In industrial settings, air leaks can lead to substantial energy waste—often accounting for 20–30% of a compressor’s total output. Facilities that have not been properly maintained frequently experience leak rates of around 20% of their total compressed air capacity. However, by actively identifying and repairing leaks, these losses can be minimized to under 10%.
We Locate and Repair Compressed Air Leaks – Promoting Energy Efficiency Across Your System
Frequent Leak Locations Include:
Control and isolation valves
Hose assemblies, couplers, and tubing
Cylinder rod seals
Quick disconnects, especially if O-rings are damaged or missing
Filters, regulators, and lubricators
Pipe flanges
Faulty or poorly installed drains
Uncontrolled air blow-offs
Open or malfunctioning condensate traps
Piping connections and joints
End-use equipment
Thread sealing materials
Degraded gaskets and seals
Hole Diameter (mm) | Equivalent Hole Quantity of Air Lost (L/s) | Annual Energy Waste (kWh) | Annual Cost of Leaks (PKR) |
---|---|---|---|
0.4 | 0.2 | 133 | 2184 |
0.8 | 0.8 | 532 | 8904 |
1.6 | 3.2 | 2128 | 35784 |
3.2 | 12.8 | 8512 | 142968 |
6.4 | 51.2 | 34040 | 571872 |
12.7 | 204.8 | 136192 | 2287992 |
Piping Material Features Comparison |
|||
Piping Features | Stainless Steel(Type 304L) | Mild Steel | Blue anodized Aluminum Alloy |
Weight (Dia 6inch, Length 6m) | 127.2 | 169.6 | 29.142 |
Anti-Corrosive | Yes | No | Yes(100%) |
Pressure drop (Dia 2 inch Length= 20m, Airflow=3 cubic metres/Minute, Pressure=10 bar) | 0.25 | 0.4 Bar | 0.1 |
Efficient Energy Use | High | Low-moderate | High( Potential Cost savings of 34%) |
Structural Durability | Very Strong | Very Strong | Strong |
High Thermal Endurance | Yes | Yes | Yes |
Installation Ease | Less Difficult | Difficult | Easy(High Flexibility and Modularity) |
Simple Installation | Approx 6 feet length per hour | Approx 6 feet length per hour | Approx 45 feet Length per hour |
Manpower and Work Hours Needed for 2″ Pipe Over 3000 Feet | Approx 600 man-hours/8 men for 2 weeks | Approx 600 man-hours/8 men for 2 weeks | About 100 man-hours with 8 workers, completed in under 2 days |
Annual Charges for Installation, Commissioning & Operation | Approx 3000 dollars | Approx 7820 dollars | Approx 1300 dollars |
Installation Cost Breakdown: Material % / Labor % | 30% / 70% | 25% / 75% | 80% / 20% |
Texture of Surface | 0.03 | 0.05 | 0.001 |
Required Specialized Tools: Welder, Threader, Groove Cutter | Yes | Yes | No |
Quality of Air | High — When needed, these pipe systems comply with ISO 8573-1:2010 air quality standards | Low( Not according to !SO 8573-2010 air quality standards) | High — These pipe systems support compliance with ISO 8573-1:2010 air quality standards when required. |
Cost Rate per Meter | Almost 2 less than Aluminum | 3 Times less than Aluminum | 163.64 Dollars |
Service Life Depends on Environment, Pipe Design, and Grade | 30 years | 40 years | 20 years |
Upfront Installation Cost | Material : 30% Labor:70% | Material : 25% Labor:75% | Material : 80% Labor:20% |
Care and Maintenance | Difficult — Rust buildup under pipes and fittings can reach machinery, requiring weekly preventive maintenance. | Difficult (Accumulation of rust under pipes and fittings which travels to machinery may require preventive maintenance every 3-4 days) | Easy — No rust buildup, with preventive maintenance needed every 4 weeks. |