Compressed air as most of us know is mainly used in industrial settings and is considered to be a fourth utility. Unlike other utilities such gas, electricity and water, compressed air is also considered an expensive one. If you are someone who wants to get the best performance when it comes to your air compressor and the air system you must look at both the supply and demand. Air leaks actually make up the biggest demand in most industries so it’s important to be able to spot air leaks, what kind of air compressor repair you have to make, and how to fix them. Fixing all the leaks at one time will not stop your problem, the best plan you can make is with routine checks and learning how to identify leaks so you can keep the standard up to optimal levels.
So well all know that compressed air that leaks can cause great strain on your industry financially, but did you know that there are many more damages that go unaccounted for? Air leaks can result in a drop of pressure in certain tools, this can make them function less effectively which ultimately drops productivity ratings. Air leaks also mean a higher demand so the entire system is cycling more frequently which reduces the lifespan of the entire compressed air system which means replacing the system more frequently. Of course, the more you have to replace the system the more your maintenance bills will be. If you are a business owner then you know higher maintenance means higher downtime which basically means the more time you spend on maintenance the less time you will have for production.
So how do you identify and fix the problem? The best way to do this is to establish a routine or program that can detect leaks in the first place. One way to do this is to walk around the air compressor system and detect noticeable sounds but keeping in mind that not all leaks are noticeable. So the next step you can take is installing an ultrasonic leak detector. As the detector identifies leaks put a tag in those locations so you can record them and keep them in a maintenance log. This tool can detect high pitched hissing sounds that the human ear cannot. It requires an operator to walk around with headphones and a display connected to the detector to find where leaks may be coming from. Fixing leaks are not the cheapest, so it’s important to stick to a general rule of thumb. The leaks with the biggest openings should be fixed first, then you can move on to the smaller ones.
Air leaks can happen in so many different places but it’s important for you to know that some places are more prone than others. Some of these places may include air hose connections, open blow-offs, control panels, electric panels, places where thread sealants are placed, worn out disconnects, disconnects that are missing o rings, unused or idle machines, filters, lubricators, regulators, old pneumatic tools, leaking drains, worn out seals or gaskets, and shut-off valves. Sometimes you can stop a leak by tightening the point of connection, or making sure that the part has been assembled and installed correctly. Other times, however, old equipment may simply need to be replaced.
Remember that the most important part to avoiding compressor repair is setting up a maintenance program that should be performed on a regular basis. You must make sure that the owner and all employees understand the procedure to identify leaks, this ensures that everyone knows what to look for and helps provide minimizing maintenance costs. Sticking to the schedule may seem difficult at first but over time, it will feel just like any other part of the job.
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