Compressed air leaks: find losses and verify repairs
An air shortage does not always mean a larger compressor is needed. Separate useful demand from leakage and unnecessary consumption first.
Map the leaks
Start with connections, hoses, quick couplings, valves and drains. Give each leak an ID, location and repair status. Ultrasound helps locate leaks; accessible suspect joints can be checked with soap solution under site safety rules.
Verify every repair
Recheck the area after repair. Compare flow and power under equivalent production duty and pressure. For reduced air use to reduce energy, compressor control must match the new load. A repair-complete list alone does not demonstrate savings.
Assess loss costs separately
Do not assume an arbitrary percentage of motor power. Estimate lost flow, measurement conditions and how the station responds to reduced load. Tracking recurring leaks helps plan maintenance and identify connections needing redesign.
What to prepare
- Leak ID and location
- Operating pressure during inspection
- Measured flow or estimation method
- Repair and reinspection dates
- Power comparison before and after
This guide helps assemble inputs. Check the complete datasheet for the specific model’s conditions.