Air leak detection in compressed air

All compressed air systems have leaks. The average leakage rate is approximately 25% but some plants lose as much as 80% of their compressed air due to leaks. A single 3mm diameter leak can cost up to £600 a year.

While it may not be practical to eliminate all leaks, it is not difficult to greatly reduce and minimise them. The percentage lost to leakage should be less than 10% of your total compressed air production. A well-maintained system with a proactive leak detection programme in place should allow you to achieve this.

In addition to being a source of wasted energy, leaks can also contribute to other operating losses. By forcing the equipment to cycle more frequently, leaks shorten the life of almost all system equipment (including the compressor package itself). They cause a drop in system pressure, which can make applications run less efficiently, adversely affecting production.

Increased running time due to air leaks can lead to additional maintenance requirements and increased unscheduled downtime. Finally, leaks can lead to increasing compressor capacity unnecessarily.

BCAS specialist engineers have extensive knowledge of compressed air systems and our state-of-the-art ultrasonic testing equipment provides accurate results to allow us to identify and quantify all air leaks – many of which are not audible. Our comprehensive leak assessment and repair programme can vastly improve the operation and efficiency of your facility and generate significant financial savings.

The benefits of an air leak detection audit:

Reduced energy consumption
Cost savings
Short payback period
Less environmental impact
Improved reliability
Prolonged equipment life
Production lines operate more efficiently and to their optimum capacity
A pro-active process that can be planned and timed
Equipment runs more quietly leading to more comfortable working conditions

Common causes of leaks in a compressed air system:

While leakage can come from any part of the system, the most common problem areas are:

Couplings, hoses, tubes, and fittings (tubes and push-to-lock fittings in particular)
Disconnects: O-rings required to complete the seal may be missing.
Filters, regulators and lubricators (FRLs): Low first-cost, improperly installed FRLs often leak.
Open condensate traps: Improperly operating solenoids and dirty seals are often problem areas.
Pipe joints: Missed welds are a common problem.
Control and shut-off valves: Worn packing through the stem can cause leaks.
Point of use devices: Old or poorly maintained tools can have internal leaks.
Flanges: Missed welds are a common problem.
Cylinder rod packing: Worn packing materials can cause leaks.
Thread sealants: Incorrect and/or improperly applied thread sealants cause leaks.
Bag houses

BCAS specialist engineers use the latest ultrasonic testing equipment to identify and quantify all air leaks, many of which cannot be easily detected by the human ear.

Once a system has been logged and leaks have been identified and tagged, a detailed report is produced, outlining the extent of the losses and the recommended works.

And if you wish, BCAS can then carry out the necessary leak repairs. In fact, BCAS can manage the entire process for you and can even incorporate it into an overall energy efficiency programme for your compressed air system.

To find out more about how we can help you to maximise the efficiency of your compressed air equipment and reduce your energy costs, contact the BCAS team today.

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“We were extremely impressed with the two gentleman who attended recently when we had a fault with our compressed airline system. I always remember companies who give a good, professional service/value for money, and on this instance they attended our site promptly and conducted themselves in a very safe and professional manner. The problem was soon rectified and they even showed us the faulty part explaining what had caused the fault.”

Dave H, Google

"We required a company to maintain our plant assets in the form of compressors. BCAS Ltd have proved to be an excellent choice. We recently required an engineer to call to site and diagnose a fault and carry out repairs to enable the plant to keep running. From our first initial call at 8.15 am and on other previous occasions, BCAS staff immediately took ownership through people like Helen, Hannah and Molly, assuring me that an engineer would be on their way as soon as possible to look at the fault. Engineers who also visit site for maintenance and call outs are also very friendly and pleasant. Our overall experience of BCAS is outstanding."

Lawrence W, Yell

"Quick response time, great customer service, professional approach. Have always looked after us, putting the 24 hour running of our site as there main priority. Highly recommended. Steve and his team are credit to the company."

David T, Yell

"Excellent work done by the engineer. He was very polite and explained from the start to end how to keep maintained the air compressor. He also suggested what needs to be done in case the compressor gets over heated. He was very efficient in quality of work and completed in within an hour."

Pankaj B, Yell

“I have used this company for many years and have had outstanding service from them, the staff who work for them are diligent and friendly. Competitive several years ago when I needed a new system installing. Faultless with current servicing.”

