Energy aware with air Published Oct. 29, 2009 By Brandice J. Armstrong Tinker Public Affairs TINKER AIR FORCE BASE, Okla. -- October may be designated Energy Awareness Month, but one Tinker squadron is energy-mindful all-year long. The 76th Maintenance Support Squadron routinely scans many of the base's compressed air systems, inert gas systems and checks the health of mission-critical industrial equipment. 72nd Civil Engineering Directorate officials said the squadron's conservation efforts are saving Tinker big bucks while providing a clean air source and reducing equipment down time. It is estimated that the Predictive Maintenance Lab's ultrasonic leak detection program has saved the base at least $380,000 in fiscal 2009. The PDM Lab is a group within the 76th MXSS and because of the ultrasonic leak detection program, the system is tighter -- gases and oil are of a better quality, and equipment has been saved. "The base spends about $100,000 a day on utilities," said Paul Garnaas, 72nd CE Resource Efficiency manager. "So, if we can save $300,000 over a year just on leak detection, which is a constant battle, that's significant." Donald "Donnie" Hunt, 76th MXSS mechanical engineer and team lead for the PDM Lab, which oversees the leak detection program technology, agreed. "There is an opportunity for saving our resources and energy use by tightening up our pressurized piping systems," he said. "This allows us to use much less high-cost process gases for production and to reduce run time on our shop air compressors if our systems are leak free." Compressed air is used to run hoists and hand tools. Mr. Garnaas said compressed air is often referred to as the third utility, behind electricity and natural gas. Argon, on the other hand, is a tasteless, odorless and colorless gas used in welding. The leak detection program, used for both compressed air and Argon, allows 76th MXSS maintenance personnel to find leaks that may not be identified by the human ear. 76th MXSS personnel typically look for a leak after a maintenance worker has detected one but cannot pinpoint its exact location, when a work order is submitted or during a routine inspection. 76th MXSS personnel, donning a pair of headphones and carrying an ultrasonic leak detector, spot the direction of the leak and measure the sound quantitatively, display sonic patterns and determine the flow of the leak. "A 16th-inch diameter hole costs about $860 a year. One-hundred such 'little' leaks in a system wastes $86,000 per year, plus it harms the quality of the compressed air," Mr. Garnaas said. "You can't really put a number on the cost of water that gets 'wicked' in the system because it's hard to put a value on good, high-quality air." "Wick" refers to water getting pulled into the piping causing rust and corrosion. Wicking damages tools and destroys the air quality. Mr. Garnaas said the leaks don't typically expand, but become nuisances. He compared them to leaks found in a home. "It's like spotting a leak in the water system in your house. You wouldn't allow water to run on the floor all day, every day. You'd fix that leak," he said. "It's the same kind of mentality with air. It's expensive and damaging to allow the compressors to run more than they should." One-thousand cubic feet of compressed air costs roughly 30 cents. "It doesn't take long to lose a lot of air," Mr. Garnaas said. Prior to the implementation of the leak detection program in 2001, base officials spent up to $1.8 million each year for the installation compressed air utility bill. Since the program was instituted, 76th MXSS maintenance personnel have repaired more than 600 leaks. In fiscal 2009, approximately $659,000 was spent on compressed air. The 76th PDM Lab also used the ultrasonic leak-detection method to locate a leak in one of the large Argon storage tanks. Engine maintenance production personnel had determined they needed to add an extra Argon storage tank for an increased workload, but following a suggestion from the PDM Lab, 76th MXSS personnel scanned the Argon distribution system with an ultrasonic leak detector. Several leaks with one large leak valued at $40,000 per year, were found. Once the leaks were fixed, it was discovered there was actually enough Argon available in the existing storage tanks to handle the increased workload. "Tightening up the process gas systems also insures cleaner welds and heating processes by eliminating contamination inducted at leaks in the system," Mr. Hunt said. The 76th MXSS also checks oil quality to ensure that machinery, air compressors and motors contain clean quality lubrication as part of the preventive maintenance program. "Instead of being responsive to a failure, the 76th MXSS goes out and finds that failure," Mr. Garnaas said. "It helps with better budgeting and lower maintenance costs overall." To suggest energy ideas and concerns send an e-mail to 72abw.ce.energy@tinker.af.mil.