Finding Compressed Air Leaks at a Petrochemical Plant

The challenge

A petrochemical plant was facing high costs to produce compressed air. A preliminary assessment indicated significant leaks in the system.

Equipment

The following tools were used:

• LEAKChecker — a dedicated leak detector
• SDT270 — for documentation and quantification
• LEAKReporter software — for cost calculation

The process

1. System audit

Five compressor stations were inspected:

• 150+ connections and fittings
• 50 control valves
• 30 pneumatic instruments

2. Leak detection

47 leaks of varying severity were found:

Size	Count	Loss (kW)	Cost/year
Small (<1 mm)	28	0.5 kW each	$200
Medium (1–3 mm)	15	2 kW each	$800
Large (>3 mm)	4	8 kW each	$3,200

Total losses: 75 kW, cost: $37,600/year

3. Prioritization

Leaks were classified by criticality:

• Critical (immediate repair) — 4
• Important (within a month) — 15
• Scheduled (next maintenance) — 28

Results

Savings

• Energy: 612,000 kWh/year
• Money: $37,600/year
• CO2: 150 tonnes/year

Payback

• LEAKChecker cost: on request
• Payback = instrument cost / annual leak losses

Additional benefits

1. Reduced load on the compressors
2. Longer equipment service life
3. Higher reliability of pneumatic systems
4. Lower noise levels in production areas

Recommendations

1. Monthly ultrasonic monitoring
2. Training of LEAKChecker operators
3. Inclusion in the predictive maintenance program
4. Consider permanent monitoring for critical zones