Brian V, Yell

"Our compressor broke down at the most crucial time - we had orders to fill and we were at a stop. Rung BCAS and spoke to Helen who quickly established what we required - sourced our replacement and organized payment and collection of item. We know who to use next time and highly recommend BCAS"

David S, Yell

“We had an urgent and service critical issue with one of our compressed air systems and BCAS Ltd responded immediately, professionally and resolved the issues whilst we waited for full replacement of our systems. BCAS supplied us with an immediate temporary solution that met our requirements and kept our services operational whilst we waited for a new unit. A great and professional service throughout the whole job, from callout through to new installation.”

Akin M, Yell

“Excellent service provided. Kept me fully informed of when the work would commence and delivered on time. Would def use this company again.”

Neal G, Yell

"Extremely professional and truly genuine professionals. Fantastic service. Now a repeat customer."

Charles G, Yell

“BCAS were invited to quote for a compressor/vac system installation for a new composite dept. They were quickly able to understand the requirements for the job and even suggested ways in which cost could be saved by using alternative components. Their quote was submitted in a timely manner and was very competitive. We needed to make several changes to the specification near the date of commencement, which was dealt with quickly and efficiently by the installation team. A job well done!”

John H, Yell

“Having used a competitor for a significant number of years, we were sceptical. However, after several service visits, these unfounded concerns disappeared, and BCAS Ltd's attention to detail above and beyond the original remit has proven refreshing."

Will B, Yell

“BCAS Ltd are knowledgeable and very customer orientated. They have always been very helpful and prompt whenever we needed their help.”

Dion B, Yell.com

“We called upon the services of BCAS to address a complex compressor issue, with extremely tricky access. Steve Pritchard promptly came up with a quick and workable solution, at a VERY affordable price. A full pre-install survey was undertaken. On day of install, Steve and the team arrived promptly, and within a short time, all was up and running. A very slick, professional, responsive and very intelligent team, who have surpassed my expectations repeatedly. Very impressed, and HIGHLY recommended!”

Maroon R, Yell

“We have worked together with BCAS for over 7 years and could not ask any more of them as a supplier! They have always listened and responded to our requirements, providing reliable and timely solutions to meet our business needs. In the rare cases where we have needed urgent support they have been extremely responsive and resolved the issue with minimal impact to our business. The service staff they employ are always diligent and helpful during their time on site, always ensuring that they complete the work to a high standard, as quickly as possible. We look forward to a continuing our trading relationship with BCAS for many years to come”

Tom B, Yell

“May I please take this opportunity to commend the BCAS Ltd technician, Will, who has come out to us a couple of times in the past. He has shown the company in a very good light.”

PTCPI, Yell

“We have used the services of BCAS on a number of clients' sites and found that they offer, not only vast amounts of experience in the services they provide, but are also an extremely professional company who bring excellence as standard. I would recommend BCAS to anyone who is serious in the search for professional compressed air services assistance and values customer services and delivery”

Vinci Facilities, Yell

“A good solid company with a wide variety of services and good communicators. Always available with advice and solutions to problems in my industrial environment, delivery of parts and services always prompt, in fact, BCAS are my 'get out of trouble' people.”

Jeff R, Yell

“My company, British Motor Heritage Ltd, had got into a major manufacturing problem as our essential compressors had both broken down. BCAS had a suitable replacement in stock, and the purchase, supply and fitting were all completed in a very timely and efficient manner. BCAS are an excellent company to do business with.”

John Y, Yell

“We have used BCAS Limited for over 20 years to supply and service our compressed air systems. BCAS are a great company to work with, they always get the job done on time and with no fuss, their customer support is second to none, and I would highly recommend them to anyone looking for a professional, knowledgeable and reliable provider.”

Peter W, Yell

“As a company, we have been using BCAS for a number of years and have found them to be very prompt and efficient. There have been occasions when an emergency has occurred and they have come to our rescue, we rely on our compressor to be working and have not been let down. Their service engineers are knowledgeable and friendly guys who don't try to blind you with jargon, and show you where and what the fault is rather than just tell you. Their scheduled maintenance programme is always on time. As with every business, cost is a factor, and we have found them to be reasonably priced and, as they say, you get what you pay for and we are very happy with what we pay.”

Danny M, Yell

“Great company to work with. Good communication and friendly staff”

Terry H, Yell

“We have been using BCAS Ltd., for installation and servicing of our various compressors for over 30 years. In all that time I have found their engineers and office staff to be friendly, efficient and always ready to help in a timely fashion with the inevitable mechanical problems. I would not hesitate to recommend BCAS.”

Lynn H, Google

“What fantastic service. Called BCAS on Monday with a compressor issue. Within 24 hrs the engineer attended site and speedily had us up and running the same day. Thank you.”

David P, Google