Compressed air is a critical resource in many industries, from manufacturing to food production. It powers tools, equipment, and is essential for daily operations. But what happens when leaks develop in compressed air systems? It may seem like a small issue, but air leaks can lead to significant inefficiencies, costing businesses both energy and money. The good news is that there’s a high-tech solution available: acoustic cameras. An acoustic camera makes it easier than ever to locate and fix compressed air leaks quickly and effectively.
Let’s explore how air leaks develop, why they are a problem, and how acoustic cameras can help find compressed air leaks with precision.
Wasting air
Compressed air systems can develop leaks for various reasons—deteriorating equipment, poor maintenance, or improper installation. Over time, these leaks can grow, resulting in the loss of substantial amounts of energy. The U.S. Department of Energy estimates 25% of compressed air is lost to leaks, leading to higher operational costs and decreased capacity and efficiency.
But leaks aren’t just about losing air. They also place additional strain on compressors, which means equipment must work harder and can wear out faster. This increases unforeseen maintenance costs and can lead to unexpected downtime.
Difficult to find
The challenge with compressed air leaks is that they’re often difficult to find. These leaks are usually tiny, hidden in pipe joints or behind noisy equipment in hazardous zones. Traditional methods of finding them, such as using soapy water to spot bubbles or listening for hissing sounds, are time-consuming and inefficient, especially in noisy industrial environments.
Locating leaks with acoustic cameras
This is where acoustic cameras shine. Devices like Sorama CAM iV64s and Sorama L642 use an advanced microphone array to see the sound made by compressed air leaks and pinpoint them with precision. The handheld CAM iV64s is ideal for quick inspections, enabling safe and easy detection without direct exposure.
For continuous monitoring, the L642 can be fixed in place or even mounted on robots, providing autonomous scanning in hazardous areas. These cameras make leak inspection faster, safer, and more precise, especially in challenging, hard-to-reach zones.
High-frequency sound
When compressed air escapes from a leak, it creates high-frequency sound waves. These sound waves are too high-pitched for the human ear to detect—especially in loud industrial settings. An acoustic camera microphone array picks up these soundwaves and translates them into a visual image, displayed as a heatmap on a touch screen. The leak shows up as a bright spot, indicating the precise location where air is escaping.
This makes it far simpler and quicker to locate leaks than using traditional methods. Engineers can now scan an entire facility in a fraction of the time, identifying leaks that would otherwise go unnoticed, proving that an acoustic camera is a perfect addition to a predictive maintenance plan.
Saving time and money
Once leaks are identified, companies can take action. With an acoustic camera, engineers can inspect large and complex systems with minimal disruption to operations. The time saved by using this non-invasive technology is significant—what used to take hours or even days can now be accomplished in a matter of minutes.
Additionally, the risk of human error by missing leaks in difficult-to-reach places is much lower because the device shows the leak instantly in a sweeping action.
Real-time feedback
The real-time feedback provided by acoustic cameras means that leaks can be repaired faster, preventing further energy loss and improving the efficiency of the entire system. This, in turn, helps reduce operational costs. Companies can save thousands of dollars annually after addressing leaks found using this technology.
Improve safety
In addition to saving time and money, acoustic cameras also improve safety. In some cases, compressed air leaks can pose risks to workers, such as high-pressure bursts or creating a slipping hazard if lubricants are involved. Identifying and fixing leaks reduces these risks, creating a safer working environment.
More efficient, lower costs
The benefits of using an acoustic camera to locate compressed air leaks are clear. Companies can expect to see improved system efficiency, lower energy consumption, and significant cost savings. By preventing leaks from going undetected, they can reduce the workload on compressors, extend the lifespan of equipment, and avoid costly downtime.
Proactive maintenance
These improvements don’t just happen in the short term, either. With regular inspections using an acoustic camera, companies can maintain their systems more effectively, ensuring that leaks are caught early and fixed promptly. This proactive approach to maintenance helps sustain efficiency and lower costs over time.
Long-term benefits
Compressed air leaks are a costly problem, but they don’t have to be. Acoustic cameras offer an efficient, accurate, and non-invasive way to find leaks, helping companies save time, cut costs, and enhance safety. As more industries adopt this technology, the long-term benefits of reduced energy waste and increased equipment lifespan become even more apparent.
In fact, companies would do well to consider acoustic inspection for leaks before investing in additional capacity. Often, capacity is sufficient if the system is running at full efficiency, and additional capacity or investment may not be needed.
Strong return on investment
Investing in an acoustic camera is a smart move for any company that relies on compressed air systems. By leveraging this cutting-edge technology, businesses can optimize their operations and achieve lasting savings. The initial cost of the camera is quickly offset by energy savings and reduced maintenance expenses, making it a highly cost-effective solution. In the long run, companies will see a strong return on investment as they eliminate hidden leaks and improve overall efficiency.
Conclusion
Using acoustic cameras for compressed air leak inspection, industries can efficiently address air loss while minimizing costs, enhancing safety, and supporting sustainable operations. This advanced technology offers a fast return on investment by maximizing resource efficiency and maintaining equipment performance in the most challenging environments. Contact our team and schedule a demo at your location.
