Handheld or Fixed-Installed (Ultra) Sonic Acoustic Camera

Sorama offers unique high-resolution acoustic cameras to detect and analyze noise and vibrations. The measurement device contains a visual light camera and an array of MEMS (Micro-Electro-Mechanical System) microphones. The microphones used for gas leak detection are specifically sensitive in the higher audible frequencies and well into the ultrasonic range (typical frequency range is 2-55 kHz). The result is a heatmap showing the leak source in overlay to the video stream, much comparable to a thermal imaging camera, only now one can see sound.

• Easy to use, fast and accurate localization of compressed air leaks
• Limited training required
• No downtime needed to make use of the technology
• Advanced algorithms to process the individual microphone signals and back-calculate the acoustic waves to their source
• Frequency dependent filters make sure any noise other than the leak sound sources are decimated
• By taking away the complexity of finding leaks, factory operators or maintenance personnel is capable of fixing most leaks easily and on the spot

• Compressed air networks: controls and actuators

Genie designs and builds innovative vertical work platforms and material lifts to make working at heights safer and more productive in a whole range of industries. The business’s plant in Redmond, Washington, builds material lifts and uses between 1,800 and 2,600 CFM of compressed air each day.

Their production line relies heavily on compressed air to run tools and processes, even tiny air leaks can multiply product and energy waste and lost production time. The more leaks there are, the higher the demand for compressed air. Increased demand for air pressure raises the risk of not being able to supply an adequate amount to all the tools and process equipment that need it.

Genie is vigilant about finding and fixing air leaks. Some leaks occur in hoses and fittings high up in the rafters; others show up on the torque tools on the shop floor. In the past, during monthly weekend preventive maintenance (PM) operations, Genie dedicated one or two maintenance technicians to hunt for air leaks. The technicians first sprayed joints and hoses with a soap and water mixture to reveal bubbles that indicate leaks. Then they fixed the leaks and retested with soapy water. The soap and water method works but slowly; and it requires a lot of cleanup afterward to prevent slipping hazards.

Genie also tried using ultrasonic parabolic discs connected to headphones to try to find leaks but without much success. They couldn’t get close enough to the equipment to locate the exact location of the leaks. Plus, traditional ultrasonic leak detectors detect only very high frequency leaks and air leaks occur at many frequency ranges.

“Being able to visualize where the problem is and how big it is adds another dimension,” says Josh Stockert, Genie Maintenance Supervisor. “You can identify which threads, fitting, or hose is affected. Being able to pinpoint where the leak is coming from on that image is extremely exciting. You can see different angles and determine ‘Yep it’s these threads versus that hose that feeds this fitting.
The ability to visually scan large areas from up to 50 meters (164 feet) away with the ii900 has expedited leak detection at Genie and significantly reduced the hours of labor spent on that task. Rather than taking at least an hour to move everything out of the way, put the lift in position, spray the joint, and then move everything back, it takes me all of 30 seconds to a minute to find an air leak with the acoustic camera. Some days we can find and repair 30 or 40 leaks in just a couple hours,” says Stockert. “Plus, we can use the ii900 during production hours, when it’s extremely loud in here and still been able to capture leaks at the rafter level up to 6 to 9 meters (20 to 30 feet) away. ”The ability to scan for leaks without affecting production is a huge advantage. Before, we never thought of testing for air leaks during production because we couldn’t shut down the aisles and move people out of an area to go up and look at a potential leak,” says Stockert. “Now, we can stand on the sideline and scan the airline overhead, while carts and people are moving underneath. We’re not affecting their work, but we can tag the leak and then move a lift to that spot during lunch and fix it rather than having to wait for a weekend PM shift.”

Initially, the primary objective for Genie when testing the Fluke ii900 Sonic Industrial Imager was to save energy. After the initial air leak inspections and corrections, Stockert saw a 25.7 % recovery in their compressed air capacity. “We were near the top end of what our compressor system can put out,” he said. “By correcting the leaks found using the ii900, one of our four compressors is nearly idle much of the time.”

The reduction in compressor usage translates to an estimated $48,754 in annual electrical energy savings. However, Stockert believes that there is an additional benefit derived from not having to add more compressor capacity.

• Energy consumption reduction potential by reducing leaks  between 12% and 18%

(Source: Ecodesign Preparatory Study on Electric motor systems / Compressors ENER Lot 31
Prepared for the European Commission By Van Holsteijn en Kemna B.V.)

• Additional benefit derived from not having to add more compressor capacity

Genie, U.S.A.