Ultrasound Compressed Air Leak Detection
Find Compressed Air Leaks Fast & Easy with Ultrasound
Compressed air is common, expensive, and often wasted in large quantities. Many industrial operations lose 30-40% of their compressed air supply to system leaks without noticing.
During production, plant noise masks them, but when the plant is quiet, the hiss of wasted energy becomes difficult to ignore.
75%
Of compressed air cost is energy, not infrastructure.
30-40%
of compressed air supply is lost to leaks.
25-30%
of leak energy drain is recovered after one survey.
5-15%
Realized energy expenditure reduction after one survey.
The Real Cost of Compressed Air Leaks
Compressed air leaks impact more than the energy bill and tools & processes they power. They force compressors to run longer to maintain demand and put extra wear on a systems infrastructure. Over time, extra runtime increases wear and can lead to sudden, expensive repairs.
When compressed air leaks aren’t addressed, they cause pressure instability and threaten production capability. A high volume of leaks often points to a reactive reliability culture where small problems are accepted instead of eliminated. The good news: compressed air leaks are easy to find, prioritize, and repair with routine ultrasound leak detection.
A Faster Way to Find and Quantify Compressed Air Leaks
Ultrasound is a simple compressed air leak detection tool. Ultrasonic turbulence is generated as high-pressure air passes through an orifice into the low-pressure atmosphere. These high-frequency sounds are easily detected with ultrasonic instruments.
Ultrasound leak detectors heterodyne high-frequency signals so technicians can hear them on their headphones and visual signals they can see on a display allowing them the in-field tools to their system and pinpoint air leaks.
High-frequency emission detection filters out the audible noises coming from the factory floor. Thanks to this, Technicians can reliably detect leaks even in loud industrial environments.
Our Leak Detection Tools
Ultrasound leak detectors find leaks easily and reliably. Modern ultrasound tools allow technicians to not only locate leaks, but also document and quantify them, turning a leak survey into a measurable energy savings project.
- Scan while systems are operating, no shutdown required
- Tag and quantify leaks with reporting tools like Leak Reporter or SonaVu Insights
- Estimate energy cost and prioritize repairs
- Build repeatable inspection routes for ongoing leak management
Simplify compressed air leak detection with the SDT340, a condition monitoring data collector that combines airborne & contact ultrasound with vibration to capture the full health of production assets.
Learn MoreSonaVu+ is an acoustic imaging camera designed to thrive in tough industrial environments. It visualizes ultrasound to find compressed air, gas and vacuum leaks, electrical faults, mechanical anomalies and more.
Learn MoreSonaVu InSights™ transforms every inspection into a professional and actionable report. Documenting then ranking leaks based on severity and impact, while energy losses are calculated to prove ROI.
Learn MoreThe LEAKChecker is a cost-effective, purpose-built ultrasound tool for detecting, documenting, and repairing compressed air, gas, and vacuum leaks. Reduce energy waste and improve asset efficiency with the LEAKChecker.
Learn MoreMost Common Leak Spots
Compressed air leaks can occur anywhere along a distribution system, some of the Most Common Leak Spots occur at the fittings, hoses, regulators, and drain devices.
Internal diaphragms wear and crack over time, allowing compressed air to leak through the regulator.
Damaged O-rings and heavy use make quick couplers one of the most common compressed air leak points.
Rubber hoses are easily damaged by traffic, abrasion, and bending, leading to cracks and air leaks.
Faulty drain valves and fittings can leak compressed air while removing condensate from the system.
The Inspection Process
01
Plan the Route
Map out your inspection path, gather the right ultrasound equipment, and ensure proper PPE is in place for safe, efficient scanning.
02
Perform the Scan
Use airborne sensors or acoustic imaging to sweep across target areas. Listen and look for ultrasonic signatures of turbulence caused by compressed air or gas leaks.
03
Analyze and Report
Review collected data, tag leak locations, and quantify losses. Use tools like SonaVu Insights or Leak Reporter to prioritize repairs and track ROI.
04
Repair and Resurvey
After identifying issues, fix the leaks, then scan the same areas over again to validate your repairs and ensure that nothing was missed.
Get Started in Three Simple Steps
Partnering with SDT Ultrasound Solutions
SDT Ultrasound Solutions has been supporting industry for more than 50 years, helping organizations around the world get more out of their production processes, condition monitoring equipment and reliability strategy.
Our purpose-built solutions, training, and services empower you to reduce unplanned downtime, optimize maintenance schedules, and protect your mission-critical equipment. When you partner with SDT Ultrasound, you gain more than a vendor. You gain a proactive partner prepared to support your reliability journey with the tools, training, and partnership needed for success.
Compressed Air Leak Frequently Asked Questions
Compressed air leak surveys are often delayed because maintenance teams are managing many competing priorities. Leak detection can also be time consuming without the right tools, dedicated resources, or established inspection processes.
Ultrasound is effective because leaking compressed air creates high-frequency turbulence as it escapes from a high-pressure system into the surrounding atmosphere. Ultrasonic instruments filter out audible noise, and through a process called heterodyning, they translate ultrasonic turbulence into an audible signal, allowing technicians to pinpoint leaks quickly and accurately.
Yes. Ultrasonic leak detection allows technicians to scan compressed air systems while they remain in operation. This means inspections can be performed without shutting down equipment or interrupting production.
It is common for facilities to lose 30–40% of their compressed air demand to leaks before a survey is conducted. These losses increase electricity costs, force compressors to run longer, and reduce available system pressure.
Common leak locations include pressure regulators, quick couplers, air hoses, and automatic drain traps. These components experience constant pressure changes, vibration, and wear, making them frequent sources of compressed air leaks.
Compressed air leak detection often delivers a fast return on investment. In many facilities, the savings identified during a single survey can offset the cost of the inspection shortly after priority repairs are completed.
Yes. With the right ultrasound tools and basic training, maintenance teams can find and document compressed air leaks on their own. A professional survey is helpful when teams lack time, resources, reporting tools, or want a prioritized leak list to launch or improve their leak management program.
Yes. Compressed air systems are dynamic. Hoses, fittings, couplers, regulators, and drain traps wear over time, so new leaks can appear after repairs are completed. That is why routine ultrasound leak detection is more effective than a one-time inspection.
Yes. Acoustic imaging cameras visualize ultrasound, making it easier to scan large areas and locate leaks from a distance. This is especially useful for finding leaks in overhead piping, noisy production areas, or difficult-to-access equipment.