Compressed Air Leak Survey · Ultrasonic Compressed Air Leak Survey SAMPLE REPORT Inspection Date:...

Compressed Air Leak Survey

Company Name

Location

April 2019

By

Mark Pedersen CEng

SAMPLE REPORT

Compressed Air Leak Survey

Sunrise House Hulley Road Macclesfield

Cheshire SK10 2LP

Tel: 08456 042 703

Web: www.compressedairleaksurvey.co.uk

Email: [email protected]

www.compressedairleaksurvey.co.uk

Ultrasonic Compressed Air Leak Survey SAMPLE REPORT

Inspection Date: April 2019

Report Details

Client:

Inspection Site:

Contact Person:

Contact Person Address:

Phone Number:

E-mail Address:

Surveyor: Mark Pedersen CEng

Survey Equipment: UE Systems Ultraprobe 2000 – Ultrasonic Leak Detector

Survey Date(s): 11th April 2018




Survey Information This Compressed Air Leak survey was carried out on behalf of confidential. This is a report on the conditions prevailing when the site was surveyed. A UE Systems Ultraprobe ultrasonic leak detector was used to capture the ultrasonic data which is recorded within this report. Where equipment was surveyed and no leaks or faults were found then no data is recorded i.e. individual reports are generated by exception. Some areas of particular interest may be included which the surveyor feels may be of particular interest to the client. Descriptions of equipment and locations have been noted as those in common usage within the client’s premises. Where we have been unable to inspect equipment or plant which is covered, unexposed or inaccessible, we are therefore unable to report that any such system components are free from defect. Areas un-inspected are highlighted in the scope pages of this report. To assist the Engineering Management to maintain plant efficiency, it is recommended that the survey is repeated on a twelve monthly basis. This report is an indication of the condition of the equipment inspected at the time and date of survey only. Signed: 88888888888888888 Date: April 2019

Mark Pedersen CEng Surveyor Disclaimer:

Please note that the report contained herein represents the observed conditions at the time of inspection. We accept no liability for faults that have occurred during or after the completion of the inspection. The recommendations given in this report are intended as a guide only. By issuing this report neither ourselves nor any of our employees make any warranty, expressed or implied concerning the contents of this report. We cannot accept responsibility for inappropriate actions taken as a result of this report.




Scope of Survey The scope of this survey was to carry out a compressed air leak survey across the site on all areas where compressed air systems are located. This encompassed internal and external areas throughout the site which were made accessible by the client. Report Data A summary of all ultrasonic data is contained in the report pages that follow. The pages in this report have been designed as single page entries, each of which carries its own information so that individual pages can be given to the relevant professions in order that they may carry out any remedial repairs that may be necessary. Compressed Air Leak Surveys All compressed air systems are subject to mechanical deterioration at connections, flexible pipes, regulators, valves etc. due to looseness, over-tightening, corrosion and contamination. If these conditions remain uncorrected further deterioration will occur resulting in equipment failure and leakages of expensive compressed air. Compressed air is not free and it costs hard earned revenue to generate with the following costs being part of the generation process:

• Compressor Cost (Purchase)

• Electricity costs

• Generation Efficiency Cost

• Air Drier running costs

• Maintenance costs

• Equipment deterioration As such 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. Air Supply Data Used For the purpose of compiling this report we have taken the air supply pressure to be 7.0 BarG and the annual compressor usage to be 24 hours a day for a seven day week with a 52 week working year which gives an annual compressor running time of 8760 hours.




Leak Levels and Ratings This survey has been designed to assess the performance of all compressed air generation, distribution and equipment on site and to highlight any areas which require attention. To assist in the prioritising of repairs we apply a severity rating (level) based on the results of the leak detection survey. The severity levels are ranked as follows:

Leak Costs We calculate individual leak costs based on the following information provided by the client and from compressor data:

Detail Value

Cost of Electricity (p/kWh) 9.3

Compressed Air Generating Efficiency (kW/100cfm) 19.22

Generating Pressure (BarG) 7.0

Hours of Operation per Year (Hours) 8760

Level Leak Size in CFM:

Leak Description: Minimum Maximum

1 0.01 0.50 Small

2 0.50 1.50

Medium

3 1.50 2.50

4 2.50 4.00

Large 5 4.00 6.00

6 6.00 8.00

7 8.00 10.00

8 10.00 15.00

Very Large 9 15.00 25.00

10 25.00 100.00




Cost Benefit Analysis

Leak Identification Number:

Size of Leak in CFM:

Cost of Leak per Annum £:

1 1.5 234 2 1.5 234 3 0.5 78 4 0.5 78 5 2.5 391 6 1.5 234 7 0.5 78 8 0.5 78 9 1.5 234 10 0.5 234 11 1.5 234 12 1.5 234 13 4.0 626 14 1.5 234 15 2.5 391 16 0.5 78 17 0.5 78 18 2.5 391

Total Overall Cost of Air Leakage £ £4,139 The above table provides a summary of the individual leak costs and subsequent total annual cost of wasted compressed air leak generation. Larger leaks or inappropriate uses of air should be targeted first to rapidly reduce costs associated with wasted compressed air generation.




