Compressed Air Systems - Are you Blowing Your Profits. Use the Leakshooter LKS1000v3 to save your energy and money.

1. ALL-Energy Exhibition & Conference,
Glasgow 2017
Compressed Air Systems – Are
You Blowing Your Profits ?
 Hugo Gallagher
 C.Eng, MIET, MSc, B.Eng (Hons), B.Eng, HND
 Managing Director of Logis-Tech Associates (sub division A-1 Technical Training)

2. ALL-Energy Exhibition & Conference,
Glasgow 2017
Compressed Air Systems – Are You Blowing Your Profits ?

3. Compressed Air Systems
Whole System Approach to saving energy
Pipework, valves, design
Calculating air system’s annual costs
Finding leaks using ultrasonic detection methods
Fixing leaks
Good Housekeeping and staff involvement

4. Overview of how to save energy in a typical
compressed air system
 Compressed air often referred to as the fourth utility.
 Essential to many sectors as a safe, reliable and versatile source
of power.
 Take a considerable amount of energy, generally in the form of
electricity, to produce clean, dry, pressurised air that is needed
for so many processes and applications.

5. Compressed Air
 Typically, is 10% to 30% of an industrial company’s electricity bill
 Some sectors it can equate to far more.
 Makes sense to take targeted action and make your system more
efficient.
 Reducing compressed air waste will:
• Save energy and costs
• Improve reliability and productivity

6. A Typical Compressed Air System

7. Compressed Air System
 Every element of a compressed air
system impacts upon its energy
consumption.
 A mistake to just concentrate on
one aspect of the system
 To the exclusion of other sections.
 Result in missed opportunities to
saving energy.

8. Efficient Compressor
 Eg,Purchase the most efficient compressor on the market but connected it
to a system that has a 40% leak rate
 All you are achieving is to produce waste more efficiently!
 While the largest energy consuming component in the system is the air
compressor(s)
 It is the demand by users, overall design and how well the system is
maintained that determines the demand placed on the compressor to
supply the system and therefore its energy consumption.

9. Compressed Air Pipework
 Not all parts of the network operate the same hours
or to the same pressure, so save energy by zoning
the compressed air system.
• Split the system into zones and pressurise each
only as required
• Remove/isolate redundant piping so that it does
not leak out of hrs

10. Compressed Air - Valves
Widely used for isolating parts of the distribution network.
Best option - Ball valves cause almost zero pressure drop
when fully open
Not so good - Gate valve design causes pressure drop and
leaks when left partially open for convenience
Avoid - Diaphragm and globe valves cause the largest
pressure drop

11. Compressed Air – Good Design
All compressed air distribution pipelines to min. pressure
drop and allow for possible future expansion of the
compressed air system:
• Select large radius bends instead of elbows
• Support piping to minimise movement and sagging to
reduce leaks and build-up of fluids

12. Compressed Air Pipe size and energy losses
Installing a smaller pipe to save on the initial capital cost is a
false economy.
Smaller piping causes greater pressure drop across the
system, resulting in higher energy consumption and this
increased energy cost soon exceeds the price of larger
diameter piping.

13. General Rule – Pipe Diameters
Calculated based on having a max. air velocity of 6m/s,
in the main supply line.
In branch lines with a total length less than 15m,
velocities up to 15m/s are acceptable.

14. Pipe Systems
 Two basic distribution systems for compressed air are single main and ring main.
 For larger systems with numerous take-off points then a ring main is recommended.
 Isolation valves can be fitted to isolate specific sections of the system for maintenance
purposes.
 When selecting pipe material consider the alternatives to traditional galvanised steel, which
eventually corrodes and has a much rougher internal surface.
 Smooth bore aluminium pipe (both tube and box types), stainless steel and specialised
plastics offer much lower friction and flow resistance to the air. This reduces pressure
 drop and saves energy, plus these materials do not corrode
 and potentially contaminate the air.

