Speed up air leak detection

May 9, 2021 | Basics, Industrial Imaging, Troubleshooting, Energy Management

Even the slightest air leak can add to wasted product and energy and lose production time – especially for production lines that can't function properly without compressed air to run tools and processes.

If there is not enough compressed air pressure to keep the equipment running smoothly, it can lead to costly consequences. The more leaks there are in the system, the harder the compressor needs to deliver the required air to the equipment, which is very detrimental to the compressor. The increased demand puts tools and process equipment at risk of running out of compressed air.

Compressed air leaks can also increase energy costs. According to the United States Department of Energy, a 1/8-inch (3 mm) hole in a compressed air line can cause up to $2,500 in additional costs per year.

A partner in the field of air leak detection

How to control air leaks in the midst of your busy schedule? This question was recently answered by a leading heavy equipment manufacturer who found a new partner in the field of air leak detection.

The manufacturer uses a compressed air flow rate of 51 to 74 cubic meters per minute per day. The compressed air runs up to 200 torque tools per production line, as well as process equipment that moves large steel plates half an inch thick and positions parts. If one line leaks, it can affect production and increase energy waste. Even if there is only one leak......

So when Fluke offered the company the opportunity to test its new Fluke ii900 Sonic Industrial Imager (Acoustic Imager), they immediately accepted. The II900's miniature, ultra-sensitive microphone array detects sound in both the human hearing and ultrasound ranges, and more uniquely, it allows the user to actually see the sound.

"Being able to show where the problem is adds another dimension." said the company's maintenance manager. "You can determine which threads, fittings, or hoses are affected. Being able to pinpoint the leak point on the image is very exciting. ”

The ii900 can visually scan large areas from up to 50 meters (164 feet) away, speeding up leak detection in the plant and significantly reducing the number of hours spent performing this task compared to the previous one.

"Sometimes, we can find and fix 30 to 40 leaks in just a few hours." The manager said. "In addition, we can use the II900 during production time, where the ambient noise is very high, but it is still able to catch leaks from the rafters 6 to 9 meters away."

Scanning for leaks without impacting production is a huge advantage for this manufacturer. "Before that, we had never thought about detecting air leaks during production because we couldn't close aisles and let people out of an area just to find potential leaks," the manager said. "Now, we can stand on the edge and scan the air lines overhead, while the trolleys and people can pass underneath the lines at the same time. We don't interfere with their work, which is better for everyone. ”

Speed up air leak detection

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