Ultrasonic leak survey

Compressed Air Leak Detection That Finds the Air You Pay For but Never Use

Compressed air leak detection uses an ultrasonic detector to hear the high-frequency sound escaping air makes, even over running production equipment. FPA traces each signal to its source, documents the location, and gives your maintenance team a repair list ranked by what is worth fixing first.

The invisible operating cost

Every Hiss Has a Price

A loose fitting looks like nothing. Multiply it across hundreds of connections and thousands of operating hours and it becomes a compressor running longer than it needs to.

Each compressed air leak adds demand to the system. The compressors work harder to hold pressure, and the equipment at the end of the line can end up with less air than it was designed for. Because the sound sits above human hearing and the cost never appears as a line item, the problem grows quietly until someone proposes buying another compressor.

FPA uses ultrasound to locate compressed air leaks in noisy plants, then turns the findings into an inspection record your maintenance team can work from and verify against.

Compressed Air Leak | Failure Prevention Associates
Why inspect

3 Things a Compressed Air Leak Survey Gives Back

Leaks consume capacity before it ever reaches the process. The U.S. Department of Energy recommends ultrasonic acoustic detection for finding the high-frequency sound of escaping air, and because leakage varies enormously between facilities, a plant-specific survey is the only way to know your own number.

01

Energy

Reduce avoidable compressor demand once repairs are verified, rather than assuming the load is real.

02

Pressure

Support steadier delivery at the points of use that actually matter to production.

03

Capacity

Recover usable air you already generate before budgeting for another compressor.

What a repair actually returns depends on leak size, system pressure, operating hours, compressor controls, repair quality and system configuration. FPA does not publish a savings percentage, because a number from another plant tells you nothing about yours.

Detection built for real plants

How Ultrasound Hears Past the Background Noise

Escaping compressed air produces turbulence, and turbulence produces sound well above the range of human hearing. That is the advantage: plant noise sits mostly at low frequencies, so an ultrasonic instrument can isolate a compressed air leak that nobody standing next to it can hear.

The detector shifts that high-frequency signal down into an audible range for the inspector, who then narrows the beam until the sound peaks at the source. It is a directional signal, which is what makes a leak findable rather than just detectable.

The same technology and the same technicians cover air and gas leaks, vacuum leaks, bearing condition and electrical faults. This survey applies that capability to the compressed air network specifically.

Explore Ultrasound Services →
Compressed Air Leak | Failure Prevention Associates
Compressed Air Leak | Failure Prevention Associates
From sound to a repair list

The 4-Step Compressed Air Leak Survey: Inspect, Document, Repair, Verify

The fourth step is the one most programs skip, and it is the one that makes the first three worth paying for. A leak survey without a verification pass is a document, not a result.

Step 01

Define the route

Review the accessible systems, operating conditions, production constraints and inspection priorities, so the survey covers what matters and nothing gets skipped by accident.

Step 02

Locate the leaks

Scan the piping, air preparation sets and equipment with ultrasound, then narrow each signal down to the component that is losing air.

Step 03

Record the findings

Capture the location, the component and the observations, tagged so a millwright can walk straight to it. Quantification methods for your system are discussed here, not assumed.

Step 04

Close the loop

Repair and reinspect. The follow-up survey confirms which leaks were resolved, catches the ones that were missed, and gives you a baseline for the next round.

Service areas

Related Visual Vibration Analysis landing pages

Louisiana

Alexandria

Baton Rouge

Geismar

Lafayette

Lake Charles

New Orleans

Shreveport

Nebraska

Omaha

New Mexico

Hobbs

Oklahoma

Oklahoma City

Tulsa

Texas

Amarillo

Austin

Beaumont–Port Arthur

Corpus Christi

Dallas

El Paso

Fort Worth

Houston

Laredo

Lubbock

McAllen

Midland

San Antonio

Frequently asked questions

Compressed Air Leak Detection Questions From the Plant Floor

Every survey depends on the system, the access and the production schedule. Send those details and FPA can scope the right route.

An ultrasonic detector listens for the high-frequency sound produced as pressurized air escapes through a fitting, hose, valve or other opening. The inspector narrows the instrument until the signal peaks, which identifies the leak location. Ultrasound is used because plant noise is mostly low frequency, so the leak signal stands out.

Usually yes, and running is often better. The system has to be pressurized for a leak to make any sound at all, so a survey during normal operation reflects real conditions. Access, site safety requirements and production constraints determine the route.

Ask about the measurement and estimation method available for your system. Any cost figure depends on pressure, leak rate, operating hours, your electricity rate and compressor performance, so it is an estimate for planning rather than a guaranteed saving.

Repair the priority findings, note any areas that were inaccessible, and schedule a follow-up inspection. The reinspection confirms the completed repairs and keeps new leaks from quietly becoming a recurring cost.

Annually is a common baseline for a plant with an active maintenance program, with a follow-up pass after each repair round. Facilities with high leak counts, frequent line changes or heavy pneumatic tool use often benefit from twice a year until the count comes down.

Compressed air leak detection time depends on the size of the distribution system and how much of it is accessible. A single production area is often a day; a full plant with multiple buildings takes longer. Sending a layout or a list of areas lets FPA scope it properly before quoting.

No. Compressed air leak detection is non-contact and non-invasive, done while the system is pressurized and running. What matters is safe access to the piping and equipment, which is arranged with your site team beforehand.

Yes, and it is usually the efficient way to do it. The same instrument and inspector can check bearing condition, steam traps, vacuum leaks and electrical faults on the same visit, so one mobilization covers several technologies.
Get in touch

Turn a Hidden Cost Into a Clear Repair List

Tell us about the system, the areas that matter and when the plant runs. An FPA inspector will scope a compressed air leak detection route and tell you what the survey and the follow-up pass involve.

Main: (832) 930-0756