Find, value, repair and verify
Ultrasonic measurement can locate leaks. For decision-making, locations are recorded, approximate flow is quantified and repairs prioritised. Night-time consumption measurement helps establish baseline losses, but legitimate continuous consumers and equipment regeneration must first be separated out.
Cost also depends on compressor control
Annual lost volume is calculated from flow at a defined reference and the time the branch remains pressurised. The energy estimate uses specific energy consumption. Actual savings after repair depend on the control response; reduced flow does not necessarily produce an immediately equal percentage reduction in input power.
What to check in practice
- Consider the time under pressure, which may exceed the production shift.
- Use orifice flow only as an indicative compressible-flow model.
- Repeat the measurement under comparable conditions after repair.
Example scenario
A 100 L/min leak at a defined reference over 4,000 hours loses 24,000 m³. At 0.12 kWh/m³ and CZK 4/kWh, the energy estimate is 2,880 kWh and CZK 11,520 per year. Operational measurement verifies actual electricity savings.
What to watch out for
- Counting only production hours when the network stays pressurised continuously.
- Converting hole diameter to flow without pressure and discharge coefficient.
- Repairing leaks without checking the resulting compressor settings.
Is it worth repairing only large leaks?
Large losses may take priority, but many small ones often add up to a significant amount. Consider accessibility, downtime risk and repair cost. The aim is a regular inspection system, not a one-off search for the loudest spot.