Compressed Air Leak Detection Surveys

Compressed air is one of the most expensive utilities on a manufacturing site, and leaks are the most common reason for excessive energy consumption. ALS Industrial Services Ltd carry out compressed air leak detection surveys using calibrated ultrasonic detection equipment. The survey is carried out with the system live and under pressure. No production shutdown is required.

Following the survey, we issue a written report identifying every leak found, its location in the system, its estimated flow rate and the annualised energy cost of leaving it unrepaired. The report gives you everything you need to prioritise repairs and present a cost-of-inaction case internally.

How the survey works

Our engineer walks the full compressed air distribution system: compressor house, ring main, branch drops, point-of-use connections, condensate drains and isolation valves. The engineer works a calibrated ultrasonic detector. The instrument identifies the high-frequency sound produced by air escaping through fittings, joints, couplings, valve seats and worn components.

Each leak is tagged and recorded with its location, estimated flow rate and the type of component or joint responsible. The survey covers the whole system in a single visit and can be worked around live production without interruption.

Why leak detection matters

A poorly maintained compressed air system commonly loses 20 to 30% of its total output through leaks. That wasted air still requires the compressor to generate it. Every cubic metre of leaking compressed air represents electricity consumed, compressor hours accumulated and maintenance intervals brought forward. On a typical manufacturing site, a programme of leak detection and repair will pay for itself within months.

Beyond energy cost, leaks reduce system pressure, which affects the performance of pneumatic tools and processes downstream. Chronic low pressure is sometimes addressed by raising system pressure rather than finding the leaks, which compounds the energy waste further.

Leak detection surveys are also a standard element of compressed air energy audits under the Energy Savings Opportunity Scheme (ESOS), and are expected on sites working towards ISO 50001 energy management certification.

What you receive

Following the survey we issue a written report containing:

• A numbered list of every leak found, with its location in the system
• The estimated flow rate for each leak
• The annualised energy cost of each leak at current electricity rates
• A repair priority rating for each leak
• A site-level summary showing total estimated leakage rate and total annual cost of inaction

The report gives you a clear basis for prioritising repairs and, where relevant, for making the case internally for a repair programme.

How can we help?

If you have rising energy bills, unexplained pressure drops or a compressor that runs continuously without obvious cause, a leak detection survey is a useful starting point. Our engineers carry the equipment and can typically complete a survey for a standard manufacturing site in a single visit.

Call us on 01789 867640 or email enquiries@alsindustrial.co.uk. We respond to all enquiries the same working day.