Compressed Air Leak Detection Survey By Sunrise House Hulley Road Macclesfield Cheshire SK10 2LP Tel: +44 (0)8456 042 703 Web: Email: info@pixelthermographics.co.uk
Survey Information This sample report has been issued to provide an example as to the layout, content and quality of our compressed air leak survey service. A UE Systems Ultraprobe 3000 Ultrasonic Leak Detector was used to capture the Ultrasonic data which is recorded within this report. Where equipment was surveyed and no leaks or faults were found then no data is recorded i.e. individual reports are generated by exception. Some areas of particular interest may be included which the surveyor feels may be of particular interest to the client. Descriptions of equipment and locations have been noted as those in common usage within the client s premises. Follow up work including remedial work and investigations into causation etc. or any other factors outside the control of are not the responsibility of and are not covered by this contract. Where have been unable to inspect equipment or plant which is covered, unexposed or inaccessible, we are therefore unable to report that any such system components are free from defect. Areas un-inspected are highlighted in the scope pages of this report. To assist the Engineering Management to maintain plant efficiency, it is recommended that the survey is repeated on a twelve monthly basis. This report is an indication of the condition of the equipment inspected at the time and date of survey only. Signed: <<<<<<<<<<<<<< Date: Surveyor Disclaimer: Please note that the report contained herein represents the observed conditions at the time of inspection. accepts no liability for faults that have occurred during or after the completion of the inspection. The recommendations given in this report are intended as a guide only. By issuing this report neither Pixel Thermographics Ltd nor any of its employees make any warranty, expressed or implied, concerning the contents of this report. cannot accept responsibility for inappropriate actions taken as a result of this report. 2 (27)
Scope of Survey The scope of this survey was to carry out a compressed air leak survey across the site on all areas where compressed air systems are located. This encompassed internal and external areas throughout the site which were made accessible by the client. Report Data A summary of all ultrasonic data is contained in the report pages that follow. The pages in this report have been designed as single page entries, each of which carries its own information so that individual pages can be given to the relevant professions in order that they may carry out any remedial repairs that may be necessary. Compressed Air Leak Surveys All compressed air systems are subject to mechanical deterioration at connections, flexible pipes, regulators, valves etc due to looseness, over-tightening, corrosion and contamination. If these conditions remain uncorrected further deterioration will occur resulting in equipment failure and leakage of expensive compressed air. Compressed air is not free and it costs hard earned revenue to generate with the following costs being part of the generation process: Compressor Cost (Purchase) Electricity costs Generation Efficiency Cost Air Drier running costs Maintenance costs Equipment deterioration As such compressed air is one of the most costly utilities in a facility today. A simple program of leak inspection and repair can go a long way towards reducing excessive energy costs. Air Supply Data Used For the purpose of compiling this report we have taken the air supply pressure to be 7.0 BarG and the annual compressor usage to be 24 hours a day for a seven day week with a 52 week working year which gives us an annual compressor running time of 8736 hours. 3 (27)
Leak Levels and Ratings This survey has been designed to assess the performance of all compressed air generation, distribution and equipment on site and to highlight any areas which require attention. To assist in the prioritising of repairs we apply a severity rating (level) based on the results of the leak detection survey. The severity levels are ranked as follows: Level Leak Size in CFM: Minimum Maximum Leak Description: 1 0.01 0.50 Small 2 0.50 1.50 Medium 3 1.50 2.50 4 2.50 4.00 5 4.00 6.00 6 6.00 8.00 Large 7 8.00 10.00 8 10.00 15.00 9 15.00 25.00 Very Large 10 25.00 100.00 Leak Costs We calculate individual leak costs based on the following information provided by the client and from compressor data: Detail Value Cost of Electricity (p/kwh) 9.4p Compressed Air Generating Efficiency (kw/100cfm) 21.15 Generating Pressure (BarG) 7 Hours of Operation per Year (Hours) 7488 4 (27)
