Key features of the compressed air leak detector:
- High-precision leak detection : Thanks to advanced ultrasound technology, even the smallest leaks can be reliably detected and located.
- Easy operation : The device is designed to be user-friendly, with an intuitive interface that allows for quick and easy handling.
- Leakage measurement and calculation : In addition to locating leaks, the device also offers the possibility of precisely calculating the size and cost of the leak. This helps to minimize energy losses and save costs.
- Versatile application : Suitable for a wide variety of compressed air systems and applications, from smaller plants to large industrial complexes.
- Robust design : The device is robust and durable, designed for use in demanding industrial environments.
Technical specifications of the compressed air leak detector:
- Ultrasonic frequency range : Optimally suited for the detection of compressed air leaks.
- Display : High-resolution, easy-to-read display for showing the measured values.
- Battery life : Long operating time for extended inspection rounds without frequent recharging.
- Weight and dimensions : Compact and lightweight for comfortable handling and transport.
- Optional Software : Leak Reporter V2 software – creates detailed ISO 50001 reports. It provides an illustrated overview of detected leaks and their potential savings. Remediation measures, including status updates, can be defined for each leak. – License for 2 workstations
Advantages:
- Energy saving : By precisely detecting and calculating leaks, companies can achieve significant energy savings.
- Cost reduction : Reduction of energy losses and associated costs through fast and efficient repair of leaks.
- Optimization of compressed air systems : Regular leak checks contribute to long-term efficiency improvements and maintenance of compressed air systems.
The compressed air leak detector is an indispensable tool for companies that want to make their compressed air systems more efficient and save costs. It offers a combination of advanced technology, ease of use, and robust design, making it the optimal solution for leak detection in industrial compressed air applications.
How are the compressed air leaks visualized?
With the UltraCam, you can find compressed air leaks much faster than with conventional leak detectors, making the process far more intuitive and easier. Here's how it works: The UltraCam uses 30 digital MEMs, an FPGA, and a processor to calculate the ultrasonic map. The algorithm used is called beamforming. The compressed air leak detector receives the data and automatically displays the superimposed image to the user on its screen.
The invisible costs of compressed air leaks
Leaks in pressurized systems can cause very high costs per year , especially:
1. Energy losses
Leaks in compressed air systems lead to continuous energy losses. Even small leaks can cause significant amounts of compressed air to escape. A leak with a diameter of just 1 mm can result in a loss of approximately 1.5 m³/h at an operating pressure of 7 bar. This means that up to 13,140 kWh of energy can be lost per year, which, at an energy price of €0.10/kWh, causes annual costs of around €1,314.
2. Increased operating costs
Leaks increase the need for maintenance and repairs. Compressors and other system components wear out faster when constantly overloaded. Additional maintenance costs due to more frequent servicing and premature failures can amount to several thousand euros annually. For example, premature failures and more frequent servicing can result in additional annual costs of approximately €2,000 to €5,000.
3. Environmental pollution
Increased energy consumption due to compressed air leaks also has negative environmental impacts. Higher energy consumption also means higher CO2 emissions. A single leak consuming 13,140 kWh of energy can generate approximately 6.5 tons of CO2 emissions annually (based on an average CO2 emission of 0.5 kg/kWh). This is equivalent to the annual emissions of an average passenger car driving approximately 25,000 km.
4. Production losses
Leaks can negatively impact the efficiency of entire production processes. Insufficient pressure can cause machines to malfunction or even break down. This leads to production downtime and delays, which can result in significant financial losses. Depending on the industry and production volume, production losses can range from €10,000 to several hundred thousand euros annually.
5. Making invisible costs visible
To make the hidden costs of compressed air leaks visible, regular inspection and maintenance of compressed air systems is essential. Modern leak detection devices and monitoring systems help to quickly and accurately identify leaks and calculate the associated costs. Investing in such technologies can quickly pay for itself by minimizing energy losses and reducing operating costs.
Conclusion
The costs of compressed air leaks are often not immediately apparent, but can have a significant impact on operating costs and the environment. Regular inspection and maintenance of compressed air systems allows companies to save energy, reduce operating costs, and increase production efficiency. Investments in leak detection equipment and monitoring technologies pay for themselves quickly and contribute to sustainable and cost-effective operations in the long term.
In summary, the annual costs caused by leaks, including energy losses, increased operating costs, environmental impact, and production downtime, can quickly reach tens of thousands of euros. Proactive maintenance and the use of modern technologies are therefore crucial for reducing these hidden costs.
