Reducing air leaks is the single most important energy-saving measure that can be performed. The leak rate on an unmanaged compressed air system can be as much as 40% of the output.
Compressed air leaks also lead to additional costs through:
- Fluctuating system pressure, which can cause air tools and other air-operated equipment to function less efficiently — potentially stalling and affecting production.
- Reduced service life and increased maintenance of equipment due to unnecessary compressor cycling and running time.
- Excess compressor capacity. The sources of leakage are numerous, but the most frequent causes are:
- Manual condensate drain valves left open.
- Shut-off valves left open.
- Leaking hoses, couplings, pipes and pipe joints.
- Leaking pressure regulators.
- Air-using equipment left in operation when not needed.