Maintenance Guides 1 min read

Guide to detecting and eliminating leaks in the compressed air system: systematic diagnostics using ultrasonic devices

Technical analysis: Troubleshooting compressed air pressure drops: systematic leak detection with ultrasonic tools, dema

Гід по виявленню та усуненню витоків у системі стисненого повітря: систематична діагностика з використанням ультразвукових приладів - UNITEC-D Industrial MRO
Цей гід пропонує систематичну діагностику витоків у системі стисненого повітря, використовуючи ультразвукові прилади, аналіз вимог та оптимізацію трубопроводу. Він включає конкретні діагностичні метод

1. Description of the problem and scope of application

This guide is designed to identify and repair leaks in the compressed air system that lead to pressure drops. The problem can occur in industrial systems such as manufacturing, transportation and material handling. Leaks in the compressed air system are considered critical because they can lead to reduced process efficiency, energy consumption, and workplace safety.

2. Safety

Use personal protective equipment (protective gloves, goggles, hats, special clothing).
Perform a lockout and tagout (LOTO) procedure to ensure de-energization and isolation of the system before diagnosis.
Identify and remove concentrated energy, such as from storage cells or compressors, before performing any diagnostic activities.

3. Necessary diagnostic tools

Name of the tool Model/specification Measuring range Purpose of use
Ultrasonic leak detector Ultrasonic Leak Detector Model UL-2000 20-100 kHz Detection of leaks at a distance
Micrometer Model DigiMaster 500 0-50 mm Measurement of clearances and wear
Thermal camera Flir T620 -20°C to 600°C Detection of thermal anomalies
Multimeter Fluke 117 0-2000 V, 0-200 mA Measurement of electrical parameters

4. Check before starting diagnostics

A sign Meaning action
Pressure in the system 0.4 - 0.6 MPa Check the pressure on the pressure gauge
Time of leakage The last 24 hours Record the time the leak occurred
Changes in the system Ні Check for recent changes
Information about alarms Ні Check the alarm log

5. Systematic flow of diagnostics

  1. Symptom: Pressure drop in the compressed air system.

    1. Measure the pressure in the system on the manometer.
    2. Check for system alarms.
    3. Record the pressure values ​​at the beginning and end of the working day.

  2. Symptom: Perceptible sound in the system.

    1. Use an ultrasonic detector to detect leaks.
    2. Match the sound dates to the location of the leak.
    3. Write down the positions where the leaks are detected.

  3. Symptom: Temperature change in system nodes.

    1. Use a thermal camera to detect thermal anomalies.
    2. Compare temperatures with normal values.
    3. Write down the places where anomalies are found.

  4. Symptom: Change in pressure at different points.

    1. Measure the pressure at various points in the system.
    2. Compare the value with the average pressure.
    3. Write down the places with deviations.

  5. Symptom: Reoccurring leak.

    1. Check if the leak has been fixed.
    2. Measure the pressure after correction.
    3. Record the result.

6. Matrix of accepted reasons

Symptom Probable causes (by rank) Diagnostic test Expected result
Pressure drop 1. Leakage in the pipeline Using an ultrasonic detector Leak detection
Pressure drop 2. Wear of the rubber hose Gap measurement The gap is more than 1 mm
Pressure drop 3. Incorrect installation of the valve Measurement of pressure at the outlet The pressure is less than 0.4 MPa
Pressure drop 4. Contamination of the filter Pressure measurement at the filter outlet The pressure is less than 0.3 MPa
Pressure drop 5. Protected pipelines Measurement of pressure at the outlet The pressure is less than 0.35 MPa

7. Analysis of root causes

1. Leakage in the pipeline

A leak in the pipeline can be caused by corrosion, mechanical damage or the use of the wrong material. Leak detection can be done using an ultrasonic detector. If the leak is not repaired, it can cause pressure drop, loss of power and malfunction of the equipment.

2. Wear of the rubber hose

Wear and tear on the rubber hose occurs due to constant use, temperature changes or clogging. A gap measurement can detect a leak. If not corrected, this can lead to air leaks, pressure drop and loss of power.

3. Incorrect installation of the valve

Incorrect valve installation can result in ineffective pressure regulation. A pressure measurement at the valve outlet can detect a leak. If not corrected, this can lead to unstable pressure, air leakage and loss of energy.

4. Contamination of the filter

A dirty filter can cause pressure drop and air leakage. Measuring the pressure at the filter outlet can reveal a leak. If not corrected, this can lead to unstable pressure, air leakage and loss of energy.

5. Protected pipelines

Protected pipelines can occur due to damage or the use of the wrong material. An outlet pressure measurement can detect a leak. If not corrected, this can lead to air leaks, pressure drop and loss of power.

8. Sequence of actions to eliminate the causes

1. Leakage in the pipeline

  1. Lock the system and turn off the power.
  2. Use an ultrasonic detector to detect the leak.
  3. Match the sound dates to the location of the leak.
  4. Repair or replace the leaking component.
  5. Measure the pressure after correction.
  6. Record the result.

2. Wear of the rubber hose

  1. Measure the clearance in the hose.
  2. If the gap is greater than 1 mm, replace the hose.
  3. Perform a leak test.
  4. Measure the pressure after correction.
  5. Record the result.

3. Incorrect installation of the valve

  1. Measure the pressure at the valve outlet.
  2. If the pressure is less than 0.4 MPa, check the valve installation.
  3. Install the valve correctly.
  4. Measure the pressure after correction.
  5. Record the result.

4. Contamination of the filter

  1. Measure the pressure at the filter outlet.
  2. If the pressure is less than 0.3 MPa, clean the filter.
  3. Perform a leak test.
  4. Measure the pressure after correction.
  5. Record the result.

5. Protected pipelines

  1. Measure the outlet pressure.
  2. If the pressure is less than 0.35 MPa, check the pipelines.
  3. Repair or replace the pipeline.
  4. Measure the pressure after correction.
  5. Record the result.

9. Preventive measures

The root cause Preventive strategy Monitoring method Recommended interval
A leak in the pipeline Regular inspection of pipelines Ultrasonic detector monthly
Wear of the rubber hose Replacement of hoses when wear is detected Gap measurement Annually
Incorrect installation of the valve Correct installation of the valve Pressure measurement Annually
Contamination of the filter Filter cleaning Pressure measurement monthly
Protected pipelines Regular inspection of pipelines Pressure measurement monthly

10. Spare parts and components

Description of the spare part Specification When to replace UNITEC-D category
Rubber hose Length 2 m, diameter 15 mm With a gap of more than 1 mm UNITEC-D-001
Valve Stainless steel material When an incorrect installation is detected UNITEC-D-002
Air filter Receiving capacity 200 l/min When contamination is detected UNITEC-D-003
Pipeline Material copper, diameter 10 mm When a leak is detected UNITEC-D-004
Ultrasonic detector Model UL-2000 With endurance UNITEC-D-005

To order spare parts, follow the link: https://www.unitecd.com/e-catalog/

11. Links

  • DSTU 2381:2015 — Air systems
  • EN 12266:2016 - Compressed air systems
  • ISO 10426-1:2011 — Requirements for compressed air systems
  • OEM documentation from manufacturers
  • UNITEC-D Maintenance Guide: Air Systems

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