15. Calculating the system’s annual costs – Option 1
 The actual electrical consumption of the compressor(s) in
kilowatt hours (kWh) can be obtained by sub-metering the
compressor house.

16. Calculating the system’s annual costs – Option 2
 A quicker temporary solution is to install a data logging system over a period
of at least seven days.
 This will determine:
• Pattern of demand (demand profile)
• Off load running time when there is no demand for air
 In addition to add further information to help build a usage picture, you could
also incorporate flow monitoring into the system.

17. Calculating the system’s annual costs – Option 3
 If no metering is in place, then you can estimate the energy
consumption of each compressor
 Eg, A 75kW compressor operates at 7 bar.
 It is on load for 65% of the production time (2,000 hrs/year).
 Motor is assumed to be 90% efficient.

18. Calculating the system’s annual costs – Option 3
 Energy consumption of the compressor whilst on load =
(75 ÷ 0.9) x 0.65 x 2,000 = 108,333 kWh/year
 There is also energy consumption from the offload running, assuming for a screw compressor that a
part-loaded running draws 25% of the full load power:
(75 ÷ 0.9) x 0.35 x 0.25 x 2,000 = 14,583 kWh / year
 Total energy consumption of the compressor = 122,916 kWh

19. Electricity Cost
 For unit electricity of £0.12/kWh, the annual energy cost is £14,750.
 If production time is 6,000 hours per year, this increases to £44,250/year.
 For older or less efficient compressors where the offload electrical draw can be nearer
70% of on load power (not 25% as in the example), then the annual energy cost for
2,000 hr operation increases from £14,750 to £17,900 per year.
 Another method for estimating energy consumption of compressors is to use the max.
rated package power, a figure available from the manufacturer.

20. Calculating System’s Annual Costs - Summary
 The cost of the compressor, not the system.
 However, it is a starting point and helps you understand the
scale of expenditure
Examine the entire compressed air
system to maximise energy savings

21. Compressed Air Leaks
 All compressed air systems have leaks.
 Leaks are often ignored since they are not an immediate H&S hazard
 Reducing air leaks is the single most important energy saving measure you can take.
 A high leak rate causes fluctuations in pressure, resulting in hidden costs such as
slower running or the stalling of production lines
creates a noisy environment for staff.

22. Common leakage sources are
Air-using equipment left running when not needed
Manual condensate drain valves left open
Leaking hoses and couplings
Leaking pipes and pipe joints

23. Estimate your leak rate as a percentage of
total demand,
 Carry out the load /no load cycle test
 This is easily done with a stopwatch to find the percentage of time the
compressor is on-load when there is no demand for air.

24. Estimating a Compressed Air System’s Leak
Rate Using the Load /No Load Cycle Test.
1. Use a timer e.g. stopwatch to measure the time (T) that the compressor is actually
delivering air (on-load).
2. Repeat this for the duration of time (t) that the compressor is off-load.
3. Repeat these measurements through at least four cycles to obtain accurate average
values.
 Note: If the air compressor actually switches off and on, then this is
straightforward.
 If the machine keeps running but uses an off-loading mechanism, then listento the
tone of the compressor as it cycles between the two states.

25. Estimating a Compressed Air System’s Leak
Rate Using the Load /No Load Cycle Test.
4. Note the delivery capacity of the air compressor (Q) from the nameplate or literature.
5. Use the following formula to determine the leak rate, Qleak which will have the same
units as Q (e.g. litres/s or m3/min):
Qleak = Q x T/(T+t)

26. Identifying and Measuring leaks
Initially conduct an out of hours survey and walk the site
listening for leaks.
Confirm the location by using any of the following
methods: ultrasonic leak detector, a soap solution
brushed onto pipe fittings, or a leak detection spray.
Handheld ultrasonic leak detectors are the best way to
detect leaks whilst production is running.

