Compressed Air Leak Survey

Inspection template for conducting an ultrasonic compressed air leak survey, tagging leaks, documenting repairs, and estimating energy savings.

Survey Details

• Survey area and system identified
  Specify the building, line, compressor room, or production area included in the survey.
• Survey date and time recorded
  Document when the survey was performed.
• System operating pressure recorded
  Record the observed system pressure during the survey.
• Operating conditions documented
  Note whether production was running, equipment was isolated, or any conditions affecting leak detection.
• Survey scope and exclusions documented
  List any areas, machines, or lines excluded from the survey.

Ultrasonic Detection Equipment

• Ultrasonic detector functional and calibrated
  Confirm the detector powers on, responds properly, and is within calibration interval if applicable.
• Headphones or listening device available and functional
  Verify the inspector can clearly hear ultrasonic signals through the listening device.
• Sensitivity setting documented
  Record the detector sensitivity or gain setting used during the survey.
• Background noise conditions assessed
  Rate whether ambient noise or process noise affected leak detection.
• Reference document or SOP available
  Identify the procedure, checklist, or work instruction used for the survey.

Leak Identification and Tagging

• Leak location identified
  Describe the exact location of the leak, including equipment, fitting, valve, hose, or connection.
• Leak tag number assigned
  Record the unique tag or asset identifier applied to the leak.
• Leak severity estimated
  Classify the leak size or priority based on audible intensity, estimated flow, or repair urgency.
• Leak photo captured
  Take a photo of the leak location and tag for traceability.
• Leak source type identified
  Select the component type associated with the leak.

Repair Planning

• Repair action defined
  Describe the corrective action required to eliminate the leak.
• Repair owner assigned
  Identify the person, team, or contractor responsible for the repair.
• Target repair date set
  Record the planned completion date and time for the repair.
• Repair priority assigned
  Set the repair priority based on leak severity and operational impact.
• Lockout-tagout required for repair
  Indicate whether OSHA 1910.147 lockout-tagout is required before repair work begins.

Energy Savings and Verification

• Estimated leak flow rate recorded
  Record the estimated leak flow rate for the identified leak.
• Estimated annual energy savings recorded
  Estimate the annual energy savings associated with repairing the leak.
• Repair verification completed
  Confirm the leak was retested and no longer detectable after repair.
• Closeout notes documented
  Record any remaining issues, follow-up actions, or verification details.