COMPRESSED AIR ULTRASONIC LEAK DETECTION …

1 MOISTURE SEPARATOR MAIN FILTER COMPRESSOR ROOM INTAKE FILTER AIR COMPRESSOR AFTERCOOLER RECEIVER SECONDARY FILTERS AND LUBRICATORS COMPRESSED AIR ULTRASONIC LEAK DETECTION GUIDE V 1406R Increased Productivity through ULTRASOUND 14 Hayes Street, Elmsford NY 10523-2536 USA Tel: 914-592-1220 Toll Free USA & Canada 24 Hour Fax Email: Internet 800-223-1325 914-347-2181 UE Systems COMPRESSED Air Leak DETECTION Guide 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.

2 In addition to your leak survey, take the time to review your COMPRESSED air system. Look for areas of misuse, check for inefficiencies. Review your compressors: are they too large or too small for the load? If you re not sure about how well your system is designed or working, invite your local compressor dealer over or you might hire the services of a consultant who specializes in COMPRESSED air systems. If you would like to use a leak DETECTION company to perform your survey look up our on-line directory of service providers: UE Service Partners at: Our guide is full of useful information to help you get your leak DETECTION and repair program started.

3 You ll find a step by step guide for leak DETECTION and data that can help you report your leak savings. In addition, we ve included two Guesstimator charts to help determine the cfm loss through specific leaks. One is for the analog instruments: Ultraprobe 550 and Ultraprobe 2000 and the other is for the digital Ultraprobe 9000. If you should have any questions, or comments, please feel free to contact us at: 914-592-1220, Fax: 914-347-2181 or mail: Increased Productivity through ULTRASOUND Setting up a COMPRESSED Air Leak DETECTION Survey 1. Walk through your plant. While you walk, pay attention to obvious problems such as loud leaks that you can spot and tag without the aid of an ULTRASONIC detector.

4 Observe misuse of air such as valves left wide open, rags placed over pipes to reduce the noise level of large leaks, unattended machines left on with air blowing all over the place. Check and repair all drain traps, do not leave them cracked open. Check defective tools, quick connection points, etc. As you walk, try to determine the best route for inspection. If possible, take a print of the COMPRESSED air piping system, or make a simple sketch. These graphics will help you identify the leaks and make it easier to find them for repair. 2. Use an Ultraprobe to scan for leaks. Always wear your headphones. If you have difficulty determining direction, reduce your sensitivity.

5 Follow the sound to the loudest point. 3. For consistency, start at the compressor/supply side and work your way to the use side. 4. When you begin your inspection, create a series of inspection "zones". This will help organize your approach and prevent the possibility of overlooking a section and missing some leaks. Move from one "zone" to the next in a planned organized manner. 5. Tag all leaks. The tag will make it easy to spot the leaks for repair. 6. Test all leaks after they have been repaired. Sometimes leaks can be fixed and new ones created inadvertently. 7. Calculate your savings using cfm charts and formulas accompanying this guide.

6 8. Report your results. Let management know what a great job you're doing. 14 Hayes Street, Elmsford NY 10523-2536 USA Tel: 914-592-1220 Toll Free USA & Canada 24 Hour Fax Email: Internet 800-223-1325 914-347-2181 In the field of leak DETECTION there are many confusing elements that appear when two or more people try to convey the type or size of loss that they need to detect. One way to resolve this is to convert all forms of leak loss descriptions into one common format. Below is a formula that converts a divergence of leak descriptions into the term: CFM or cubic feet per minute.

7 The formula is: The formula is universal, in that one can use any form of leak measurement. To use the formula factors, refer to the chart that explains what one atmosphere is for a particular measurement unit. This measurement unit can be PSI, Inches of Mercury, Feet of Water or Bars. EXAMPLE: A leak in a system of 300 cubic feet is losing 10 psi in 2 minutes. The system pressure is 100 PSI. NOTE: the system pressure will almost always be given. It is not to be used in this formula. The only reason it is given in this example is to alert you to the fact that it is not necessary even when provided. FORMULA COURTESY OF UE TRAINING SYSTEMS Pressure Loss x Volume in ft3 1 Atmosphere =CFM Time in minutes Conversion Chart 1 Cubic Foot = 1728 cubic inches 1 Atmosphere = PSI = inches of HG (Mercury) = Ft.

8 Of H2O = Bars 10 CFM = x 300 = .680 x 300 = 102 CFM 2 2 2 2 14 Hayes Street, Elmsford NY 10523-2536 USA Tel: 914-592-1220 Toll Free USA & Canada 24 Hour Fax Email: Internet 800-223-1325 914-347-2181 Table is based on 100% coefficient of flow. For a well rounded entrance, multiply values by For sharp edged orifices a multiplier of may be used for approximate results. Values for pressures from 1 to 15 lbs. gauge calculated by standard adiabatic formula. Values for pressures above 15 lb.

9 Gauge calculated by approximate formula proposed by Moss Where: W = ACp1 Where: W = discharge in lbs. per sec. T1 A = Area of orifice in sq. in. C = Coefficient of flow p1 = Upstream total pressure in lbs. per sq. in. absolute T1 = Upstream temperature in oF. Values used in calculating above table were: C = , p1=gauge pressure + sq. in., T1 = 530oF. abs. Weights (W) were converted to volumes using density factor of ft. This is correct for dry air at per sq. in. absolute pressure and 70oF.

10 Formula cannot be used where P1 is less that two times the downstream pressure. Inches x = mm; psi x = kPa; chn x = rn3/rnin; 70oF = Gauge Pressure before Orifice in Pounds per sq. in. DIAMETER OF ORIFICE 1/64 1/32 1/16 1/8 3/8 5/8 " 7/8 1 Discharge in cubic feet of free air per minute 1 .028 .112 .450 115 2 .040 .158 .633 124 162 3 .048 .194 .775 111 152 198 4 .056 .223 .892 128 175 228 5 .062 .248 .993 143 195 254 6 .068 .272 109 156 213 278 7 .073 .293 117 168 230 300 9 .083 .331 132 191 260 339 12 .095 .379 152 218 297 388 15.