Festo leak detection using ultrasounds detector
Festo leak detection using ultrasounds detector

Compressed air is one of the most important energy transmission media used in industry. More likely than not, these pneumatic installations do not include any monitoring facilities, this is a serious error, since 79% of the costs of compressed air are accounted for by the electricity used for generation and preparation. Even if compressors, distribution systems and pneumatic actuators are correctly dimensioned, leakage often causes losses of up to 600 l/min.

Q. What does this matter? It is only air?

A. Does 1000 Euros matter? Is it only money? Even a reduction of compressed air losses of 100 l/min saves up 1000 Euros a year.

Users often fail to exploit the potential savings due to lack of know-how. Furthermore, in many cases the technical equipment necessary to localise leakages is not available. Lack of time and clarity regarding operational responsibilities prevent the implementation of energy-saving measures. This is precisely where Festo Energy Saving Services come into play.

Festo Energy Saving Services

These help monitor and optimise compressed air consumption by simple means.

Step 1: Thorough Analysis

These services always begin with a report thoroughly describing the actual situation and an analysis of the complete pneumatic installation in question in order to identify all the weaknesses, from the compressor through to the applications.

Energy analysis of compressed air generation
Energy analysis of compressed air generation

Step 2: The Master Plan

With optimum leak management, costs drivers have no chance of escaping detection. Each leakage point which is eliminated has an immediate effect in reducing compressed air costs, the elimination of leaks alone enables around 42% of total potential savings can be achieved. As part of an efficient leak-management system, a specialist will use an ultrasound detector to check the compressed air system for leaks and will record each leak together with all associated technical data, such as details of the spare parts required. This documentation with then serve as a master plan for possible savings. This will show all the required maintenance measures and lists the long-term savings against short term repair costs.

Step 3: Make Huge Savings

More and more companies are using precise compressed air consumption data as the main criterion for the choice of new equipment. With a detailed compressed air consumption analysis, they can make savings of up to 50% more than with conventional methods. Even before commissioning, a compressed air consumption analysis can determine the precise air consumption of an installation – both during normal operation and with machines at a standstill. Therefore guaranteeing optimum dimensioning of the compressed air supply system and prevents the possibility of collapse of the supply system due to overload.

Particularly important: a compressed air consumption analysis prevents unnecessary costs right from the start, which might be caused by an over-dimensioned and therefore overly expensive compressed air distribution system. Measuring compressed air delivery with machines at a standstill provides a mathematical indication of leakage losses and therefore possible savings in the compressed air system as a whole.

So is it worthwhile?

The simple process consists of:

  1. A professional conducting a full analysis to identify creeping energy losses in compressed air systems
  2. Results translated by the professional into optimisation measures, implantation, and watch the savings day after day.



Learn more about this at our Energy Saving Day Event on the 26th February 2013

If you would like any more information please CALL: 01529 416200 or e-mail: customerservices@kiowa.co.uk