MAINTENANCE

Pneumatic System Leak Detection

Air leak detection in pneumatic lines, preventing energy waste, and maximizing system performance.

December 10, 2025

12 min read

BRS PROSES Engineering Team

An air leak you can't see or hear quietly adds to the electricity bill all year round. Nearly a third of the compressed air produced in industrial facilities is estimated to be lost to leaks.

Leak Cost Example

3mm hole, 6 bar → thousands in yearly electricity cost

1. The Real Cost of a Leak

A small hissing sound is actually a hidden, constantly-running load, since the compressor keeps working overtime to compensate for the loss.

2. Detection Methods

Method	Cost	Speed	Suitable Scale
Soap test	Very low	Slow	Small line, single point
Ultrasonic detector	Medium	Fast, remote	Large plant, noisy environment

Soap Test: apply soapy water to suspect points and watch for bubbles; effective for small leaks
Ultrasonic Detector: picks up turbulence's high frequency, detects from meters away without stopping production
Periodic Scanning: a program repeated every three months prevents leaks from accumulating

"Logging the repair date and estimated cost of every detected leak is the easiest way to show management the investment's payoff in concrete numbers."
— BRS PROSES Engineering Team

3. Most Common Leak Points and BRS Proses Support

Hose connections, quick couplers, and old cylinder seals are the most common leak points:

Ultrasonic leak scanning
Leak cost reporting
Periodic leak detection program setup
Repair and follow-up plan