A compressed air system inspection looks at your compressors, receivers, dryers, filters and piping to find leaks, wasted energy and safety hazards. You get a clear picture of the system's condition and a ranked list of fixes, from quick leak repairs to larger changes in how the system is set up.
Compressed air is one of the most expensive forms of energy in a plant, because most of the electricity a compressor uses becomes heat rather than useful work. Leaks, high pressure settings and poorly controlled compressors add to that cost every hour the system runs. Compressed air is also stored energy, and receivers are pressure vessels, so condition and safety matter as much as efficiency.
What we look at
- Compressors: type, condition, controls, loading and unloading behaviour, and how multiple units are sequenced.
- Air receivers: condition, drains, pressure relief valves, nameplates and registration.
- Air treatment: dryers, filters and condensate drains, and whether air quality matches what end uses need.
- Distribution piping: material, sizing, pressure drop, drops and hoses, and isolation valves.
- Leaks: located and tagged using ultrasonic leak detection, with an estimate of relative severity.
- End uses: inappropriate uses such as open blowing or cabinet cooling, and pressure set higher than needed.
- Safety: guarding, hose condition and whip restraints, lockout points, and how stored pressure is released before work.
Pressure vessels. Air receivers above certain size and pressure limits are regulated under provincial boiler and pressure vessel programs, which may require registration and periodic inspection by the province or its designated authority. Our inspection does not replace that. We assess condition independently, help you prepare for the mandated inspection and follow up on its findings.
How it works
- We start with why. High power bills, pressure problems at the end of the line, a compressor that runs constantly or a new production line all lead to different questions.
- System review. We gather equipment data, drawings if they exist and any maintenance or energy records.
- Site inspection. We walk the compressor room and the distribution system, inspect equipment in operation and record pressures at key points.
- Leak survey. Where included, we survey for leaks with ultrasonic equipment and tag each one for repair.
- Report and priorities. We rank findings by safety, cost and effort, and walk you through them.
What you get
A written report covering equipment condition, safety deficiencies, a leak list with locations and tags, and recommendations on pressure settings, controls, treatment and piping. Recommendations are grouped into things maintenance staff can fix now, items for a contractor, and larger changes to consider in capital planning. We can also coordinate repair work and re-check the system afterwards.
Leak tags stay on the piping until the repair is made, so your maintenance team can work through the list on their own schedule and see progress. Leaks come back as fittings age and equipment is moved, so many sites repeat the survey periodically and treat it as part of routine maintenance rather than a one-time project.
Who it's for
- Plant and maintenance managers looking to cut energy use or fix pressure problems.
- Safety managers who want compressed air hazards identified and controlled.
- Owners planning to add production equipment or replace a compressor.
- Facilities with a compressed air system that has grown piece by piece over the years.
Our guides on compressed air leaks and what they cost and compressed air system safety cover the background. For wider plant work, see mechanical system inspections.
Common questions
Can leaks be found while the plant is running?
Yes. Ultrasonic leak detection works with the system pressurized, and is often easier during quieter shifts. Some leaks only appear when certain equipment is running, so timing matters.
Will you tell us to buy a new compressor?
Only if the findings support it. Leaks, pressure settings and controls are usually worth fixing first, because they change how much compressor capacity you actually need.
Do our air receivers need a provincial inspection?
It depends on the vessel's size, pressure and your province's rules. We can help you check the nameplate and registration and point you to the right authority.