauge, or if someone from the plant is available when the leak survey is being conducted, have someone who is familiar with the compressed air system. For specialty gasses, such as helium, nitrogen, or argon, the cost of the leak is based off of the decibel level reading at the confirmed leak location, pressure, and the cost of the gas as in a dollar amount per thousand cubic feet. Several independent studies have been done comparing an ultrasound leak survey report to actual energy savings, and it has been found that an ultrasound leak survey is within 20% of the actual savings of the compressed air leaks. When done correctly, an ultrasound compressed air leak survey can have tremendous payback in a short period of time. Once the leaks have been repaired of course. Compressed air is an expensive utility whose maintenance and cost is generally taken for granted. A successful compressed air leak survey depends on having the right ultrasound instrument for the needs of the survey, proper training of personnel who will perform the survey, planning how the survey will be performed by doing an initial walk through, documenting the leaks and the associated costs, and initiating repairs once the leaks have been identified. Through proper documentation and reporting, an ultrasonic compressed air leak survey can show tremendous payback and energy savings without a significant capital expenditure. For further information please visit: www.uesystems.eu AERZEN Rental provides immediate assistance throughout Europe if it concerns 100 % oilfree process air. With blower and compressor systems for conveyance of air and neutral gases for almost every industry segment, you are well prepared for any situation. Whether, for example, in case of overproduction, failure or maintenance, process optimisations or new buildings and conversions. Decide on absolute process safety: with the 24/7 rental service for efficient assembly solutions including accessories – also turnkey including installation, commissionning and maintenance. Fast, flexible, reliable. www.aerzen.com WHY OUR RENTAL SERVICE IS THE BEST SOLUTION FOR YOUR PROCESS ISSUE? LET’S TALK Debbie Mayes, Account Manager Rental UK & Ireland +44 (0) 7 903 645 925 debbie.mayes@aerzenrental.com