The easiest and fastest way to save money and energy
On average, 30% of energy in industrial compressed air systems is wasted due to leaks. This not only causes unnecessary energy waste, but also contributes to a lower plant operational reliability. Therefore, improving energy efficiency in compressed air systems is an important issue in all areas of manufacturing and process technology, as compressed air is one of the most expensive energy resources.
Ultrasound is a proven technology for air leak detection which helps to avoid additional costs associated with misdiagnosed equipment failures and unplanned downtime. Detecting air leaks and repairing or replacing defective equipment can result in significant savings and help companies meet their energy targets.
The ultrasonic testing devices SONAPHONE® and SONASCREEN®, which are developed and manufactured by SONOTEC, offer simple, precise and fast leak detection and help significantly cut costs and reduce CO2 emissions. A clear benefit is that ultrasonic leak detection can be performed with the machines running, which means no additional downtime is required. It saves a lot of time and allows plants to focus on the core production tasks.
SONAPHONE®: The Powerful Ultrasonic Testing Device For Preventive Maintenance
The SONAPHONE® is used in combination with a BS10 airborne sound sensor and a very intuitive "LeakExpert" software app to detect and evaluate leaks in compressed air systems. The broadband frequency of the SONAPHONE® which is ranging from 20 to 100 kHz enables a quick and precise leak detection despite the industrial noises typical for manufacturing facilities. Graphical output of the test data is shown as a spectogram and leaks are displayed in litres per minute and cost per year. This information can be used to set priorities for repair. The integrated documentation functions enable modern broadband ultrasonic analysis and maintenance management. All relevant information about a leak is stored directly in the SONAPHONE® database. Your measurement data can be exported in pdf or csv format in just a few steps and integrated into your maintenance software.
SONASCREEN®: Extend Your Senses
The new handheld acoustic camera SONASCREEN® generates acoustic images from both the audible and ultrasound frequency range. The device with IP54 protection has integrated data acquisition. It locates sound sources in real time and displays the results immediately on the screen. Additionally, the camera provides audible feedback through industrial headphones. It makes ultrasound not only audible, but also visible as you can see the leaks directly on your display. The SONASCREEN® enables fast leak detection in compressed air systems and helps to unlock energy saving opportunities. The device makes it possible to start the maintenance process without prior training, as it is very intuitive even for beginners. Thanks to the intuitive handling as well as pre-set setups, even inexperienced users can correctly evaluate the results at a glance.
It’s time we weighed the overall cost of compressed air leaks, shifting the discussion from energy cost to asset accountability. Afterall, some of the largest and most important rotating assets in industry are air compressors.