KAESER Compressors - compressed air pipework

Compressed air leak management

Detection is half the battle

June 2024

Sustainable compressed air station operation begins with the details. Even the smallest leaks in your compressed air system cause continuous unnecessary energy losses, increase the running times of your compressors, and therefore reducing maintenance intervals. This not only burdens the environment but can also become quite costly. In our blog post, we provide you with valuable tips on how to effectively prevent costly compressed air leakage losses.

Even new, well-maintained compressed air networks can experience compressed air losses of around 15-20% – with older networks, this can quickly rise to 30-40%. Consequently, leak protection measures save considerable amounts of energy and money, whilst preserving compressed air generation and providing preventative maintenance.

Replacement of faulty components

Leaks may be found in any part of a compressed air network. However, those occurring at the beginning of the network tend to make up the majority of cases. For example, leaking plug-in couplings, hoses and valves, or defective tools, all cause significant air losses. Simple replacement of faulty components can result in considerable energy savings.

But ageing pipework can also lead to problems – leaks occurring here often go unnoticed and needlessly increase compressed air consumption and therefore energy costs. Professional leak detection is the solution here, as it identifies and locates leaks.

Compressed air leaks result in high annual costs

KAESER Know How: what are compressed air leaks costing you?
Leakage costs within one year. Basis for calculation: 365 days x 24 h/day = 8760 h/year, 0.15 NZD/kWh, Specific package input power of compressors 6.0 kW/m3/min

And this is how leak management works at KAESER:

  • Analysis and assessment
    Our experienced service technicians inspect your compressed air pipe network on-site. Following a comprehensive assessment of the savings potential, the necessary measures are planned on an individual basis.
  • Detection and marking
    You don't need to do anything – our service technicians ensure a seamless and interruption-free process during ongoing operation. For this purpose, state-of-the-art ultrasonic measurement technology is used to perform leak detection and assessment.
  • Professional reporting
    As a basis for the repairs, you will receive detailed descriptions in accordance with ISO 50001. Forecast savings are provided in kWh, NZD, and CO2. Photo documentation is also created.

  • Support for repairs
    Initial measures for leak minimisation can already be implemented during the detection process. We are available to provide guidance and support for sustainable leak elimination at any time.
Compressed air leak detection with Kaeser Compressors
KAESER service technicians use state-of-the-art ultrasonic measurement technology.

KAESER's compressed air leak management offers several advantages: Leak detection can be carried out at any time without the need for production downtime. These measures not only ensure significantly increased compressed air station reliability, but also result in a noticeable reduction in compressed air consumption and, therefore, energy costs. Furthermore, your compressed air station is subject to less burden, leading to longer maintenance intervals and extended service life.

For sustainable energy savings, we offer leakage maintenance contracts. This means that we conduct comprehensive leak detection at regular intervals. You don't have to do anything other than save energy and money.

Enquire today!

Compressed air leak detection and management

Find out more about compressed air leak detection and management with Kaeser Compressors and discover your energy savings potential! Just phone 0800 447 820 or fill in the form below and we will get back to you.

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