While seemingly simple, an unchecked air compressor leak could greatly impact your operational expenses. Luckily, they're quite easy to detect and fix, especially if you invest in equipment with a smart controller like the ES4000 connect.
Even without such tools, you can use other methods for detecting an air compressor leak. If a 10% drop or greater in air pressure is observed, as indicated by gauges and performance, the cause is likely escaping air.
If you notice a significant change in performance, it's important to rectify the problem as soon as possible. Since electricity consumption makes up as much as 80% of owning and operating an air compressor, maintaining optimal performance is important.
Combining this with how the average amount of air lost from leaks is 20%, means significant extra costs for untreated compromised connections. The good news is that since leaks form at valve and pipe contact points, they're fairly easy to spot.
One common method is to apply soap where you suspect air is leaking. If bubbles form, then an air compressor leak is present. As mentioned above, there are also digital tools to monitor and automatically detect leaks. Read on below to learn more about their impact.
How an air compressor leak affects operations
When a leak is present, an air compressor usually works harder to overcompensate for the loss. This added strain increases electricity consumption, as well as adds wear and tear. As an example, a leak of 3/8 inch operating at 100 psig can cost roughly 32,500 EUR a year.
As you can see, regular maintenance and repairs of such problem areas is a worthwhile investment. With this, you'll always want to use OEM parts and services. Replacing compromised components with generic fittings may result in an imperfect connection.
Usually, you'll need to replace pipes, o-rings, seals, and other related parts. Sometimes, air leaks also impact the pressure switch. If there's air escaping around an unloader valve, this will lead to a pressure switch issue.
You may also decide to upgrade or replace your pipe network. With constant temperature changes, high pressure, and constant strain, it's a good idea to check for weak points throughout your air compressor's piping. This is true even if no apparent hole is found.
Digital tools to detect issues
If you'd like a more automatic approach to leak detection, you can invest in an air compressor with advanced monitoring and control. As pointed out in the introduction, the ES4000 connect offers such capabilities.
Available on Ceccato CSM models, it analyzes over 30 data points. With this insight at your fingertips, you can spot problems early - before they become costly. Making this even easier is how the ES4000 connects to mobile devices via Wi-Fi through ICONS.
While keeping your operations running smoothly, it helps you avoid the need for a full system audit. The way the ES4000 connect notices potential leaks is by indicating a change in pressure levels. This isn't too different from checking manually, except you're aware much quicker.
Of course, you can always call in a professional if you need a second opinion. The ES4000 connect is simply a tool to make your service requests more focused on specific problem areas, potentially saving time and money.
Why air treatment is important
In addition to external leaks, you can also run into issues with rust and corrosion from untreated moisture within an air compressor. This can cause internal issues where air is escaping from a worn tank.
Make sure you have a proper air treatment system including the right dryers and filters. Otherwise, you could run the risk of needing to replace the air compressor tank. You can read more on this topic through related articles on dryers, filters, and aftercoolers.
We're here to help
We hope this guide provides enough information on how to spot and address leaks. If you have any questions about the topics we've covered, our team is happy to help. Feel free to reach out today.
