Leaks In Compressed Air Systems

In addition to being a source of wasted energy, leaks waste money. By having a proactive leak detection and repair programme, leaks can be reduced to less than 10% of compressor output.

Leaks can be a significant source of wasted energy in an industrial compressed air system, sometimes wasting 20-35% of a compressor's output.

A typical plant that has not been well maintained will likely have a leak rate of about 20% of total compressed air production capacity.

By having a proactive leak detection and repair programme, this can be reduced to give leaks to less than 10% of compressor output.

In addition to being a source of wasted energy, leaks can also contribute to other operating losses.

Leaks cause a drop in system pressure, which can make air tools function less efficiently, adversely affecting production.

In addition to this, by forcing the equipment to cycle more frequently, leaks shorten the life of almost all system equipment (including the compressor).

Increased running time can also lead to additional maintenance requirements and increased unscheduled downtime.

Finally, leaks can lead to adding unnecessary compressor capacity.

While leakage can come from any part of the system, the most common problem areas are: a.

Couplings, hoses, tubes, and fittings.

b.

Pressure regulators.

c.

Open condensate traps and shut-off valves.

d.

Pipe joints, disconnects, and thread sealants.

The Cost of Leaks The Energy Efficiency web site www.energy-efficiency.org states: "Compressed air; A 5-mm diameter hole in an airline costs around £1,400 per year.

"While out on site, during a demonstration visit and using the New EP2400 ultrasonic stethoscope/leak detector several minute leaks where found in a very short time period.

Thus paying the initial cost of the EP2400 during the initial visit.

There is not many industrial handheld devices capable of such a feat.

The EP2400 Detector The EP2400 uses New ultrasonic technology ( incorporating Analogue + Digital Leak Seek + External Leak Seek Sensor.

It also has a extended LED Display.

EP2400 is used to find leaks (e.g in compressed air installations, vacuum installations, steam traps, in tanks, on car windows et cetera) as to find and measure mechanical malfunctions on movable parts (e.g ball bearings, gears, etc).

As ultrasonic equipment EP2400 works by "listening" in a frequency band normally containing no interference and non-audible for humans (>20 kHz=ultrasonic).

Leaking compressed air or electrical flashover (sparks) generates e.g ultrasonic.

Audible noises from the surroundings are filtered off so that the device can also be used in noise filled areas.

The new "ultra search" technology has improven both the close leak seek and for detection at a distance up to 6 metres.

Analogue leak detection (with Hearing protector): If leaking a "buzz" can be heard in the headphone.

The sound level depends on the size of the leak.

If looking for a very "small" leak close by, the directional probe can be applied to the sensor at the top of the instrument and optimum listening-sensitivity is achieved.

The analogue detection is very precise, both close and at distance.

Digital Leak Detection (without hearing protector): The unit makes use of a new developed digital technology, where the ultrasound transforms into a digital signal which the user sees at and hears from EP2400 as a flashing light and a pulsating sound.

The faster the light flashes/the sound pulsates the closer you are at the leakage, and this speed is also an expression of the size of the leakage (The faster - the bigger leakage).

Digital leak detection is very fast and handy, but not as precise as analogue detection.

Detection with external ultrasonic sensor and flexible directional probe (accessory equipment): Leak detection at narrow and difficult places - both analogue and digital detection.

Flexible probe improves this close leak detection.

Make sure sealing all the leaks found at the examination - leakage costs a lot of money! As a "mechanical malfunction feeler" the EP2400 picks up interference from movable parts through a stethoscope or a clip.

The stethoscope only "listens" to low-frequency mechanical vibrations so the stethoscope can also be used in noisy areas.

It is also possible to construct a permanent measure removal place e.g by a built-in piezoe component with a connection plug at a certain machine part that is wished supervised so that the measuring can be made a pure reading task (20 points LED display).

Please contact Logis-Tech Associates for further details on the use of this! EP2400 can als be used with the EP512 - ultrasonic transmitter that transmits pulsating ultrasonic.

The transmitter is placed inside the item, e.g a steel tank, that is then closed.

The user can then examine the tank from the outside and can easily find leaks, if any, sounding like "pips" in the headphones.

Noise filled areas: EP2400 can be adjusted (0 - 35 dB) and makes EP2400 able to cut off disturbing ultrasonic disturbances not coming from leakages (ventilation, etc).

The EP2400 equipment is delivered together with authorized and CE approved EP921 - hearing protector.

So fulfilling the rules for personal security in areas where the sound level can exceed 80 dB.

Scopes of application: Cars, industry, workmanship, laboratories, hospital service, all types of industrial plants, aeroplane industry etc,.

Examples of application: Leakage searching in compressed air systems both at high as low pressure - also in extremely noisy surroundings.

Vacuum systems.

Electric installations where flashovers can be found - including insulators.

Leakage searching in laboratory glove boxes in combination with EP512.

Mechanical transmission both instantly and permanently supervised.

The EP2400 ultrasonic detector set is an essential piece of equipment required by the maintenance department of all industrial plants.

All companies should reduce in-house costs and maximise profits.

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