27. EP500Air leak Ultrasonic “Easy Flex” Detector
 Finds the leak fast, easy and efficient reducing energy costs considerably.
 EASY” to operate without any training at all – you simply use it.
 A leak will produce an audible sound in the headset and even tiny leaks can
be detected from 15 - 20 meters away.
The device is equipped with a gooseneck allowing access to hard to reach
hoses and connections.
 Technical Specifications
Light-weight headset with vol. control
Freq. range: 38 – 42 kHz
Max. distance to leak (7 bar, size Ø0.5 mm): 20m
Battery: 9V (PP3 / 6LR61), alkaline
Operating time: more than 25 hrs
Operating temp.: -10°C to +45°C
Weight: 270 g

28. LEAKSHOOTER® LKS1000-V2

29. TURBULENT FLOW & ULTRASONIC WAVE
ULTRASONIC DETECTION-WHY?
Turbulence in the flow of fluids and gases emit high levels of
ultrasonic waves. In an industrial plant, pressurized leaks in
pneumatic air lines, steam lines and vacuum lines emit
ultrasonic waves.
Internal leaks in valves, steam traps and hydraulic systems
also produce ultrasonic waves as well as mechanical wear
in bearings and gears.
Ultrasonic waves are very strong at the leak origin and
decrease with distance. They are also very directive.
For years, ultrasonic inspection techniques have been used
in plant maintenance programs to reduce energy costs and
increase equipment reliability.
Pressure
P
Pressure
P ATM
Turbulence
Ultrasonic waves
Leak

30. LEAKSHOOTER® LKS1000-V2 – What is it ?
SEE & HEAR LEAKS:
LEAKSHOOTER® LKS1000-V2 is a portable
leak detection camera, which combine
ultrasonic and visual camera technologies
around a “real time” calculation software, to
give you an easy way to view the leak location
on the screen and to hear the leak in the
headphone.
LEAKSHOOTER® LKS1000-V2 stores the
leak location photo to be downloaded later to
a PC for reporting.
LEAKSHOOTER® LKS1000-V2 quickly
repays its initial cost outlay and could save
your company substantial energy costs and
improve overall system efficiency.

31. LEAKSHOOTER® LKS1000-V2 – How does it work ?
SEE THE INVISIBLE:
Simply scan your installation with the handheld
LEAKSHOOTER® LKS1000-V2.
When the cone is aligned with the ultrasonic
waves, LEAKSHOOTER® LKS1000-V2 shows
you a dynamic target (yellow or red depending on
the size of the leak) on the screen. This is the
location of the leak.
If the target has a cross inside it, you are in front
of the maximum ultrasonic waves, so in front of
the leak.
Of course, you can manually adjust sensitivity
(Gain) of the integrated ultrasonic sensor to be
able to find both big (less sensitive) or small
(more sensitive) leaks.

32. LEAKSHOOTER® LKS1000-V2 – For which applications ?
COMPRESSED AIR :
LEAKSHOOTER® LKS1000-V2 will
help you to find compressed air leak
locations, even in a very noisy
environment.
Find, identify and repair the leaks.
Make Energy Savings, work more
efficiently (ISO 50001).
LEAKSHOOTER® LKS1000-V2 can
help you saving a lot of money.
Do not forget one permanent 1mm
leak@7BAR cost about 250 €/year.

33. LEAKSHOOTER® LKS1000-V2 – For which applications ?
COMPRESSED PROCESS
GASES :
LEAKSHOOTER® LKS1000-V2 will
help you to find compressed process gases
leak locations like O2, CO, CO2, N2,
Argon, H2…, even in a very noisy
environment.
Find, identify and repair the leaks.
Work more SAFELY.
LEAKSHOOTER® LKS1000-V2 can help
you saving a lot of money.
Do not forget a process gas leak can be very
dangerous...

34. LEAKSHOOTER® LKS1000-V2 – For which applications ?
VACUUM :
LEAKSHOOTER® LKS1000-V2 will
help you finding industrial vacuum leak
locations, even in a very noisy
environment.
Find, identify and repair the leaks.
Work with a better EFFICIENCY.
LEAKSHOOTER® LKS1000-V2 can
help you saving a lot of money.
Flexible probe is often useful for close
vacuum leak detection.

