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2006 LE Meeting





Andy Lyczak LE,
Lockport-IL

July 20, 2006
Miami, FL
Best Practice: How to Sell and Conduct a
Mobil Air Leak Inspection
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So How Do I Sell This?
Know what your customer already
knows!
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Question: The U.S. Department of Energy has determined that
_______ ______ are one of the largest users of electrical
energy.
Answer: AIR COMPRESSORS! They
constitute 7-40% of total electrical plant use.
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Conditions for Conducting a
Mobil Air Leak Inspection Study
Compressor demand increases under static production
conditions
Plant operators notice sluggish operation of pneumatic
controlled machines
Plant personnel report increased noise levels in production
areas
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So How Do I Sell This?
Know what your customer doesnt
know!
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Question: In a typical plant, air leaks account for ___% of total air
usage.
Answer: 18. Also, one 1/8 air leak for standard
plant air system operating at 100 psi will lose about
26 cfm. At $0.06 kw/hr, this will cost about $2,600
for one leak!
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Air Leak Cost Chart
Diameter of Leak CFM Loss ($/Yr)
1/64 576 $48
1/32 2,304 $186
3/64 5,270 $424
1/16 9,288 $744
3/32 20,880 $1,674
1/8 37,152 $2,981
3/16 83,952 $6,738
1/4 148,320 $11,904
5/16 233,280 $18,721
3/8 336,960 $27,036
Based on 100 PSIG, $0.22/MCF & 8,760 hours/year
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So How Do I Sell This?
Know what your competition
knows!
Typical Fee is $10,000 and up for this
service
Our fee is $2,000/eng-day
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So How Do I Sell This?
Scope work for time estimate
Typically 50 machines/day

Utilize PES DB/IRL for Collateral
Suncast, Batavia-IL
Pactiv, Wheeling-IL

Present & Obtain Advance
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Conducting the Study
Step 1: Getting Baseline Information....

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Conducting the Study
Step 1: Getting Baseline Information....
Identify machines and compressors for study
Record machine make, model, age, and maintenance history
Log hours of operation
Obtain electrical utility cost
Estimate/calculate maintenance hours spend due to additional
compressor demand

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Conducting the Study
Step 2: Assemble the Toolkit.....
Amprobe model ULD-300 ultrasonic leak detector or equivalent
Tags for air leak points
Secure use of plant hydraulic lift for inspection of overhead air
lines
Plant required safety gear (safety shoes, glasses, and fall
protection are minimum)
Digital camera
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Conducting the Study
Step 3: Planning the Study
Schedule the event during outage (external plant noise affects
detector operation)
Arrange for a mechanic to assist
Allow for at least 10 minutes per machine
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Conducting the Study
Step 4: Find the Leaks
Begin search for leaks by scanning compressed air lines from
air storage vessel to plant machines. Adjust sensitivity of
detector.
Utilize hydraulic lift to inspect overhead plant air lines
Photograph and tag air leaks.
Log location
Estimate diameter size of hole (translates to CFM loss)
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Follow the LED light

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Tag those Leaks for Future Repair!

Other examples............
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Leak at valve block divider

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Leak at hole on ALO regulator

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Leak at fitting to grease pump

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Conducting the Study
Step 4: Document Results to Customer
Prepare a TCO Engineering Report
Benefits Include:
Reduced electrical energy consumption (big $)
Less compressor maintenance to maintain system load
Potential avoidance of additional compressor purchase to
meet production demands
Improved plant safety through noise reduction
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Questions..................