Importance of Leak Detections

Compressed air leaks are an extremely costly issue when it comes to compressed air. Leaks provide a significant source of wasted energy, wasting as much as 20%-30% of your compressor’s output! Aside from wasted energy, output, and cost, leaks can also create other problems within your system, including but not limited to:

• Fluctuating system pressure that can cause inefficient operations that can affect production lines
• Excess compressor capacity which also increases costs
• Shorter service lifespan of your compressor with an increased need for maintenance and possible repairs due to unnecessary cycling and increased run times

While some leaks are easy to spot, others are more discreet but still pose a major threat to your operations. Ultrasonic leak detections are a thorough, effective way to detect problem areas to be repaired quickly. These leaks can occur at any point throughout the system, but they are especially prone to couplings, hoses, tubes, fittings, pipe joints, quick disconnects, filters, regulators, lubricators, condensate traps, valves, flanges, packings, thread sealants, and point-of-use-devices.

Leakage rates will be unique to each system and its application. These rates are directly related to the supply pressure, meaning as system pressures increase, if there is a leak, the leakage rate will also increase. These rates are measured in cfm (cubic feet per minute) and are proportional to the square of the orifice diameter.

The Process

As mentioned above, ultrasonic leak detection is the best way to accurately locate all leaks within your system. An ultrasonic acoustic leak detector is used to recognize high frequency hissing sounds that air leaks can cause. This is especially helpful when the hissing noise is unnoticeable to the human ear.

A Zorn Compressor Technical Solutions Group (TSG) expert will bring the portable leak detector to your facility and complete a full leak detection which includes identification, tagging, and logging of all compressed-air leaks. A thorough report will then be compiled and shared that quantifies the leaks and provides recommended repairs and next steps. If applicable, it will also detail possible energy incentives available from local energy companies that Zorn Compressor & Equipment is in partnership with. You can learn more about these incentives in our blog post: Increasing Energy Efficiency While Using Compressed Air, or contact us today!

Ideally, this program is aimed to reduce leak loss to less than 10% of your compressed air demand.

The Result & Repair

The detailed report mentioned above will establish your current leak loss, while estimating the current annual cost of those leaks based on your energy costs. The report will include your quantified leak loss, provide a complete list of leaks, prioritize the severity of each leak, and provide space for all repair documentation. Our experienced technician will also assist in completion of the proper paperwork to qualify your facility for local energy incentives upon completion of the leak repairs.

For any tagged leaks in accessible areas such as pipe fittings, poly tubing, quick connects, hose connections FRLs, and auto drains, a trained Zorn technician can repair onsite with little to no downtime. For any leaks that are integral to the production equipment, the Zorn technician may need to shut down your machine and order the necessary parts to complete the full repair.
Depending upon the local energy companies and their contract rules, continuously performing leak detections and repairs on an annual basis may qualify you for annual incentive savings as well- rather than just a one-time incentive! These incentives are paid directly to the customer upon completion of their program’s requirements.

Zorn’s Perspective

Zorn Compressor & Equipment hopes to provide the most efficiently operating compressed air systems for both current and future customers. We want to save you energy and money, while also decreasing the carbon footprint that compressed air operations leave in our world.

Our Leak Detection program is efficient and accurate, providing a full scope of all problem areas and recommended repairs. All our Leak Detection technicians are expertly trained and have extensive experience performing these energy saving audits. Contact us today to learn more about the program, obtain pricing, and to schedule a visit with our Zorn experts!

ZORN'S PROMISE

Zorn is the Midwest leader of custom, engineered compressed air and vacuum solutions. We provide the best customer experience by understanding your applications and needs and offering an unparalleled commitment to customer satisfaction. 

Our comprehensive product and service solutions keep you running 24/7.

• Reliable equipment
• Trusted brands
• Seamless, easy installation
• Post-sales support
• Local, 24/7 service

Our compressed air experts look forward to meeting you to discuss your equipment and support needs. Please contact us directly at (262) 695-7000 with any questions or to schedule service for your system moving forward.

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