How Leaqs System becomes the world's most used program for leakage management ?
The Leaqs system has become the world’ most used system for leakage management. The system contains close to 8000 documented projects from virtually all types of industry. The information and know-how gained from these projects benefit all our clients and partners. Having access to such an extensive base of information allows us to better understand the factors that affect and provide results. If you are about to initiate an energy saving project or are evaluating various options of addressing the leakage problem. The decisions you make will not only determine the technical results in actual reduction of your compressed air consumption but also the financial results. It is well invested time to familiarize yourself with the various aspects of leakage management.
How does the Leaqs system reduces the project time, how important the factor is for the success.?
Compressed air is a very expensive utility. Most compressed air systems have a leakage rate between 20 and 30%. In a system that produces 50 cubic meters (M3 leakages is € 86,000 or € 7,200 per month based on € 0.02 per M3 and hour of the year. By using project time as the primary factor of evaluation of a leakage management program you will achieve better financial results. In the vast majority of cases the total cost of survey and repair represent less than a month’s delay in a project.) per minute with a 20% leakage rate, the annual cost of.
What is the key to successful repair ?
It is important to establish, that without repairing the leakages that there simply will not be any savings realized. Without a system that fully addresses the repair issues, the likelihood of succeeding with a leakage management program, is virtually eliminated. The LeaqsTM web based software facilitates an effective repair process. It enables identification of parts, brands, product codes, purchase-, work – orders, repair times, accessibility. The LeaqsTM system also allows you to fully customize reports according to your own requirements.
What is the reliable measure to establish the optinal interval ?
There is only one reliable method of establishing the optimal interval. That is to measure and track your air consumption on a continuous basis. Estimating interval without knowing air consumption is uneconomical. The interval will either be too long which results in an unnecessary amount of leakages. If the interval is too short then leakage management becomes too costly. When you monitor your air consumption you can easily determine if your consumption has increased to a level that warrants action. It is also a precautionary measure. Severe leakages can occur at any time, a burst pipe or hose can cause massive leakage volumes in locations and environments where they can leak unnoticed for years.
How the leakage detection survey can be carried out ?
Prior to the survey the client will receive information from LeaqsTM concerning the leakage survey project, such as technician name, contact details, time of arrival and is also requested to provide production layouts.

In the morning of the first survey day, a briefing meeting will take place. The technician will inform the client about the process and establish how they want the site documented with regards to departments, workplaces and machine numbers so that the documentation is according to the clients standards.

Comprehensive surveillance of the compressed air system and other pressurized gases. The survey will be carried out with the aid of the advanced DNDTM technology ultra-sonic equipment. A technology that filters background noise and only detects sounds generated by leakages.

The leakage detection can therefore be carried out under normal production time which enables control of machinery under operating conditions. Detected leakages are labeled and reported to the client for repair. Larger leakages that require immediate attention are notified immediately. All leakages are entered into the Leaqs web based system. This is done on-site, further increasing survey revenue whilst being able to provide results before we leave. We are also able to provide the client with the login details beforehand so that they can monitor progress.
What willl the client recive after the leakage detection survey ?
Prior to the survey or in the startup meeting the client will be issued with their log in details to the Leaqs system. Upon completion of the survey the clients welcome page looks like this:

Opening page for client. Each area, Graphs, Leakage Character, Overview and Last 5 projects open new pages related to specific fields of information, reports or tasks

Various reports available on-line

Leakage list – An overview of number of leakages and where they are located.

Repair report all leakages – A complete report providing all necessary information required for repair. Workplace, tag no. component, brand and product code and eventual comments related to each specific leakage. Report can be printed out in word format and is normally used as a work order.

Repair report Partially Accessible During Production – PNADP - Partially accessible means that leakages are not accessible during normal production hours but they do not require full production stop. If for instance the leakages are accessible to repair during breaks, nights or weekends then they are defined as PNADP and the repair report specifies when they are available to repair.

Using the Leaqs™ on line reporting system – All your leakage data is processed in the Leaqs™ Internet based software. After completed survey you will receive a password which gives you access to leakage data via the internet. This is the main tool for efficient and controlled repair procedures, in addition for analysis purposes.

What are the reports that is available on-line ?

Leakage list – An overview of number of leakages and where they are located.

Repair report all leakages – A complete report providing all necessary information required for repair. Workplace, tag no. component, brand and product code and eventual comments related to each specific leakage. Report can be printed out in word format and is normally used as a work order.

Repair report Partially Accessible During Production – PNADP - Partially accessible means that leakages are not accessible during normal production hours but they do not require full production stop. If for instance the leakages are accessible to repair during breaks, nights or weekends then they are defined as PNADP and the repair report specifies when they are available to repair.

Using the Leaqs™ on line reporting system – All your leakage data is processed in the Leaqs™ Internet based software. After completed survey you will receive a password which gives you access to leakage data via the internet. This is the main tool for efficient and controlled repair procedures, in addition for analysis purposes.

What is repair management ?

Repair management is the most underestimated part of the leakage management process. It is not possible to effectively begin repairing the leakages without first establishing a plan for the work. It is therefore essential that the planning phase is started as soon as possible. Preferably with the Leaqs™ technician still on site.

The Repair Management process.

  • Practical training using the Leaqs™ on-line system.
  • Establish the list and location of the priority leakages using the Leaqs™ CALM system.

  • Separate accessible (ADP), partially accessible (PNADP) leakages and the leakages that are not accessible during production (NADP)

  • Establish the required time and labor resources according to accessible, PNADP and NADP leakages.