Summary of Air Leaks Detected

Ultrasonic leak detection equipment was utilised to locate and measure air leakage from compressed air systems. Below is a summary of all leaks found:

Leak No.

Area: Leak details: Level:

1 B19 Compressor Shed Leak on 1" screwed connection to Tee 2

2 B19 Compressor Shed Leak on 2" screwed connection to 2" tee 2

3 B19 Compressor Shed Leak on Testo air probe 0554.3303 1

4 B4 Loft HVAC Area (B2 Side)

Leak on 2" coupling 1



6 B2 Walkway Entrance Leak on coupling 2

7 B2 Cable Store Leak on coupling 1

8 B2 Lab Loft Leak on screwed connection to valve body 1

9 B2 Lab Loft Leak from flexible steel hose connection 2

10 B2 Lab Loft Leak from regulator body 2

11 B2 Lab Loft Leak on 6mm nylon push fit connection 2

12 B1 Utility Hall Leak on ball valve to Testo probe by compressor

2

13 B1 Utility Hall Leak From regulator body on wall by Quattro system

4

14 B21 Compressor Room Leak on 8mm nylon push fit connection 2

15 B1 HVAC Area - Zone 1,2 &3 Above rm32

Leak on 8mm nylon push fit connection 3

16 B1 HVAC Area - Zone 1,2 &3 Above Rm 1

Leak on screwed conn to 90° steel bend 1

17 B1 HVAC Area - Zone 7 Air Receiver

Leak on stop end on receiver body 1

18 B1 HVAC Area - Zone 4 & 5 Partition wall

Leak on 1.5" Coupling 3




Leak No. Location Nature of Leak Level

1 B19 Compressor Shed Leak on 1" screwed connection to Tee 2

Images of Leak Site

Annual Cost of Air Leakage: £234

Estimated Time Required to Repair (Hours) 1

Repair Completion

Repair Date: Repaired By:

Comments:





2 B19 Compressor Shed Leak on 2" screwed connection to 2" tee 2

Images of Leak Site



Repair Completion


Comments:





3 B19 Compressor Shed Leak on Testo air probe 0554.3303 1

Images of Leak Site



Repair Completion


Comments:







Images of Leak Site



Repair Completion


Comments:







Images of Leak Site



Repair Completion


Comments:





6 B2 Walkway Entrance Leak on coupling 2

Images of Leak Site



Repair Completion


Comments:





7 B2 Cable Store Leak on coupling 1

Images of Leak Site



Repair Completion


Comments:





8 B2 Lab Loft Leak on screwed connection to valve body 1

Images of Leak Site



Repair Completion


Comments:





9 B2 Lab Loft Leak from flexible steel hose connection 2

Images of Leak Site


Estimated Time Required to Repair (Hours) 0.5

Repair Completion


Comments:





10 B2 Lab Loft Leak from regulator body 2

Images of Leak Site



Repair Completion


Comments:





11 B2 Lab Loft Leak on 6mm nylon push fit connection 2

Images of Leak Site


Estimated Time Required to Repair (Hours) 0.5

Repair Completion


Comments:





12 B1 Utility Hall Leak on ball valve to Testo probe by compressor

2

Images of Leak Site



Repair Completion


Comments:





13 B1 Utility Hall Leak From regulator body on wall by Quattro system

4

Images of Leak Site



Repair Completion


Comments:





14 B21 Compressor Room Leak on 8mm nylon push fit connection 2

Images of Leak Site



Repair Completion


Comments:





15 B1 HVAC Area - Zone 1,2 &3 Above rm32

Leak on 8mm nylon push fit connection 3

Images of Leak Site



Repair Completion


Comments:





16 B1 HVAC Area - Zone 1,2 &3 Above Rm 1

Leak on screwed conn to 90° steel bend 1

Images of Leak Site



Repair Completion


Comments:





17 B1 HVAC Area - Zone 7 Air Receiver

Leak on stop end on receiver body 1

Images of Leak Site



Repair Completion


Comments:





18 B1 HVAC Area - Zone 4 & 5 Partition wall

Leak on 1.5" Coupling 3

Images of Leak Site



Repair Completion


Comments:

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