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Air Leaks in Compressed Air Systems

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Every plant has them, we just don’t like to admit it and we never seem to fi nd the time to deal with them. So much has been written about the subject in the past and to sit down and hammer out a few words once again on the keyboard may just encourage a few folks to get out into the plant and do something about it. So let’s make today, the day we act!

Energy costs are skyrocketing and that means each leak could be costing you thousands every year. A 50hp Air Compressor will cost you in the region of $19K per year in energy costs alone, if you are operating a 3 shift system.Add to this the cost of service, consumables and depreciation and you are up to $25K.

If your leaks represent only 5% of your total compressed air production, it’s like taking out two $50 notes and placing them on the BBQ every month. Of course, there are many plants that leak even more than that, where the wastage can be up to 10 or 15% of compressed air production.

Do you need help to sort this out? In most cases you do not. However;if you feel that the task is greater than the resources, give us a call. Generally speaking, if your plant runs 24/7,you will probably need some help, including a ultrasound detector to pick out the leaks from the background noise.

If your plant only operates a one or two shift system, then bite the bitter pill and tell your significant other, “I am going in to work”, ona weekend day. While its quiet. Start up the air compressor and bring it up to full pressure. Then turn it off and walk the plant. You can now hear every single leak as the compressed air squeals andsqueaks it’s way to freedom. Have some brightly colored tags and tie them to the pipe, valve, joint, hose or equipment that is leaking.Each tag has a number for the tag, also a number for the estimated size of the leak. All you need is a system from 1 to 5. 1 represent only a minor leak, right up to 5 which indicates that it is costing you a vacation in the Bahamas’.

More sophisticated equipment is available that will calculate exactly how big the leak is and provide a value. But let’s face it, you know you have a leak, you know you have to fi x it. Plot your report on a spreadsheet.Detail someone to repair the worst leaks immediately and set a plan for the remainder.

ICE PREVENTION AND BUBBLER SYSTEMS FOR MARINAS AND DOCKS

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So you own and operate a marina in our amazing country. Boating in the spring and summer and even the fall but in the winter? No.Winter is coming and sometimes it's fiercer than ever before. So the boats are winterized and pulled out of the water onto the dry docks and trailers. But what about all your docks? Are they ready for the impending doom and gloom of the weather man?Heaving ice floes and ice pressure buildup, can shift dock pilings or even lift them right out of their footings. By taking a few steps to winterize your dock before the lake freezes over, you can lengthen its life exponentially and protect your investment.

So come the springtime, you're back at it earning a living and enjoying the joys of boating life.

But do you have the right equipment for ice prevention at your marina? Got a compressor thumping away all day ​long trying to make air bubbles across the expanse of your dock area? Yeh, you might have that, at best.

CompreVac specialize in water bubbling systems and not by plugging a compressor in the wall sourced from the local hardware store either. You require something that is designed for exactly what you need. 15-20psi of low pressure efficient low cost air. There are seven models to choose from ranging from to 353CFM!

This single claw compressor, that's right, a claw compressor services the complete marina. Through hundreds of feet of submerged piping, this pump runs 24/7 without the need for maintenance.That's right, all day long without a care in the world and not a single drop of oil will enter the water from this Oil-Free miracle of engineering.

Water Pump Priming - How It's Done

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So what do we usually see when we look closely at one of these systems? They normally consist of one or two liquid ring vacuum pumps mounted on the top plate of a horizontal vacuum receiver tank, such as the one shown in Fig. 1. A simple control panel will be mounted on or close by this assembly, which offers a selector switch with basic on/off control buttons for pump “A” or “B.” As can be seen from Fig.1, which has two liquid ring pumps side by side, there are pipes for feeding make-up water to the pumps. Usually the complete system has been leaking both sealing water and vacuum for years. Due to vacuum leaks, the system has usually been running almost continually, attempting to keep up with the required vacuum level set point.This is why it is severely corroded.

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