FEATURE ENERGY MANAGEMENT


LEAKED


In this article, Andy Batey, head of Engineering, Brammer Buck & Hickman, provides a handy guide with useful tips that will help you save money on your fourth utility – air


O


n average, 10 per cent of all industrial electricity consumption can be attributed to


the production of compressed air. Compressed air leaks are therefore a significant source of lost energy, often wasting as much as 20-30 per cent of your compressor’s output, and can lead to your machinery and tools functioning less efficiently.


AIR LEAK LOCATIONS & HOW TO FIX THEM The most common places to find a leak is in the couplings, hoses, tubes and fittings, along with disconnects and pipe joints. Filters, regulators and lubricators (FRLs) are


something to look out for as well as, if incorrectly installed, they often show leakage signs. Open condensate traps could also be the issue. This can be due to the improper installation of solenoids alongside dirty seals. Other common places that air leaks occur are


through stems of control and shut off valves, missing welds in flanges and worn packing materials in your cylinder rod packing. However, fixing these issues, if caught early, should not be an issue.


AIR LEAK IDENTIFICATION Of course, fixing the problem can only be done once you hve identified where the leak is coming from. Investing in a regular air leak audit is a


small but sensible investment which could save you thousands of pounds. Usually, as a scheduled routine check, an air leak


audit will address all appropriate machinery for leaks, as well as identifying possible changes in your current equipment. In most cases, a good audit will also provide a running report of items examined along with any suggestions to ultimately save you costs. By using ultrasonic equipment, a good and


thorough audit will collect the data whilst the audit provider should prepare a detailed report with a description of the leak. Alongside this, your audit provider should then estimate monetary value per leak, photograph the part or area which is leaking, and suggest a remedial list of parts or actions required to fix the problem.


AIR LEAK AUDIT IN ACTION Vehicle exteriors specialist, Magna Exteriors, invested in a Compressed Air System Audit, provided by Brammer Buck & Hickman, at its UK plant in Banbury, Oxfordshire. The compressed air systems were analysed


using ultrasonic technology and a detailed photographic report provided details of any leakage found, showing the location, size and cost of each leak. The customer’s maintenance crew then took over to address the leaks using the report as a road map. “Our technicians went around the plant using


these reports and signed each off as they completed the work” states Paul Howard, energy improvement co-ordinator at Magna Exteriors. What’s more, we did the same six months later – and every six months from then – and audited


28 SPRING 2020 | INDUSTRIAL COMPLIANCE


the results so we have proof of the success of this approach. It has really improved our energy efficiency. Air is one of the most expensive forms of energy. It’s free to breathe but is very expensive to compress and pressurise!” At Magna Exteriors, the audit resulted in £130k


savings over three years. The company has gone from running three compressors full time to two, with the third for back-up. They are now using just two thirds of the energy and have reduced their servicing costs. There are further benefits to be had, as Howard


explains: “Another useful aspect to this service is the safety data provided. Compressed air is potentially very dangerous; it can damage equipment and cause serious injury. Knowing where the potential risks are is important and Brammer Buck & Hickman were able to recommend and provide suitable equipment to address any such issues.”


Brammer Buck & Hickman www.buckandhickman.com/en


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