Leaks commonly waste 20–30% of output in an unmanaged plant.
1
Leaks at couplers, hoses and fittings
medCheckSurvey with an ultrasonic leak detector during a shutdown; tag every find.
FixRepair by tag order, largest first; replace disposable couplers with quality ones.
ToolsUltrasonic leak detector
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2
Condensate drains stuck open or timers set too long
medCheckListen at each drain; a timer draining longer than it needs blows live air.
FixConvert to zero-loss / demand drains and shorten timer open periods.
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3
Idle equipment left pressurised
lowCheckWalk the plant during a no-production period and measure how much the compressor still runs.
FixFit isolation valves at machine drops and close them out of hours.
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4
Leaking safety relief or blowdown muffler
medCheckCheck the relief valve and blowdown muffler for continuous airflow while running loaded.
FixReplace the relief valve (never reseat), rebuild the blowdown valve.
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Safety
Lockout/tagout before opening enclosures. Verify zero energy. Bleed system pressure before opening any pneumatic connection.