Calculating Compressed air leaks within a system

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Discussion Overview

The discussion revolves around calculating the leak rate of compressed air within a system, including the determination of energy wasted due to these leaks. Participants explore methods for measuring leak rates based on various parameters such as hole diameter, dB readings, and system pressure, as well as potential resources for standard calculations.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Mathematical reasoning

Main Points Raised

  • One participant seeks assistance in calculating the leak rate in CFM and the energy wasted in kW after conducting an air leak survey, noting specific parameters like hole diameter and pressure.
  • Another participant describes a method involving sealing the input/output of a unit, increasing internal pressure, and measuring pressure drop over time to determine leakage rate.
  • A different participant mentions using a chart for flow calculations related to a specific hole size and pressure, suggesting a method to calculate the cost associated with leaks based on compressor capacity and utility rates.
  • One participant provides a link to formulas that could assist in the calculations, indicating potential resources for further exploration.

Areas of Agreement / Disagreement

Participants express various methods and approaches to calculating leak rates and energy loss, but no consensus is reached on a single method or formula. Multiple competing views and techniques are presented.

Contextual Notes

Some methods rely on specific setups and assumptions about pressure and measurement intervals, which may not be universally applicable. The discussion includes references to external resources that may have varying levels of reliability.

Who May Find This Useful

Individuals involved in industrial maintenance, energy management, or those conducting air leak surveys may find the discussion relevant.

rl424
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Hi all, new to the forum, but I was wondering if anyone could help me as I'm going round in circles. After completeing an air leak survey and noting the hole diameter, dB reading of the leak and knowing the pressure of the system (bar) how can I calculate the leak rate CFM and the Energy wasted (kW). Or is there some kind of standard/approximate table I can use.

Thanks in advance
 
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I've done something similar in the past for testing various units.

You seal input / output of the unit and increase the internal pressure to a set value. You then take internal pressure readings over a set period (we used each minute for 15 minutes).

After which time you know the pressure drop over a set time which you can convert to leakage rate per unit time.

I'll try to dig out the equation for you (it's fairly simple), but if you could describe your setup it would help me determine if it's right for you.
 
rl424 said:
Hi all, new to the forum, but I was wondering if anyone could help me as I'm going round in circles. After completeing an air leak survey and noting the hole diameter, dB reading of the leak and knowing the pressure of the system (bar) how can I calculate the leak rate CFM and the Energy wasted (kW). Or is there some kind of standard/approximate table I can use.

Thanks in advance

I've done this for my work also. I used a chart like this one for the flow calculation for an example of a 1/8th inch hole leak at 24-7. http://www.trident.on.ca/orifice-air-flow.htm
Divide the flow into the compressors capacity and find the percent of it's capacity. Multiply the compressor loaded kw by the calculated percent of the leak. That times the utility kwh rate is part of your cost. The other cost is the maintenance of the compressor for the percent of the leaks. The cost of air leaks in a large plant is mind-blowing.
 
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