Test & Measurement Catch here


edible product not meeting consistent texture or flavour requirements.


• Product safety: Leaks that cause contamination lead to high costs from waste, compliance penalties and reputational damage.


• Environmental impacts: Systems with air and gas leaks become inefficient, which impacts a company’s carbon footprint and prevents them from meeting sustainability or environmental targets. The formula used to determine the extent of compressed air leaks at a facility is: Leakage (%) = (T x 100) ÷ (T + t) T = onload time (minutes), t = offload time (minutes). If the compressed air system is configured with start/ stop controls, start your air compressor when there is no


system demand — after hours or off-shift. Then take several readings of compressor cycles to determine the average time to unload the system.


The first step in controlling processing and costs is to find air leaks at their point of origin. Common leak points include Condensate traps, Couplings, Fittings, Flanges, FRLs (filter, regulator, lubricator combinations), Hoses, Packings, Pneumatic holding tanks, Quick disconnects, Threaded pipe joints, Tubes and Valves.


Air leaks are a big issue because they’re abundant and hard to find. Once found and fixed, more leaks tend to pop up due to normal wear and tear on the system. While it may not be possible to eliminate every single leak, it is possible to reduce the total number with focused inspection using traditional detection methods. With these methods, once a leak is located, a paper tag is used to mark the spot. Four traditional detection methods include: 1. Sound: Hissing indicates leaks, which means the leak is sizeable since only a sound level greater than 60 dBA is audible without leak detection equipment. Since most plants are noisy and often require worker ear protection, listening for leaks must occur during downtime — between shifts, on weekends, or during scheduled maintenance.


2. Water and soap: Technicians spray soapy water on areas of audible leaks, and where bubbles appear is the leak spot. The method is protracted, far from precise, and requires cleanup since soapy water overspray


www.cieonline.co.uk


sound and then presents them visually. The device then applies proprietary algorithms to the results and instantly produces a visual map of the leak on screen. The image of the leak is layered over a visible-light image of the area so operators can quickly pinpoint the leak location. The Fluke sonic industrial imager scans areas up to 50 meters in normal industrial conditions. The sonic imager can also be used to verify successful repairs. If there’s a question, scans captured as stills or live videos can be shared and discussed with colleagues. The captured images eliminate the need to climb ladders or mark the leak with the usual fragile physical tag. Using common or new


creates a slipping hazard. In some clean and contamination-protected processes it is not allowed.


3. Ultrasonic acoustic detection: During downtime, technicians wearing earphones scan potential leak spots with a parabolic- dish or cone-shaped accessory. When a leak-indicating noise is detected, the technician switches to a wand-shaped device that must be held a couple of inches from the leak to pinpoint the exact location.


4. Using outside experts: Engineers or other experts are engaged usually once a year to save money and disruption. They use one or all the traditional techniques, and repairs and checks handled by in-house technicians. None of these methods is foolproof and most require downtime, which leads to lost time and money.


Project engineers at a coffee roasting company participated in a pilot study using sonic imaging technology in a facility where conditions tend to generate many leaks. The test identified the company could save more than 10% per year in energy consumption with the new leak detection device. The 300,000-square-foot facility houses a coffee roasting and packaging area, coffee wet process area, and tea blending and packaging area. All operations require proper air pressure to efficiently complete processes and traditional leak detection methods couldn’t keep up.


On an average day, the facility uses from 1,000 to 1,600 cubic feet per minute (cu. ft/min) of compressed air. The company’s compressed air system, which consists of five air compressors totalling 585


horsepower, powers automation and tubing used to feed the operation’s nitrogen generation system. Nitrogen is used to improve the quality of coffee. Additionally, the inert gas is used for blending of tea.


With the sonic imaging device, the team identified potential energy savings of 10%, which is in keeping with its goal of improved sustainability. The new approach also showed how the team could simplify the air leak detection process, allowing the project engineers to keep staff working on products rather than stopping for long periods to detect and fix air leaks.


In a pilot test, a coffee roaster used a sonic imager to easily identify and tag as many as 52 air leaks – including leaks in many difficult locations.


An advancement in leak detection technology in the form of a portable sonic industrial imager is making it easier to detect leaks and avoid lost profits. The sonic imager introduced by Fluke Corporation allows users to locate and view air leaks on an LED screen in real time with a point-and-shoot process that doesn’t require a specialised technician. Most users can get up to speed in about 10 minutes. Technicians can also work quickly from a safe distance while equipment is running. Additionally, the device makes it easier to find leaks in hard-to-reach spots or to distinguish between multiple leaks within the same area.


The hand-held sonic industrial imager contains an array of ultra-sensitive microphones that detect sounds in both the human hearing and ultrasonic ranges for


detection methods, there’s no time like now to remove the hidden costs and unnecessary waste of air leaks. Here are some best practices to follow: • Take a systems approach: Often fixing a leak will increase system pressure, making smaller leaks larger, affecting the entire system. Combine changes with overall strategies for improved energy use and more robust control systems. Although they may be challenging to make, capital purchases often yield energy savings that substantially reduce payback time.


• Audit frequently: Frequent auditing — more often than the typical yearly or quarterly leak inspections — saves time, money and resources over the long run, even if you need to shut down equipment. New imaging technology means you can zero in on leaks and fix them on an ongoing basis without losing valuable production time.


• Confirm root causes of pressure drops: Pressure drop can be misdiagnosed as equipment failure. Before making capital expenditures, leak checks and fixes may save thousands or hundreds of thousands of dollars and help instantly regain capacity.


• Log and track and verify over time: It’s important to record exactly where leaks have occurred since these weak spots tend to be where new leaks will happen and inspect those areas regularly. Logging information online allows data to be easily shared and used to impose discipline on the review process. Check soon after the repair is made to determine whether leaks have either been eliminated or need further attention.


fluke.com Components in Electronics May 2021 25


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54