According to estimates, losses caused by leaks in compressed air systems can account for up to 50% of total capacity. Leaks also increase energy costs because the existing compressed air compressors have to generate more output to compensate for the resulting pressure loss. This leads to wasted energy.
Conventional leak detection methods, such as identifying hissing noises or spraying on soapy water, are usually very time-consuming and not very practical. Maintenance technicians must be close to the machine, which limits use in difficult-to-access areas such as ceilings or recesses, for safety reasons alone.
The particularly common method of detecting high-frequency noises with ultrasonic detectors can also generally only be used during planned shutdown periods. To make leak detection easier, modern technology is required that works not only in loud industrial environments and without shutting down machines, but can also be used efficiently and safely from a greater distance from the system.
Compressed air, gas, and vacuum systems in industrial plants can be damaged by wear or inadequate maintenance. Leaks, for example at machine connection points, in pipes, or in worn hoses, have a negative impact on the energy and cost efficiency of the systems and may lead to quality problems or even production downtime. It is therefore essential for utility and industrial companies to detect and repair compressed air leaks at an early stage.
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Fluke has developed an industrial acoustic camera that meets precisely these requirements. The ii900 is a pioneering solution for locating compressed air leaks. Compared with conventional ultrasonic detectors, the acoustic camera detects a wider frequency range. SoundSight™ technology is used for optimized visualization of leaks; it is similar to the detection of temperature profiles with thermal imaging cameras.
The ii900 makes sounds visible and thus expands the possibilities for troubleshooting. The camera’s highly sensitive microphones detect sounds in the human hearing range as well as in the ultrasonic range. This enables leaks in hoses or screw connections, for example, to be localized from a distance of up to 50 meters, significantly accelerating maintenance. Leak detection can be carried out during ongoing production operation; vehicles or people moving within the plant are therefore not affected.
The ii900 uses a large number of tiny, highly sensitive microphones that detect sound and ultrasonic waves. Potential leaks are identified as sound sources using special algorithms and displayed on the 7-inch LCD as a SoundMap™ in the form of a color map. The image is displayed as a still image or real-time video. It is overlaid onto the digital visual image so that a leak can be precisely localized. For documentation purposes, up to 999 image files or 20 video files can be stored. This enables even larger plant areas to be inspected within a short time. Leaks can be found and repaired much faster than with conventional methods.
With the innovative ii900, compressed air and gas leaks can be localized quickly and safely in loud industrial environments. The acoustic image is overlaid with the visual image from the digital camera in real time. The lightweight, compact camera is designed for convenient on-site use and makes it easier for maintenance technicians to make leak detection part of their maintenance routine. This enables performance losses and system defects to be minimized efficiently.
You are not quite sure yet or have further questions about the products? Do not hesitate to contact us. Whether directly on the phone or via online demo conveniently in front of your screen - our experts are there for you.
