Compressed Air leak Detection Services
Advantiv made one of the UK’s largest and most well known food manufacturers aware of the potential costs associated with compressed air production and ultimately the losses incurred through leakage in the system.
Following meetings and a demonstration of our reporting and leak management system, the client placed an order to carry out a complete survey of their entire site.
Results can be seen on the following pages. During the survey it was quite apparent that significant losses were being seen and that huge energy savings could be made after advised rectification works were carried out.
Results
Over the 6 days of our survey we identified £101,147 worth of annualised losses in compressed air leaks on the client’s site. A random more detailed sample of the larger leaks showed that this figure was factually nearer £135,267. These figures are relatively conservative as was shown by the random sample of larger leaks. If the average size leak had been applied to the whole survey the leakage cost would have risen to £500,650, this is not an unrealistic figure. The figures used are based on those advised independently by the Carbon Trust and backed up by BCAS.
Leakage Detection Survey 1
|
Extent
|
1
|
2
|
3
|
Total
|
Annual leakage £
|
Volume %
|
Rep. hours
|
Rep. time
|
|
Area 1
|
4
|
18
|
22
|
44
|
14 880
|
15
|
15
|
14
|
|
Area 2
|
0
|
0
|
5
|
5
|
2 891
|
3
|
2
|
2
|
|
Area 3
|
1
|
5
|
9
|
15
|
5 801
|
6
|
9
|
9
|
|
Area 4
|
1
|
0
|
7
|
8
|
4 067
|
4
|
2
|
2
|
|
Area 5
|
1
|
2
|
4
|
7
|
2 564
|
3
|
2
|
2
|
|
Area 6
|
1
|
1
|
3
|
5
|
1 870
|
2
|
3
|
2
|
|
Area 7
|
1
|
21
|
29
|
51
|
19 215
|
19
|
19
|
19
|
|
Area 8
|
7
|
25
|
81
|
113
|
49 860
|
49
|
49
|
49
|
|
Total
|
16
|
72
|
160
|
248
|
101,147
|
100
|
100
|
100
|
Total number of leaks
248
Leakage volume (m3/yr)
6,743,112
Leakage Cost
£101,147 pa
Tonnes CO2
447 pa
As well as identifying, tagging and grading the leaks, we provided the client with the data taken to allow them to self administer and manipulate the results enabling them to identify the leaks in list of priority, those that were able to be repaired during/not during in production and producing a full list of the spares and parts required to carry out the repairs amongst many other benefits. By inputting repaired leak data back into this report the client gets real-time visibility of their leakage character and the savings achieved.
We also produced a payback figure against the cost of the survey and resulting parts requirement. We have shown that the payback period is significantly reduced if the client uses our repair services, as time is not lost waiting for in-house engineering resource to become available to carry out the necessary rectification works. This client subsequently placed an order with Advantiv to carry this work as part of an ongoing compressed air system management contract.
As a Premier Stockist for Festo and through our Energy Efficiency Division, Advantiv were also able to advise technically on ways in which the compressed air system could be improved and new products introduced to help improve life expectancy of air parts & systems. As well as the ongoing compressed air savings that are now being seen further significant savings on consumable parts were also shown as these parts were rolled out across the plant. Further optimisation of the air system is also being carried out based on advisement we have given.
As a result of our survey and subsequent repair actions the client was able to turn down a significant sized compressor and show a large annual saving in compressor running costs. It is anticipated that further significant savings will be identified and made as on going leaks are detected and repaired and optimisation methods implemented.
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