A silent air compressor uses a lot of energy. It could take about 7 – 8 HP —horsepower— of electrical energy to generate 1 HP of compressed air power. It’s essential to keep your compressed air system running at peak performance with such high energy demands and effects. If you hear a hiss or sound coming out from a component in your silent air compressor, you might not know how much damage it could cause your system and your bottom line. Silent air compressor leaks can be incredibly costly, not only in terms of money but also through productivity and efficiency.
For any company that regularly uses a silent air compressor, knowing how to prevent its leaks, how to find a leak and how to fix it in the future can give you enormous benefits.
Finding A Silent Air Compressor Leak
The fact is that not every leak is audible to human ears, and many plants or production lines do not have regular shut-down periods. However, the best thing you can do for your company is to establish a regular leak detection programme in which someone walks through the plant during a non-production period to listen for leaks with noticeable sound.
That could be one of the most straightforward means to check or listen if your quiet air compressor is leaking air. To be on the safer side, an industry should best practice the usage of ultrasonic leak detectors.
To use an ultrasonic leak detector, an operator will have to walk the plant with the unit in hand. Headphones or displays within the detector signal the operator to the precise location of the leaks and because combinations of directional microphones, amplifiers and audio filters allow them to identify high-frequency hissing sounds produced by air leaks.
Additionally, these units have become highly compact and portable with advances in technology. While also investing in one can help you to improve your low noise air compressor leak detection methods. So, ultrasonic leak detectors are sophisticated tools that accurately detect leaks, whether they make a noise audible to humans or not, within loud production environments.
Some components can also be checked in other ways while some can appear throughout your compressor system. But you can more effectively find leaks by listening closely or using ultrasonic leak detectors.
- Drains and condensate traps. When you discover your ultra-silent air compressor leaking water, it could be due to a bad drain. And any loose components or buildup can also indicate problems with airflow and system health. If they start to gather sludge or rust, just maintain them and consider a replacement as soon as possible.
- Tubes. Make it a hobby to always look for rust or cracks within these tubes or even loose connections. Because certain metal tubes that link up certain parts of the silent air compressor systems can also begin to leak anytime.
- Air hoses. To indicate the location of the air leak, lather up some hand soap along with the hoses. Now switch on the system, and look for where you can find bubbles in the soap. This could be achieved when the ultra air compressor has been switched off and its cable has been unplugged.
- Connectors. Always pay attention to connectors. They are often common places where leaks spring up. Ensure you regularly listen for wheezing noises and always check their condition to avoid unprecedented problems.
Also, some areas deserve a little extra care while it is very important to pay attention to the whole system. Leaks can happen throughout a plant — from the source of compressed air to the distribution pipes and the point of usage.
Though the most common problem spots for leaks include: Thread sealants, couplings, fittings, hoses and tubes, cylinder rod packing, control and shut-off valves, pipe joints, open condensate traps, missing O-rings, open blow-off, filters, lubricators and regulators, flanges, leaking or botched drains, worn seals or gaskets, point-of-use devices and disconnects, especially if they are worn.
Additionally, diaphragms are one other area that could be so tricky to identify. For an ultra air compressor system, diaphragms inside a lot of components. To find out if the parts are failing or not working well, you may need to use the elimination method to identify or find the problem. It can become cracked or worn and may require replacement. You’ll most likely find them in a regulator, pressure switches and more.
Finally, another source for energy loss is created by employees if they use air for a purpose which it wasn’t meant for, such as a blower for cleaning or cooling electric control panels or cabinets. Another commonplace to lose silent compressed air isn’t technically through a leak, it can also leak or waste through misuse. It’s best to find or identify alternative use by having your employees use more efficient and appropriate tools for the job they intend to accomplish.
Some of these tools may be cooling units that are intended for electrical panels or cabinets, or engineered nozzles, which are explicitly designed for the task at hand. These tools will also help in removing some loads from your silent air compressor and they also consume less energy. For them to use air power effectively, always ensure that the tools are well-maintained.