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07/30/2012 02:18 PM
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Hey there,
I am wondering if anyone has any documentation of how to implement a leak management program? Ideally, something that could lead me through a step by step process to implement a program of this type.
Any help or advice is appreciated!
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07/31/2012 12:41 PM
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My suggestions for Compressed Air Reduction Program (worked for me to the tune on $45K reduction in annual power costs, two years running)
1) Create a simple marketing slide/sheet/poster showing cost of leaks
- somewhere between $2K and $4K for a 1/8" leak all year at 90 psig
- local power utilility should have some fancy documentation here to help
and cost of power for poor compressor use/maintenance (20% plus of wasted energy)
2) Set a target for reduction in dollars (or local currency) for improved compressed air usage
3) Figure way to isolate compressed air actual costs for facility (power meters at MCC level?)
4) Purchase some ultrasonic acoustic detector meters
5) Have "Leak Detection Days" for maintenance/operations group whereby plant is split in manageable areas and leaks are identified with some tag system
6) Commit to a "Leak Correction Daytm" with some of PM group to repair identified leaks (twice monthly). DON'T DROP!
7) Track leaks identified/corrected on a chart that is accessible to all
8) Perform Compressor Use/Loading/Maintenance audit with reputable firm (i.e. if they only talk about leak reduction, find another!)
9) Take action on audit findings (with a caveat)
10) Produce monthly compressed air power cost change chart for all to see (wherever this is appropriate in the facility)
11) Incentifytm the Program
12) Have fun!!!
13) Forget this number!
Cheers
Craig
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08/01/2012 05:07 PM
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Dave,
Here is the cheap way to find air leaks -
Turn off all machines, fans, motors - anything that moves or makes noise - everything except the lights and the air compressor.
You will hear the leaks. Use a funnel, hose, or rolled up sheet of paper in your ear to narrow it down. FInd 'em & fix 'em. No putty or duct tape.
And get rid of plastic hoses. They leak sooner or later. If you use them put in a solid shuttoff valve at the solid connection, and use it. (part of 5S shutdown check sheet).
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08/02/2012 11:12 AM
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Good info guys, thanks!
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