Compressed Air Leak Detection & Energy Optimization

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Find and Fix Leaks Before They Drain Profit

Compressed air leaks are one of the most common sources of wasted energy in industrial facilities. Even small leaks can cause compressors to run longer, consume more power, and shorten equipment life. Legacy Industries provides professional compressed air leak detection and energy optimization services to help you find, fix, and prevent leaks , keeping your system efficient, reliable, and cost-effective.

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Why Leak Detection Matters

Issue	Cost Impact	Legacy Solution
Small leaks	Continuous compressor run time	Ultrasonic detection to locate hidden leaks
High pressure demand	Increased energy use	System balancing and pressure correction
Frequent cycling	Shortened compressor life	Load/unload optimization and pressure sequencing
Moisture at tools	Air quality issues	Dryer and drain evaluation
Noise and vibration	Operator safety and air loss	Targeted repair and isolation

Every 1/8-inch hole in a 100 psi line can waste over 1,000 dollars per year in electricity. Leak detection directly translates to measurable savings.

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How Our Leak Detection Process Works

1. System Evaluation

We start by reviewing compressor capacity, pressure settings, and operating hours to identify where air demand and loss occur.

2. Ultrasonic Leak Survey

Technicians use high-frequency detection equipment to locate leaks too small to hear, even in noisy production environments.

3. Leak Tagging and Documentation

Each leak is tagged, documented, and prioritized by severity, including an estimated cfm loss and cost impact.

4. Immediate Repairs or Scheduled Fixes

Depending on accessibility, our team repairs leaks on-site or schedules replacement parts for safe shutdown periods.

5. Verification and Reporting

Once repaired, each leak is rechecked under operating pressure to confirm a complete seal. We deliver a detailed report showing energy recovery and total system improvement.

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Energy Optimization Services

Leak repair is just one part of the solution. Legacy Industries analyzes your entire air system for efficiency improvements.

Optimization Area	Benefit	Service Action
Pressure control	Lower energy cost	Adjust setpoints and balance demand
Sequencing	Improved compressor performance	Optimize load sharing between units
Storage and receivers	Reduced cycling	Install or resize tanks for steady pressure
Filtration and dryers	Cleaner air	Replace clogged filters and maintain dew point
Flow analysis	Identify restrictions	Measure pressure drop and correct piping layout

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Key Benefits of Our Leak Detection Program

• Reduced compressor runtime and energy costs
• Verified performance improvements with before-and-after readings
• Fewer maintenance calls and longer equipment life
• Lower operating pressure requirements
• Improved air quality and reliability at every point of use

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Tools and Technology We Use

• Ultrasonic leak detectors with pinpoint accuracy
• Digital pressure and flow logging instruments
• Thermal imaging for heat and airflow studies
• Inline dew point and differential sensors
• Energy monitoring software for cost tracking

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Leak Repair and Maintenance Options

On-the-Spot Repair

Technicians can reseal fittings, tighten joints, and replace small components immediately after detection to prevent further loss.

Planned System Repair

For complex leaks or worn fittings, we schedule full component replacements during maintenance windows with proper isolation and safety.

Preventive Maintenance Plan

We provide regular surveys and leak audits to maintain system efficiency year-round.

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Energy and Cost Savings Example

Leak Size	Air Loss (CFM)	Annual Energy Cost	Cost After Repair
1/16 inch	7	$500	$0
1/8 inch	28	$1,200	$0
1/4 inch	110	$4,700	$0

Based on 100 psi system pressure and $0.10 per kWh electricity cost.

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Safety and Compliance

• Lockout tagout and depressurization before major repairs
• OSHA-compliant inspection methods
• Clear tagging and documentation for maintenance tracking
• Proper PPE and confined space procedures
• Certified technicians trained in industrial safety protocols

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Recommended Leak Detection Frequency

Facility Type	Recommended Inspection	Key Benefits
Light industrial	Annually	Keeps energy usage stable
Multi-shift operations	Semiannual	Maintains consistent air pressure
Large plants	Quarterly	Continuous savings and early fault detection
Food or pharmaceutical	Quarterly	Ensures product integrity and compliance

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Frequently Asked Questions

Can leaks really cost that much energy?

Yes. Even a small leak can cause compressors to run longer, increasing power consumption and maintenance costs.

Can you test while production is running?

Yes. Our ultrasonic tools allow us to locate leaks during normal operations without interrupting production.

Do you fix leaks on the same visit?

Most leaks can be sealed immediately. For larger or inaccessible ones, we provide a plan with parts and labor estimates.

Do you provide documentation for energy audits?

Yes. Every service includes a full report with readings, repair logs, and projected annual energy savings.

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Service Area

Legacy Industries provides leak detection and energy optimization services across Greenville, Spartanburg, Anderson, Simpsonville, Laurens, and Gaffney, as well as Western North Carolina and North Georgia.

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Reduce Waste, Improve Efficiency, and Save Energy

A leak-free compressed air system means lower costs, fewer shutdowns, and better performance. Legacy Industries delivers measurable results through advanced detection, professional repairs, and ongoing optimization that protects your investment.

Phone: (864) 431 4670

Email: tyler.abbott@legacyind.net

Service Region: Upstate South Carolina and surrounding areas