· BOSAN
Compressed-air leaks commonly occur at fittings, hoses, valves and equipment connections. An individual leak may seem minor, yet persistent losses can keep compressors supplying air without productive demand. Effective management requires a cycle of detection, recording, repair and verification rather than simply finding the loudest leak.
Identify Air Users Outside Production Hours
Flow during non-production periods is not necessarily all leakage. Instruments, dryers or other essential equipment may legitimately consume air. Separate normal demand from abnormal losses by recording pressure, flow and compressor operation, then investigate through a planned zone-isolation process. Confirm that isolation will not affect safety-related equipment or necessary processes; do not close the main valve indiscriminately.
Create Traceable Leak Records
Record location, component, inspection date and repair status for each leak, with photographs where helpful. Zone-based identification is more useful to maintenance teams than a count alone. Use suitable detection tools for concealed points and keep hands away from high-pressure jets. Estimated leakage depends on pressure, opening geometry and detection method, so unverified estimates should not be converted directly into fixed cost claims.
Prioritize Repairs by Operational Impact
Prioritize leaks affecting personnel safety, point-of-use pressure or sustained losses. Schedule repairs with shutdown, isolation and depressurization before replacing seals, fittings or hoses. Do not tighten or dismantle pressurized connections or use temporary materials without suitable pressure ratings. Recurring leaks also require investigation of vibration, mechanical strain and material selection rather than repeated seal replacement alone.
Verify Repairs under Comparable Conditions
After restoring supply, recheck repaired points and compare flow and compressor records at similar pressure and production conditions. Track completed and outstanding repairs separately, with ongoing attention to aging hoses, quick couplings and frequently moved equipment. Before-and-after records establish whether improvements persist or air demand quickly returns to its previous level.
Make Leak Detection Part of Routine Management
Assign inspection responsibility, recordkeeping and follow-up dates so leak management becomes part of the maintenance plan. Combining station efficiency with point-of-use management helps reduce unproductive air supply consistently.