35. LEAKSHOOTER® LKS1000-V2 – For which applications ?
TRAP/VALVE INSPECTION :
LEAKSHOOTER® LKS1000-V2 will
help you inspecting trap or valve, to find
malfunctions, even in a very noisy
environment.
See & Hear what happen inside.
Make Energy Savings, work more
efficiently (ISO 50001).
LEAKSHOOTER® LKS1000-V2 can
help you saving a lot of money.
Contact probe is needed for trap &
valve inspection.

36. LEAKSHOOTER® LKS1000-V2 – For which applications ?
HIGH VOLTAGE INSPECTION :
LEAKSHOOTER® LKS1000-V2 will
help you inspecting from the ground high
voltage electrical installation.
See & Hear malfunctions like corona,
partial discharges, tracking, arcing...
Work with a better efficiency and avoid
high cost breakdown.
LEAKSHOOTER® LKS1000-V2 can
help you saving a lot of money.
Detect up to 15m with integrated cone.

37. LEAKSHOOTER® LKS1000-V2 – STANDARD PACK
 1x LEAKSHOOTER® LKS1000-V2 device
 1x universal power charger 230V-50Hz/60Hz > 5V/2A
 1x USB cable for PC connection
 1x stereo headphone with jack cable
 1x strong aluminum case
 1x user manual
 1x manufacturer certificate
 Leakshooter Ultrasonic Leak Detector Camera
 leakshooter Video with Cone
 Leakshooter with Flexible Probe

38. LEAKSHOOTER® LKS1000-V2 – ACCESSORIES
(1)
LEAKSHOOTER® LKSFLEX 1500 mm or 400 mm
LEAKSHOOTER® LKSPROBE LEAKSHOOTER® LKSCOVER LEAKSHOOTER® LKSBATT

39. LEAKSHOOTER® LKS1000-V2 – ACCESSORIES
(2)
LEAKSHOOTER®
LKSLEAKTAG
LEAKSHOOTER® LKSDOME
(for tightness tests in big
volume, 13 ultrasonic powerful
emitters)
FRONT BACK

40. Air Leak Survey
 Survey Carried Out By …………………….
 Report Compiled By ………………………
 Date ………………………
Company: XXXXX Ltd

41. Compressed Air Pipework and fittings Survey
Checked using a Leakshooter
LKS1000 v1 acoustic/ultrasonic leak
detector.
Where a leak was found it was tagged
and numbered using red or white
tags. Leaks were numbered for
identification and given a rating from
1 to 5 based on the severity of the
leak. This is shown in the table
Leak
Rating
Severity
1 Low
Leakage
2 Low/Medium
3 Medium
4 High
5 Major

42. Compressed Air Pipework and fittings Survey
Checked using a Leakshooter
LKS1000 v1 acoustic/ultrasonic leak
detector.
Where a leak was found it was tagged
and numbered using red or white
tags. Leaks were numbered for
identification and given a rating from
1 to 5 based on the severity of the
leak. This is shown in the table
Leak
Rating
Severity
1 Low
Leakage
2 Low/Medium
3 Medium
4 High
5 Major

43. Leak 1
Packing Plant, Line 3 Mezzanine Floor
Flexi Hose Rating - 3

44. Leak 2
Packing Plant, Line 3 Mezzanine Floor
Flexi Hose Rating - 2

45. Leak 3
Packing Machine (Floor 1)
Flexi Hose Rating 4

46. Leak 4
Packer 1 (Top Floor)
Major Air Leak underneath machine Rating 5

47. Leak 41
Raw Mill
Fitting Rating 4

48. Leak 51
Cooling Tower (Floor 1)
Big door air tight seal Rating 5

49. Leak 54
Dome
Dust Covers Rating 3

50. How Much Could You Save?
54 leaks in total taking a average leak at 3cfm (cubic
feet/minute). = 162cfm of waste.
162cfm = 26kw Compressor
26kw x £0.12p/kw/hr x 24hrs x 7days x 50 weeks
= £26,208.00 Electrical costs in Leaks, Per Annum

