Compressed air systems are widely recognised as one of the largest sources of hidden energy loss within industrial facilities. Despite this, leaks often go undetected for months or even years, quietly driving up electricity consumption and compressor wear without any obvious outward sign. Research consistently shows that a poorly maintained compressed air system can lose a significant proportion of its output to leakage – waste that carries a direct and measurable cost. Ultrasonic leak detection surveys offer a fast, accurate, and non-intrusive way to locate those leaks and quantify the energy loss they represent.
Baseline RTS performs ultrasonic leak detection surveys using high-sensitivity acoustic instruments capable of identifying the high-frequency sound produced by escaping gases. This approach allows leaks to be located quickly and accurately while equipment remains fully operational, making it suitable for facilities that cannot afford to interrupt production for inspections.
When a gas escapes under pressure through a crack, loose fitting, or worn seal, it produces a distinctive high-frequency turbulence that is largely inaudible to the human ear but clearly detectable with specialist ultrasonic equipment. Our engineers scan the pipework, fittings, and associated equipment using directional ultrasonic detectors, allowing them to pinpoint even small leaks in noisy industrial environments where traditional listening methods would be ineffective.
The technology is effective across a broad range of gases and system types, including:
This versatility makes ultrasonic surveys a valuable tool not only for energy management but also for process reliability and electrical safety programmes.
Following the inspection, Baseline RTS provides a comprehensive leak register documenting every leak identified during the survey. Each entry includes the location of the leak, an estimated flow rate, and a calculated energy cost based on your system pressure and local electricity tariff. This gives you a clear picture of the total energy loss attributable to leakage and allows your maintenance team to prioritise repairs according to their individual impact.
For facilities with larger compressed air systems, the potential savings identified through a leak detection survey can be substantial. In many cases, the cost of the survey is recovered within a very short timeframe through the energy savings generated by repairing the leaks found.
Beyond the direct energy savings, ultrasonic leak detection surveys support a broader programme of asset management and sustainability. Reducing leakage reduces the load on your compressors, which in turn reduces wear and extends equipment life. Lower compressor demand also means reduced maintenance costs, fewer unplanned breakdowns, and improved system pressure stability – all of which contribute to a more reliable and efficient facility.
For organisations with energy reduction targets or carbon reporting obligations, a documented leak detection and repair programme provides clear, auditable evidence of action taken to reduce energy consumption. The combination of a baseline survey, a repair programme, and a follow-up inspection creates a measurable improvement record that supports both internal reporting and external verification.
Even after a comprehensive repair programme, new leaks will develop over time as fittings age, seals degrade, and systems are modified. A single survey provides a snapshot of current conditions, but a regular inspection programme ensures that leakage levels are kept under control on an ongoing basis. Many facilities find that scheduling an annual or bi-annual ultrasonic survey as part of their planned maintenance calendar is the most effective way to maintain system efficiency and prevent energy waste from accumulating.
Baseline RTS can work with you to develop an inspection schedule that fits your operational requirements, whether that means a single comprehensive survey of your entire site or a rolling programme targeting high-priority systems on a defined cycle.
Our engineers are experienced in working within active industrial environments and carry out all surveys with minimal disruption to operations. Surveys can typically be completed within a single visit for most sites, with the written report and leak register delivered promptly following the inspection.
If you suspect your facility may have compressed air or gas leaks – or if you simply want to understand what your system is losing – speak with Baseline RTS today to arrange an ultrasonic leak detection survey.
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