COVER STORY
AN EXPENSIVE NOISE
Teledyne FLIR explains how advanced acoustic imaging technology detects pressurised gas leaks inaudible to the human ear –
transforming costly, hidden noise into actionable insights that save energy, reduce expenses, and enhance safety in industrial operations
L
ast week, I had the misfortune to suffer a puncture on my car’s rear tyre. I didn’t need the automatic pressure sensor to
flash the warning on the dashboard – the first telltale sign was the high-pitched hissing sound coming through the driver’s open window while we were stuck in traffic. The puncture was hidden from view, so I couldn’t tell what object had pierced the tyre, but the sound of air escaping through the unseen hole told me all I needed to know: I had a problem.
The Challenge of Air Leaks in Industrial Settings
Think about this phenomenon in an industrial
setting. When air – or any gas for that matter – passes through a small orifice, it emits a sound with a set frequency. The frequency depends on the size of the hole and the amount of air passing through it, which is linked to the pressure forcing the air through. In a centralised compressed air system, commonly found in industrial manufacturing facilities, air is transported through joints, reducers, valves, condensers, and other components. Over time, these structures are susceptible to leaks due to fatigue or corrosion. Often positioned overhead or in noisy environments, these leaks can go unnoticed for months. While a single leak may seem inconsequential, a systemic problem with multiple leaks across a facility could lead to significant energy loss. Compressors compensate for the air loss by working harder, which increases energy consumption – a critical concern as energy costs continue to rise in Europe. If left unattended, leaks can also cause system failures, leading to unplanned stoppages, costly downtime, and increased maintenance demands. For businesses striving to cut costs and improve their carbon footprint, undetected air leaks present a hidden and expensive challenge.
Revolutionary Leak Detection with the FLIR Si2-LD
The biggest challenge in addressing these leaks is detecting them. Just as a punctured tyre produces a hissing sound, any gas leak in an industrial setting emits a sound, often one inaudible to the human ear. Teledyne FLIR has developed a groundbreaking solution: the FLIR Si2-LD acoustic imaging camera. This advanced ultrasonic device can detect leaks in air and gas systems by
10 FEBRUARY 2025 | PROCESS & CONTROL
simply pointing the handheld camera at a specific component. It can identify leaks as small as 0.05 litres per minute at a distance of 10 meters and as small as 0.0032 litres per minute at 2.5 meters, making it ideal for overhead systems.
Safety and convenience are enhanced by the Si2-LD’s ability to scan large areas from a secure distance and work from ground level, reducing the need for elevated platforms or ladders. Intuitive and lightweight, the camera is operable using only one hand and requires minimal training. The Si2-LD features improved microphones capable of detecting sounds across a 2–130 kHz frequency range, powerful LED lights for illuminating dark environments, and a 12-megapixel camera paired with a high-definition 5-inch screen for detailed visualisation.
Advanced Features for Accurate Reporting and Savings Equipped with Industrial Gas Quantification software, the FLIR Si2-LD goes beyond detection. It calculates gas losses for systems using industrial gases such as ammonia, helium, hydrogen, argon, carbon dioxide, and compressed air, providing monetary data that highlights the cost of leaks. Maintenance engineers can not only address leaks promptly but also compile detailed reports to demonstrate cost savings to senior management, with fleet management features streamlining device oversight and reporting across multiple sites at enterprise- level organisations.
With its advanced features and intuitive design, the FLIR Si2-LD offers companies a powerful tool to improve operational efficiency, reduce energy costs, and enhance their environmental impact. To learn more or request a demo, visit
www.flir.com/condition- monitoring or contact your local FLIR distributor.
Teledyne FLIR
www.flir.com/condition-monitoring
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