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Case Study

Compressed Air Flow Leakage Surveys

    We analysed over 35 compressed air flow measurement locations at a coal fired power station in Queensland.

    Aquip’s on-site compressed air flow surveys provide an overall view into compressor performance, total air usage and identifying losses in real time. The service was easily deployed without disruption to the process or shutdown of machinery. This ultimately reduces downtime and minimises risks with added cost savings.

    Specifications

    Project

    Compressed Air Leakage

    Project Overview
    • Aquip Flowservices were approached to provide an analysis of over 35 compressed air flow measurement locations at a coal fired power station in Queensland.
    • The test locations included:
      • Outlet of Main Compressor Supply
      • Instrument Air
      • General Purpose Air
      • Demin Plant Supply Air
    • The team tested the flow measurements with Clamp-on Ultrasonic Flowmeters with one flowmeter being installed at each of the compressors as a reference.
    • A second and third meter were simultaneously installed along the supply line to confirm the reference flow. In many cases lower flow was detected.
    • Existing flowmeters, where installed, were verified.
    • The F601 Portable Ultrasonic portables logged the data in 1-second intervals on pipelines, with the average logging time at each point being 30 minutes.
    • Where pressure gauges/sensors were available, the team recorded details to infer Standard and Actual Volumetric flow rate, as well as totalised flow.
    • We also utilised clamp-on temperature probes where temperature elements were unavailable.
    • Pipes were constructed of varying materials including:
      • Stainless Steel
      • Copper
      • Carbon Steel
      • HDPE
    • Pipe tables, in conjunction with ultrasonic wall thickness gauges, were utilised to verify pipe dimensions.
    Project Challenges
    • Our assessment identified several pumps displaying poor hydraulic efficiencies, resulting in us deploying portable clamp-on flowmeters on pipes which varied in size from 40mm to 350mm.
    • Where significant or unexplained lower flow was detected, we deployed additional meters.
    • In a few cases, the ‘loss’ of flow was identified as an unknown flow diversion or a leak.
    Project Results
    • The team collected the information and summarised the data into individual reports for each compressor line, outlining compressor performance with the corresponding flow usages within that production area.
    • Specific repairs/upgrades to compressors were able to be identified or delayed where leaks or diversions were found to be the cause of unwarranted air demand.
    • By using our on-site Compressed Air Flow survey, the team were able to test multiple air lines within a short period of time.

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