  • Create a list of material requirements and purchase orders for material not available from stock.

  • Purchase orders and delivery times will determine repair times. Issue purchase orders as soon as possible.

  • Initiate repair on priority leakages that does not require external material.

  • Create a time schedule for all remaining leakages based on priority, material, and available labor resources.

  • Secure deliveries and that all material is clearly labeled upon arrival at site.

  • Review the reports for the reason of leakages. Address main problems, such as methods, parts (brands) that cause most problems.

  • Suggest technical improvements on methods and components.

  • Review the progress of repair report on a weekly basis and check documentation of the repairs.

  • If monitoring & surveillance is in place the results will be verified and analyzed. Results may vary depending on a number of factors that are directly system related such as initial pressure differential, type of compressors and load factors of the compressors. Required time for repair management is related to required time of survey. ie 3 days survey = 1 day repair management, 5 days survey = 2 days repair management.
  • Why repair service is an important factor for optimal results ?

    Time is the critical factor for optimal results. The repair issues should be addressed well before the survey, taking into account that that the required time is usually underestimated. The rule of thumb is that if you are not confident that the repairs can be managed within a month from the survey completion date, then it is more economical to outsource this work. We will normally provide the client with what we call a Financial Deadline calculation. The calculation is used to determine whether it is economical to outsource the repair work or do it in-house. It is simply a calculation that is automatically provided by the Leaqs system which takes into account the cost of delay from the time of discovery of the leakage and predicted time of repair. As Leaqs we can very accurately predict when our repair process will be completed. This is normally within a month of completion of the survey. This is regardless of the size of plant. If it is a large site we simply use more manpower to make sure we can complete it. Clients will almost always predict that it will take them 3-4 months to complete the repair work. Using this period and calculating the leakage cost during this period, adding their own labor costs you will normally find that the Leaqs cost is substantially less despite our considerably higher daily rate.. The reason is that their daily leakage cost quickly digests any saving potential in doing this in-house. The reality is that very few, if any, will actually have the repairs done within 3-4 months. Therefore it is essential that we upon completion of the survey have a serious discussion based on the financial dead line calculation.

    What does the working method of repair includes ?

    The C.A.L.M.-System has been developed by Leaqs™ in order to enable the control all of the aspects involved in the leakage management process. A central function is the report generator. It is designed to satisfy the information requirements for the different stages of the process that are not provided by the standard reports. All data surrounding each leakage can be correlated and provided in a report form. Some basic examples:

  • Material list by manufacturer or supplier

  • Repair times – by department, production line or machine

  • Repair planning – specification of dates and hours of accessibility to each leakage

  • Identifying main causes of leakages by the brand or product code

  • Leakage volumes broken down to department or machine level

  • Repair follow up – identify repair times and their accuracy

  • Follow up of individual technicians and their repair performance

  • What is P.I.P ( Product Identification Process ) ?

    When presenting the C.A.L.M. system for clients we have many times been accused of “overkill” on what on the surface appears to be a relatively simple problem. However, we have yet to meet a client with what we would call a working in-house system that has a leakage rate below 5% . There may be some out there but If we did come across one, then we would be very interested in the total costs of achieving that. The fact is that all clients underestimate the information requirements for an efficient process and their internal cost of procurement. Some clients have state of the art maintenance systems but they are not designed for leakage management and do not provide the information required for a true leakage management program. Naturally, the value of the Leaqs system increases by the size of the plant or the problem. Some projects on larger sites involve thousands of leakages and sourcing products and planning the repair work to repair all of them is simply impossible to do without a systematic approach and a system. Our approach when meeting sceptics is to ask what reports they think are unnecessary? They quickly realize that every report and function has a specific purpose and will at some stage of the process be necessary. It is why it is available. After 8000 documented projects we have come across just about every difficult problem and information requirement and have tried to accommodate that.

    How does the progress and improvement increases repair efficiency ?

    This is our latest function added to the Leaqs system which has proven extremely useful in reducing project time. Many components are difficult, if not impossible to identify on site. Age, location, absence of product code plates are just some of the reasons why this is difficult. However, they have to be replaced one way or another or simply left to leak which often is the case. After analyzing hundreds of projects we have found that one of the major causes for the leakages not being repaired was simply due to this reason. In order to solve this problem we developed the P.I.P function. The P.I.P. function means that when a component can’t be identified, a photo is uploaded. We also provide as much information as possible. E.g. 3/2 valve, ¼ “ connection, 24 V spool and if possible its function. This is done for each component. During or upon completion a PIP list is provided which is easily filtered according to manufacturer or type of component. This becomes one single document (file) that can be sent to your preferred pneumatics supplier or the Leaqs partner arranges the logistics. If you click on the photo it is enlarged. This has proven to be very effective and very popular with the pneumatic companies. It will drastically reduce time sourcing products and will increase repair efficiency.

    Why it is important to continue the leakage management program.?

    The Leaqs™ system is one of continuous improvement. Used correctly, it will reduce the survey and repair times in a very short space of time. It is fully possible to achieve a permanently, very low level of leakages. The level of success depends on a number of factors. The quality and responsiveness of your compressed air system being a major factor. The presence of control systems or frequency driven compressors will improve results. Systems with a high pressure differential (difference between the highest and lowest pressure) will initially experience that the pressure will increase in the system. This does not save energy. It does however make it possible to reduce the pressure provided that the previous pressure fluctuations did not cause production problems. We strongly recommend that flow and pressure measurement is installed in order to track progress and have verified results. This will take the quality of your compressed air system into account and show the true savings.