For manufacturing plants and facilities, compressed air, gas, and vacuum systems are essential sources of transformed energy, with quiet air compressors playing a prominent role in the daily operations of the manufacturing industry.
Nevertheless, as they are used frequently over time, they will require maintenance checks, but at what cost would businesses have to pay if they are not maintained regularly?
According to research by Direct Air, air leaks are estimated to waste 20 to 40 percent of produced air in a manufacturing plant, and even a modest air system that is not maintained correctly can cost a firm £2-£7 per day.
It is estimated that UK businesses can lose over £100 million a year due to air leakages and a recent case study showed that companies could save £37,000 each year by fixing their air leaks. It is incredible how much money businesses can save if silent air compressor maintenance is practised regularly.
Benefits of Regular Air Compressor Maintenance
Air loss is a waste of money and energy that may be put to better use in the industrial process, and below are the benefits of regular silent air compressor maintenance.
Fixing your air leaks may save your company a lot of money. Even repairing a single 3mm hole may save you £600 per year, reflected in your energy cost.
Enhance Staff Safety
You’ll want to comply with your area’s safety regulations, including your silent air compressor safety guidelines. The use of air compressor repair and maintenance indicates that the firm places a high value on onsite worker safety.
When your employees work with broken equipment, their safety is jeopardized, and it will cost your company money to get things back in order. As a result, your company’s air compressor must adhere to safety guidelines.
Air compressor maintenance eliminates the risk of injury and guarantees that the equipment is ready for work.
Maintain the machines’ efficiency.
In every sector, downtime is bad for business. Machine performance is hampered by air leaks, which are estimated to squander 25-50 percent of the system’s overall output, and it causes pressure settings to be distorted, resulting in costly repairs.
When your production tempo experiences obstacles, it has a detrimental influence on production pace and earnings. Furthermore, while your rivals send out several deliveries, you’d be left with machine maintenance that could have been handled sooner and for less money.
Reduced Carbon Emissions
Green ecosystems are harmed by air leakage. The term “air leakage” denotes energy wastage. Your company would emit more significant quantities of carbon, which air compressor maintenance might easily avoid. Therefore, we should nourish the earth’s green by acting rather than reacting.
Detecting Air Leaks and Preventing Leaks
The first step in preventing losses due to compressed air leakage is to identify the cause of the problem and take steps to resolve it. Air leaks can lie unnoticed for years, resulting in lost energy expenditures for a long time before the damage is rectified.
Below is how you can detect air leaks.
Keep an ear out for any kind of leaking noise
Although air leaks may be detected with your ears, the accuracy is restricted. Run each piece of equipment separately, then go in closer to listen for leakage noise. Unfortunately, it does not operate during business hours, and you would waste even more time listening for air leaks without success. Finding big leaks is easier; the problem is finding tiny breaches that go unreported.
Using an ultrasonic detector to detect air leaks is one of the most effective methods. These electronic gadgets use a microphone that is tuned to pick up high-frequency harmonics produced by leaking high-pressure gas. The circuitry changes the frequency of the detected signals using the heterodyne principle so that you may hear them through headphones.
Ultrasonic leak detectors can rapidly identify if access is necessary to locate leaks in hard-to-reach places. Operators can rapidly scan air/gas distribution systems with a range of up to 8m, and variants with removable sensors make testing in restricted areas easier.
Laser pointers and graded microphone probes or sensor tips are used in the detectors to pinpoint even the slightest breaches so that you may mark them for later repair.
The area of the orifice and the line pressure is directly proportional to the degree of leakage. The high-pressure lines should be checked first, as they will be the primary source of waste, and Low-pressure systems will necessitate more extensive testing due to the difficulty in detecting leakage.
You may buy or employ professionals to check for air leaks, even during business hours. Although in-house employees may handle the sensor, it is advisable to hire a professional.
To begin, combine water and soap to form a lather. Soak a sponge in the liquid and use it to clean the pipes on all of the equipment. This method takes time and is incorrect when compared to what professional air compressor services can provide. If there are air leaks, the lather will generate bubbles in the leaking area.
Investigate the Area
You can discover air leaks by looking around the machinery. One way is to produce lather by mixing water and soap. Examine where the lather bubbles up by applying the mixture to the pipe with a sponge, including the valves, flanges, and joints. The problem with this method is that it takes a long time and is incorrect.
When a company’s air compressor experiences a significant drop in air pressure, productivity does a U-turn and begins to decline. Air leaks result in a considerable reduction in output. Furthermore, you’d see higher carbon emissions, which would slow down manufacturing.
To ensure optimal performance, do routine maintenance. Most of today’s air leak treatment businesses provide flexible and customized solutions to fit your company’s specific requirements.