52. Companies using the leakshooter LKS1000v2
 Airbus, GSK, JCB, Ford, Nissan, Aptar, Nampak, Tubelines, Heidleberg,
SG Equipment, Eriks, Brammar, Atlas Copco, Premier Foods, Arla Foods,
Nestle, Tata Steel, MH Pneumatics, Sanofi, United Biscuits, Thorite, Air
Compressor Blowers, Direct Air, Morningfoods, BMW, NHS, Adastra,
Ormandy, Skretting, SmithAnderson, Kingspan, Pablon, Bellfield, Yess
Electrical, Orta, Derek lane Ltd, Agility, BMW, Unicron, Electronic
Systems, Intelligent-Energy, Defy, Perkins Engines, Dickson Bearings,
Airwise, Storm Procurement, PZ Cussons, SSE, Lomax Food processing,
Environmental Options, IRESA, Predictive Condition Monitoring, etc,…

53. Leak Management Programme
 Tag the leaks and record on a site plan
 Grade the priorities - it could be as simple as 1,2,3
 Fix the largest leaks first
 Encourage users to report leaks
 Repair all leaks as soon as practicable
 Leaks need to be monitored constantly. Carry out a leak survey at least 3 – 4 times a
year to keep the problem under control.
 If you have insufficient in-house resources, speak to Logis-Tech Associates

54. Leaks Repaired – Pressure Drop
 Once leaks are repaired, check the pressure drop from the compressor to points
of use as you may be able to reduce the generation pressure at the compressor.
 Otherwise fixing leaks could increase the pressure and the predicted savings
will not be realised.
 Also the increased pressure could create more new leaks.
 In order to monitor the leakage rate, consider installing permanent flow
metering.
 This is also an effective way of identifying any changes in consumption which
need further investigation.

55. Good housekeeping and staff involvement
 Many users are unaware that the compressed air generated is not free and
therefore ignore leaks and use air indiscriminately.
 You should involve your staff in identifying where compressed air is wasted
and how they can help by reporting the problem and making suggestions.
 The main areas of wasted usage to target are:
Leaks
Leaving air consuming equipment running during breaks
Using compressed air lines for cleaning down benches and
equipment

56. Draw up a Usage Policy
 Appoint someone with overall responsibility to ensure
coordination and implement an action plan to:
• Raise awareness of all those who use compressed air
• Establish compressed air costs
• Set targets for reducing avoidable waste

57. Switch off the Compressor When There
is No Demand
 Do not leave compressors on overnight if there is no demand for air because electricity
will be consumed to feed leaks.
 Even when off-load, compressors can consume up to 70% of their full load power.
 Fewer running hours will also reduce maintenance costs.
• Check that compressors are switched off when not needed and are not switched on earlier
than necessary
• Check time switch settings regularly
 Note: Ensure that when automatically shutting down the compressor, that other
plant areas are not affected

58. Maintain the whole system
 Effective maintenance is essential to energy efficiency.
 Cutting back on maintenance is a false economy, because doing so increases
the energy consumed, decreases service life and reduces equipment
reliability. In addition, the law requires all systems operating at greater than
0.5 bar with an air receiver installed, to comply with the Pressure Systems
Safety Regulations 2000 (PSSR).
 Reg. 12 of the PSSR requires that compressed air equipment be properly
maintained to minimise health and safety risks associated with a pressurised
system

59. Further Info: Guides, Literature, case studies
www.bcas.org.uk
 www.referenceline.com/bcas
 https://www.gov.uk/guidance/energy-technology-list
 http://e-learning.bcas.org.uk - for online training
 http://www.cagi.org
 https://www.compressedairchallenge.org
 http://www.hse.gov.uk/pubns/indg261.pdf