EPR performed a verification of final completion on a large coal plant in a developing country.
A critical system in any power facility is its instrument air (IAS), because a loss of instrument air means a loss of control in many instances. Further, IAS is expensive because air compressors take a material amount of parasitic load in addition to the drying needed to wring out any moisture.
In this facility thousands, or perhaps more, IAS leaks were observed. This is due in part to unqualified installers and also the lack of tools necessary to tighten the joints. Tubing systems are fantastic because they are high pressure, install quickly, and durable if installed correctly. However, contractors often underappreciate that a tubing system is a technical installation that requires the workers to be trained. In this plant it was apparent that any joint which did not leak, was purely an accident, because the recommended OEM installation practices were simply not followed.
This will cost the Owner hundreds of thousands per year in additional compressor power consumption and increased maintenance service.
No Savings. Probably cost more with unqualified personnel.
Really not possible to repair all leaks. Owner Cost will be several $100k/year for plant life.