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Flow calculation for air leaks

Each pneumatical equipment should be stopped before measurement is performed (usually end of shift)
Locations measure the time between 2 pressure rises of the air piping network. In other words,
the time elapsed between the moment the compressor has just stopped (air pressure is than maximum)
and the moment the compressor stops again after having restarted due to the pressure drop.
(Because of leaks in the piping network, pressure will drop and trigger the compressor to restart once air pressure has reached a minimum value)

The leak flow is calculated as follows:

( Pmax bar - Pmin bar) x Air network volume m3 x Time measured seconds
Flow Nm3/h = --------------------------------------------------------------------------------------------
3600

This measurement should be carried out per location every month (see 3 rd tab for monitoring)
Key in data in green cells only ( 2nd and tab 3rd)

Definition

Pmax : Pressure measured when compressor stops (in bar)


Pmin : Pressure measured when compressor starts (in bar)
Time : Time measured between Pmax and Pmin in seconds
Air network: includes air tanks and piping to the various equipments (filling machines, valves..). See 2 nd tab for the calculation of the air volume contained in the network

Tips, Best practice to locate leaks

To locate air leaks, best option is to walk next to the piping network/tanks and listen to the characteristic noise made by leaks (end of shifts when plant is quiet)
Remedial actions consist in tightening piping connections or changing seals. Correct setting of air pressure of each pneumatically equipment is also important
(set pressure as low as possible, compatible with equipment running features, as the higher the pressure is the greater leaks are)
Location Filling Plant 1 Choose your location (fill in colum O)

Calculation procedure:

1) Identify every air tank and their capacity


2) Estimate lengths of piping per diameter (use design drawings)
3) Log in values in table below (green cells)

Item Volume/m in m3 Length in m Total Volume in m3


" Pipe 0.0001767 0 0
" Pipe 0.0003142 0 0
1" Pipe 0.0004909 0 0
1 " Pipe 0.0008042 0 0
1" Pipe 0.0012566 0 0
2" Pipe 0.0019635 0 0
3" Pipe 0.0050265 0 0
4" Pipe 0.0078540 0 0
6" Pipe 0.0176715 0 0
Compressor tank 0
Filling Hall tank 0
Pump facility tank 0
Other Tank 0
Other Tank 0
Other Tank 0

Total volume of air network 0.0

For information
Inches ( " ) diameter ( mm)
15
20
1 25
1 32
1 40
2 50
3 80
4 100
6 150
Leak flow calculation for Filling Plant 1

Procedure :

Leak flow

Each location measures the time between 2 pressure rises of the air network. Calculation is

( Pmax bar - Pmin bar) x Air network volume m3 x Time measured seconds
Flow Nm3/h = --------------------------------------------------------------------------------------------
3600

MONTHLY LEAK FLOW RATE


Definition
Pmax : Pressure measured when compressor stops (in bar)
Pmin : Pressure measured when compressor starts (in bar) 10.00
Time : Time measured between Pmax and Pmin in secondes
9.00

Total Vol. of air network : 0.0 m3 8.00

7.00
bars bars Seconds Nm3/H
Month P max P min Time FLOW 6.00
JANUARY -
5.00
FEBRUARY -
MARCH - 4.00
APRIL -
3.00
MAY -
JUNE - 2.00
JULY -
AUGUST - 1.00
SEPTEMBER - 0.00
OCTOBER -
R
Y
R
Y
C
H IL A
Y
N
E
LY S
T
E
R
ER ER E
R
NOVEMBER - R U
U
A A
A
R P M JU JU G
B
O
B B B
DECEMBER - N R
U
M
A U EM T E
M
EM
A T C V C
JA B P O E
ANNUAL AVERAGE - FE SE N
O D