Industrial Services

Modern industrial enterprises everywhere operate vacuum systems and equipment for the production, storage and distribution of compressed air as well as industrial gases (oxygen, nitrogen, argon, CO2, methane, propane-butane, etc.). These systems consume electricity, converting it into the most valuable resources and energy carriers used in technological processes for the operation of pneumatic transport, machine lathes, tools, lasers, systems for moving goods and much more.

Maintenance of such systems is often carried out with insufficient quality, according to the residual principle. In addition, they are prone to wear, which leads to the formation of leaks of valuable resources. Localization and detection of leaks are complicated by the branching and complexity of distribution pipelines, the continuous nature of production and the high elevations of pipeline routes.

The Fight Against Air Leaks and Technical Gases Is a Saving for the Company!

Let’s take a closer look at the amount of possible losses using the example of compressed air systems. The estimated losses through a hole with a diameter of 1 mm are 75 liters of compressed air per minute (operating pressure in the system is 8 bar), which corresponds to an electric power loss of 0.6 kW/hour. Through a hole with a diameter of 5 mm, the leakage will be 1,700 liters per minute, which corresponds to 13.2 kW/hour. Unfortunately, the number of such leaks in real production is in the hundreds, which leads to overspending of electricity as well as the need to use compressors of higher power than necessary.

Gaz Service Consulting LLC uses special acoustic cameras for optical visualization of leaks of gaseous media, compressed air and vacuum. The leak detectors used are high-tech equipment that has a lens, a detector element, an electronic system for processing the signal from the detector element and a screen on which our engineer sees the image created by the camera.

The acoustic compressed air leak visualization device used by our engineers has a built-in sound receiver matrix consisting of tiny sensitive microphones that measure the noise spectrum as a function of sound level and frequency. Based on this data, the algorithm calculates a map of sound sources, which is superimposed on the visible image. The noise map automatically adjusts to the selected frequency in such a way as to filter out the background noise of the operating equipment.

Technical parameters of the equipment used

• Detection range: up to 70 meters
• Detectable sound frequency: 2 – 100kHz
• Leakage size: from 150ml/min
• Ambient temperature: -20°C to +40°C

Advantages

• Reduction of leak detection time
• Reduction of energy costs
• Improving the reliability of production systems
• Ability to identify leak sites at a distance, without disconnecting technological equipment (no need to organize work on weekends or night shifts)
• Optimization of compressed air and industrial gases consumption

Based on the results of the leak detection work, we will provide a final detailed photo/video report containing information indicating the locations of gas leaks and the estimated size of the leak. A convenient report format can be used to quickly prioritize the work of your company’s repair services or contractors.