Acoustic imaging leak detector ii900 can save factories up to millions of dollars in gas leak losses annually

Fluke's newly launched ii900 acoustic leak detector adopts array MEMS sensor technologyBy collecting sound waves from 0-50KHZ and combining them with visible light technology, small aperture leaks (related to pressure) within 1mm of compressed air/carbon dioxide/nitrogen can be quickly detected within 10 seconds from a distance of 50 meters. By adjusting the frequency of the sound waves, even in noisy environments, it will not affect the capture of leaks. At the same time, the user interface of ii900 helps users quickly master the use of the product in a short time without the need for more experience judgment Truly making the leakage point clear at a glance.

Identify energy losses with sharp eyes and don't let the factory's' gas gold 'go to waste

Although there is a lot of discussion about energy conservation and carbon reduction in various media, it is surprising that most factory workers are not aware that there are many incredible opportunities to reduce energy waste and carbon emissions right under their noses. These opportunities can greatly enhance the competitiveness of their company.

In fact, many managers are not aware that it is not always necessary to focus on large-scale capital intensive projects that can generate long-term results. They usually either don't realize it or simply ignore low-cost projects aimed at improving the energy efficiency of factories with short-term returns.

One method is to locate and repair leaks in public resources such as compressed air and steam. These projects typically have very rapid and significant outcomes. In some cases, these projects have reached hundreds of thousands or even millions of dollars per year without requiring significant capital investment.

The factory's' gas gold 'compressed air

Compressed air leakage is almost a common energy waste in factories. The average leakage of compressed air accounts for 30% of the total compressed air volume. According to the general factory, a 160KW air compressor with 2 on standby and 1 on standby operates for 8000 hours per year, with an electricity cost of 0.7 yuan per kilowatt hour. The annual electricity cost consumed by the air compressor is as high as 1.8 million yuan. A 30% leakage means that more than 500000 compressed air is wasted. Due to its high price, some people in the industry refer to compressed air as the "gas gold". Some leaks are very obvious, they not only make a lot of noise, but can even be detected through touch and vision. And some leaks are very hidden, except for small and difficult to hear sounds, "hidden" leaks often occur in environments with high background noise in the workplace. All of the above leaks constitute the leakage sources in the entire system.

In fact, as early as 1995, the US Department of Energy launched the Compressed Air Challenge to help reduce compressed air usage in the industrial sector by 10% by 2010. They pointed out that compressed air is one of the common resources of cost in factories, and there is a leakage loss of 30% in all compressed air produced in the United States. They estimate that the annual cost is about 3.2 billion US dollars!

Common compressed air leaks typically occur in the following areas:

Pipeline joint, quick plug joint

Pressure regulator (FRL)

Frequently opened condensate drain valve

Damaged hose, ruptured pipeline

If a factory wants to eliminate leaks, it is almost impossible. What we can do is to control the leakage of compressed air within a reasonable range. The scope of this' reasonable 'is closely related to the size and age of the factory:

For newly built systems (less than 1 year) or small factories, the leakage rate should be controlled between 5% and 7%

For systems or medium-sized factories with a lifespan of 2-5 years, the leakage rate ranges from 7% to 10%

For systems or large factories over 10 years old, the leakage rate ranges from 10% to 12%

Leakage detection of compressed air

The difficulty of detecting compressed air leaks lies in the fact that most of the pipelines are not easily accessible, either installed in the air or hidden in the box. Moreover, since air leaks cannot be visually detected, ultrasonic testing is a commonly used method. Ultrasonic waves usually refer to the frequency band above 20kHz, and the upper limit that the human ear can receive is 16.5kHz. Using this characteristic, ultrasonic detection of compressed air leaks can be applied in industrial testing.

Ultrasonic leak detector is an instrument that generates eddy currents when any gas passes through a leak hole, with a portion of the ultrasonic band. The ultrasonic leak detector can detect any type of gas leak. The way to determine the leakage point is by receiving the high-frequency "hissing" sound emitted by air leakage.

Effective use of Fluke acoustic imaging leak detector ii900preventGas leakage

Video 1: The leakage of the compressor itself is often overlooked by users, and the valves and joints of the compressor are often the improvement points for fast compressed air leakage

Video 2 and Video 3: After a certain beverage company established a factory, it had a complete on-site inspection standard. After using an acoustic imaging instrument to detect, more than 20 leakage points were found in the entire factory area. From pipelines to valves to flanges, long-term use will produce a large number of leaks, reducing the efficiency of the factory area. Regular acoustic imaging testing helps customers quickly identify improvement points and energy-saving potential