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Approximate estimates of losses per year for compressed air and nitrogen have become staggering. A conservative and slightly out-of-date estimate for the cost per year of one 1/8" compressed air leak is £996. Finding and repair just one leak of this size in each of the production areas on-site would result in significant savings.
Compressed air actually costs more than electricity, steam and water at most sites, and leakage has been estimated at approximately 50% of the total consumption of compressed air in a typical plant.
Figures for nitrogen leaks are even higher: just one 1/16" nitrogen leak can easily cost in excess of £16,000 per year. In addition, hydrocarbon leaks waste energy, pollute the environment and can create a serious safety hazard on-site.
Ultrasonic instruments are often considered the most appropriate detection method for leak detection of this nature, as they can detect leaks from distance and in noisy environments. This method is also far less time-consuming than alternative solutions, such as the messy 'soapy water' technique.
These instruments work by detecting turbulence generated at the leak site, which is produced as the gas escapes to atmosphere. As ultrasound is above our human range of hearing, these detectors can be effectively used in noisy plant conditions to check air cooling lines, condensate drain valves, couplings, hoses, joints and pipes.
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