Eliminating leaks in compressed air installation

Removal of leaks in the compressed air system

Compressed air leaks are one of the most common sources of energy losses in industry. Thanks to the audit and repair works by DB Energy, a client from the construction sector reduced energy consumption by 2.21 GWh annually, achieving a quick payback period.

The challenge

Compressed air is one of the most expensive energy media in industrial facilities – its production consumes significant amounts of electricity. In many enterprises, serious losses occur due to system leaks. Statistically, in 80% of plants in Europe, leaks account for 25–30% of total air consumption. Our experience shows that this is a common problem also in Poland.

In one construction sector client, an energy audit revealed a significant level of leaks, resulting in high energy costs and additional load on compressors.

Our approach

The DB Energy team conducted:

a detailed inventory of the compressed air installation,
flow and pressure measurements at various points of the system,
leak detection using specialized ultrasonic devices,
cost analysis of potential energy losses and effects of planned repairs.

A key element was not only eliminating identified leaks but also indicating areas with a higher risk of recurrence. As a result, the plant received a preventive plan including regular monitoring and maintenance of the system.

Solution

As part of the project, repair works were carried out at critical points of the compressed air system:

sealed connections and fittings,
replaced worn system components,
optimized compressor settings after air loss reduction.

Investment outlays amounted to approx. PLN 170,000, which is relatively low compared to the scale of achieved savings.

Results

The project implementation brought tangible benefits:

energy savings: 2.21 GWh annually,
energy cost reduction: PLN 574,600 per year,
simple payback period: under 6 months,
increased reliability and stability of compressor operation,
reduction of CO₂ emissions.

Conclusions

Repairing compressed air leaks is one of the most cost-effective efficiency actions in industry. The example of a construction sector client shows that even a relatively small investment can result in million-scale savings over a few years. Regular monitoring and systematic leak removal should be a permanent element of the energy management strategy in industrial plants.

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