Finding Compressed Air Leaks at a Petrochemical Plant
Five compressor rooms, 150+ connections: how LEAKChecker and SDT270 found hidden compressed air leaks at a petrochemical plant and paid for themselves within the first week of the survey.
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: $2,500
- Payback period: 1 month
Additional benefits
- Reduced load on the compressors
- Longer equipment service life
- Higher reliability of pneumatic systems
- Lower noise levels in production areas
Recommendations
- Monthly ultrasonic monitoring
- Training of LEAKChecker operators
- Inclusion in the predictive maintenance program
- Consider permanent monitoring for critical zones
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