Are you Hiding from the Hidden Cost of Leaks?

Are you Hiding from the Hidden Cost of Leaks?

      

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Download our Energy Emission Survey Case Study

It’s no myth, nor an old wives’ tale – leaks waste money. Be it the cost of lost fluid, or the cost of energy associated with producing compressed air, steam, or keeping hydraulic fluid under pressure; if not monitored closely you could be losing thousands of dollars annually to leakage. Consider this example:

Let’s assume the typical efficiency of a compressor at 20kW/100cfm (.2kW/cfm), an electricity rate of $0.09 per kWh, 100 psig and nearly continuous operation. Using the formula to calculate, the annual cost of a leak = Leakage rate (cfm) x kW/cfm x operating hours x $/kWh, a single 1/16” leak would have an annual cost of:

1/16” leak @ 100 psig = 6.5cfm x .2kW/cfm x 6500 hours x $0.09/kWh => $760

This is a conservative estimate of the potential cost per leak. It’s easy to see how the total annual cost of all system leaks can quickly add up.

How do they Happen?

Leaks are more common than you might think, especially in large plants where the on-going drone of equipment and the hustle of the operation mask the sound and sight of leakage. For tubing systems, poor installation techniques are a common cause of system leakage. Common mistakes include poorly preparing the tube – failure to properly cut and deburr – as well as ensuring the tube is fully bottomed in the fitting before installation. Under-tightening, over-tightening and placing connections too close to a tubing bend can also contribute to leakage. Another cause of leakage could be operating a system beyond the rated pressure and temperature of the lowest rated component, or with an incompatible system media. Low quality fluid system components can also be a factor in overall system leakage. It’s important to recognize the value of a comprehensive and validated leak management program at your facility.

Swagelok Evaluation & Advisory Services

We have found that about two-thirds of energy costs for compressed air can be significantly reduced without large capital outlay. The solution is a comprehensive evaluation program that utilizes innovative technology to detect and quantify even the smallest of leaks. Our Energy Emission Specialist can work with your in-house team to improve system performance and reduce operational costs.

Our process is as follows:

• Initial discussion to review your unique situation and needs
• Customized proposal
• In-plant evaluation, in concert with your team
• Detailed report with prioritized recommendations
• Customized project/program management assistance

It’s not limited exclusively to tube fittings either – we’ll review any and all connections, including instrument and process valves, process piping, and flanged and threaded connections, to ensure your operation is fully optimized. Our report will include a summary of the work we’ve completed and underline the total, annual cost of leakage at your facility. We’re able to quantify the severity and cost associated with each leak point in order to help prioritize which to deal with first. We also identify a validation process designed to review your progress against the recommendations found in the report. Through it all we’re committed to ensuring you achieve a successful and on-going leak management program.

More than just Air

We recently worked with one of our refinery customers to identify potential cost savings of over $50,000 annually in compressed air loss. Another customer was able to realize increased efficiency in their air utility systems which led them to reconsider the purchase of a new $250,000 compressor package. But it’s not just air we’re concerned about – steam, hydraulic fluid, fuel, and gases that are purchased such as helium, hydrogen and argon, are all within the scope of Swagelok’s Evaluation & Advisory Services and all can carry a significant cost of leakage.

Real World Example

Sometimes you don't know what you need - until you need it. Our customer, a large natural gas processing facility, sought the help of Swagelok Evaluation & Advisory Services during their most recent plant shutdown. Read more about how we were able to dramatically reduce the time required to address up-time leak testing, and maximize scheduling efficiency and localized labour economy.

Download the Case Study

Experience is a Great Teacher

Swagelok has 70 years of experience in fluid systems – providing high-quality components is our commitment you. We also want to make sure you get the most out of them. So give us a call or contact us through our website to set up a consultation today.

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