Leak Identification Number: Cost Benefit Analysis 10oz Area Size of Leak in CFM: Cost of Leak per Annum : 1 0.5 74.43 2 1.5 223.30 3 1.5 223.30 4 0.5 74.43 5 4.0 595.48 6 4.0 595.48 7 4.0 595.48 8 1.5 223.30 9 2.5 372.17 Total Overall value of Air Loss 2977.37 Leak Identification Number: Cost Benefit Analysis SIG Area Size of Leak in CFM: Cost of Leak per Annum : 1 6.0 893.21 2 6.0 893.21 3 0.5 74.43 4 1.5 223.30 5 2.5 372.17 6 0.5 74.43 7 2.5 372.17 8 1.5 223.30 9 2.5 372.17 10 0.5 74.43 11 0.5 74.43 12 1.5 223.30 Total Overall value of Air Loss 3870.59 The above tables provide a summary of the individual leak costs and subsequent total annual cost of wasted compressed air leak generation. Larger leaks or inappropriate uses of air should be targeted first to rapidly reduce costs associated with wasted compressed air generation. 5 (27)
Summary of Air Leaks Detected Ultrasonic leak detection equipment was utilised to locate and measure air leakage from compressed air systems. Below is a summary of all leaks found: Leak No. Area: 10 oz Leak Details: Level: 1 10oz - Bottle filler filters No access from ceiling 1 2 10oz - Labeller reject Jubilee clip on filter housing knocker 2 3 10oz - Prasmatic middle Threaded union onto filter filter housing 2 4 10oz - Beginning of labeller Threaded union on hand gun hand blower 1 5 10oz - Above bottle lid Threaded joint on pressure gauge machine 4 6 10oz - Feed to bottle filler Push fit 4 7 10oz - Lid dryer Permanently on even when line has paused 4 8 10oz - Glue tub sucker Threaded union on solenoid 2 9 10oz - Barcode label dryer Permanently on even when line has paused 3 Leak No. Area: SIG Leak Details: Level: 1 SIG - Main product tank Top of filter housing 5 2 SIG - Lid blower near Blower permanently on with no product inspection scales 5 3 SIG - Caged area near Push fit onto solenoid broken bottle bin 1 4 SIG - Pump side of oven Threaded joint onto valve control half way along 2 5 SIG - Conveyer side of oven Hole in pipe near weighing machine 3 6 SIG - Conveyor side of oven Threaded joint on solenoid near front 1 7 SIG - Conveyor side of oven Filter housing near front 3 8 SIG - Feed to labeller Push fit to T 2 9 SIG - Reject pusher before Push fit into filter housing pallet machine 3 10 SIG - Dud detector filter Push fit into filter housing 1 11 SIG - Detector after labeller Jubilee clip on main feed 1 12 SIG - Glue tub sucker Solenoid housing 2 6 (27)
10oz Bottle filler filters 1 No access from ceiling 1 Annual Cost of Leak: 74.43 7 (27)
10oz - Labeller reject 2 Jubilee clip on filter housing knocker 2 Annual Cost of Leak: 223.30 8 (27)
10oz - Prasmatic middle 3 Threaded union onto filter filter housing 2 Annual Cost of Leak: 223.30 9 (27)
10oz - Beginning of 4 Threaded union on hand gun labeller hand blower 1 Annual Cost of Leak: 74.43 10 (27)
10oz - Above bottle lid 5 Threaded joint on pressure gauge machine 4 Annual Cost of Leak: 595.48 11 (27)
6 10oz - Feed to bottle filler Push fit 4 Annual Cost of Leak: 595.48 12 (27)
7 10oz - Lid dryer Permanently on even when line has paused 4 Annual Cost of Leak: 595.48 13 (27)
8 10oz - Glue tub sucker Threaded union on solenoid 2 Annual Cost of Leak: 223.30 14 (27)
10oz - Barcode label 9 Permanently on even when line has paused dryer 3 Annual Cost of Leak: 372.17 15 (27)
1 SIG - Main product tank Top of filter housing 5 Annual Cost of Leak: 893.21 16 (27)
SIG - Lid blower near 2 Blower permanently on with no product inspection scales 5 Annual Cost of Leak: 893.21 17 (27)
SIG - Caged area near 3 Push fit onto solenoid broken bottle bin 1 Annual Cost of Leak: 74.43 18 (27)
SIG - Pump side of oven 4 Threaded joint onto valve control half way along 2 Annual Cost of Leak: 223.30 19 (27)
SIG - Conveyer side of 5 oven near weighing Hole in pipe machine 3 Annual Cost of Leak: 372.17 20 (27)
SIG - Conveyor side of 6 Threaded joint on solenoid oven near front 1 Annual Cost of Leak: 74.43 21 (27)
SIG - Conveyor side of 7 Filter housing oven near front 3 Annual Cost of Leak: 372.17 22 (27)
8 SIG - Feed to labeller Push fit to T 2 Annual Cost of Leak: 223.30 23 (27)
SIG - Reject pusher before 9 Push fit into filter housing pallet machine 3 Annual Cost of Leak: 372.17 24 (27)
10 SIG - Dud detector filter Push fit into filter housing 1 Annual Cost of Leak: 74.43 25 (27)
SIG - Detector after 11 Jubilee clip on main feed labeller 1 Annual Cost of Leak: 74.43 26 (27)
12 SIG - Glue tub sucker Solenoid housing 2 Annual Cost of Leak: 223.30 27 (27)