Compressed Air Leak Audits

Compressed air is an essential utility in many industrial applications, and it is widely used to power various machines and equipment. However, it is not uncommon for compressed air systems to have leaks, which can result in significant energy waste and increased operational costs. These leaks are often difficult to detect and can go unnoticed for extended periods, leading to substantial financial losses for the company.

To address this issue, compressed air leak audits are conducted to identify and repair leaks in the system, which can lead to significant energy savings and improved efficiency. The audit process involves several steps, including a site visit, leak detection, reporting, repair, and rebate application.

During the site visit, an experienced team will assess the facility to determine the proper course of action and generate a quote for the leak detection process. After that, the team will use specialized equipment to locate and tag all leaks in the compressed air system. The team will then generate a report that shows the number and location of each leak, the CFM of each leak, and the estimated annual cost of each leak.

Once the report is generated, the team will work with the facility to coordinate the repair of the leaks. Energy companies typically require the repair of at least 50% of all leaks, but it is highly recommended that all leaks be repaired to maximize energy savings. Repairs can be made by the facility’s maintenance team or by the team conducting the leak detection audit.

After the repairs are completed, the facility can apply for rebates offered by energy companies for leak repairs. These rebates vary depending on the energy provider, the HP of air compressors, and the CFM of the detected and repaired leaks. For example, DTE offers a rebate of $27.00 per CFM for fixed-speed compressors and $42.00 per CFM for variable-speed compressors.

While rebates can be a significant incentive, the value added by repairing leaks is even greater. Every CFM of air leakage can waste up to $232.00 in energy costs, depending on the number of shifts a facility runs. Thus, the total value added per CFM of repaired leak can be up to $274.00. Considering that typical audits locate 100-300 CFM in leaks, the potential savings for a facility can be substantial.

In conclusion, compressed air leak audits are an essential process for industrial facilities that use compressed air systems. By identifying and repairing leaks, these audits can result in significant energy savings, improved efficiency, and lower operational costs. Additionally, rebates offered by energy companies can provide a further incentive for facilities to invest in leak detection and repair.