The invisible costs of Compressed air leaks

The expensively cleaned Compressed air that escapes unused through Leakages is costly and burdens the base load of the Compressors. In this article, we will analyse the economic and environmental impact of these Leakages and present concrete solutions to reduce these Losses.

To illustrate the economic and environmental impact of Compressed air leaks, consider the following calculation example, which links three Leakages with their consumption, costs and CO2 emissions.

The operating hours that a Leakage is permanently supplied with compressed air generates the annual Compressed air consumption and thus also its energy costs and CO2 emissions.

Operating hours: 8000 hours / year under Pressure

If you multiply the electricity price in €/ kWh by the specific output in kWh / m³, you get the compressed air energy costs in € per m³. The following article(link) explains exactly how the specific power for Compressed air generation and treatment can be measured for the precise Calculation of Compressed air energy costs.

Compressed air energy costs: 0.21 € / kWh * 0.12 kWh / m³ = 2.52 € cent / m³

CO2 emissions Germany: 0.434 KG CO2 / kWh [Federal Environment Agency 2022 Germany]

Losses volume flow	Compressed air per year	Energy in kWh per year	Energy costs per year	CO2 emissions per year
1 litre / minute	480 m³ / a	57.6 kWh / year	12,09 € / year	24.99 kg CO2
10 litres / minute	4800 m³ / a	576 kWh / year	120.9 € / year	249.9 kg CO2
100 litres / minute	48,000 m³ / a	5760 kWh / year	1209 € / year	2,499 kg CO2

In practice, small Leakages predominate, but a few large Leakages cause the majority of the costs. A cost estimate and prioritisation per Leak therefore helps to act economically, as the repair may require spare parts, Maintenance and possibly production breaks.

2. where are the Leakages located?

It is important to emphasise that properly installed stainless steel pipes, which are either welded or bolted via flanges, are rarely prone to Leakages. These Robust connections offer high reliability in the compressed air system. The majority of potential leakage problems are in production onthe machines, where mechanical wear and operating conditions affect reliability.

Tip: Anyone looking for Leakages should therefore focus their attention on the machinery and its connections.

Connecting elements: These include flanges, fittings, couplings, hoses, hose connections and screw connections. These components are often the main cause of Compressed air leaks as they either become damaged, loosen over time or are affected by vibrations or mechanical stresses.

Machines and systems: Maintenance units, valves, cylinders, limit switches and other pneumatic components can leak, especially if they are not regularly maintained or checked.

3. how to locate Compressed air leaks using ultrasound?

Compressed air leaks are detected using ultrasonic waves that are generated by the Leakages and are inaudible to the human ear. One advantage of this method is the ability to localise Leakages during operation.

Ultrasonic leak detectors are essential tools for detecting and making audible ultrasonic waves that are normally imperceptible to the human ear. But how exactly does this work?

Detection of ultrasonic waves: Ultrasonic waves are generated when there is a leak, be it from air or another Gases. Thanks to the sensitive sensor in the detector, usually a piezoelectric element, these high-frequency vibrations can be detected.
Conversion into audible frequencies: The detected ultrasonic signal is converted into a signal that we can hear by means of electronic demodulation.
Clear audio playback: The converted signal is then amplified and can be heard via headphones or a loudspeaker on the device. This allows the user to locate Leakages acoustically.

Ultrasonic leak detectors therefore convert the inaudible ultrasonic sound of a leak into audible tones, allowing professionals to respond to leaks accurately and effectively.

The advanced technology of acoustic cameras transforms inaudible ultrasound into a visible image of Leakages. But how does this impressive process work?

Digital MEMS microphones - focus on precision: Specially arranged digital MEMS microphones capture ultrasonic waves with maximum Accuracy. The arrangement plays a decisive role: wide spacing between the microphones increases the resolution by taking into account time-of-flight differences, while narrower arrangements minimise false sources - a must, as ultrasound is particularly short-wave due to its high frequency.
From ultrasound to image with beam forming: Using the beam forming algorithm and the "Delay and Sum" method for all microphone channels, a detailed ultrasound map is created from the recorded data. The result? An expressive ultrasound image (visually similar to a "thermal image") or coloured representations that reveal the intensity and position of the ultrasound.
Intuitive display for quick analyses: intense ultrasound areas are shown in bright colours on the display of the acoustic camera. This enables specialists to localise Leakages and rectify them effectively.

With modern acoustic cameras and the combination of MEMS microphone technology and beam forming, detecting Leakages becomes a visual experience that emphasises precision and speed.

Whether you are interested in the classic ultrasonic leak detector or an acoustic camera - CS INSTRUMENTS always offers you the best solution for your requirements. We pride ourselves on combining tradition with innovation and always offering our customers the very best in technology and applications.