Partial discharges in high-voltage systems and leaks in compressed air or gas lines can cause enormous damage and costs if left undetected. FLIR acoustic cameras can detect early such issues and thus prevent subsequent damage. They are a safe and reliable way to identify leaks and partial discharges in good time.
Main areas of application
In most factories, compressed air systems are one of the biggest sources of electricity costs. It is therefore crucial to detect compressed air leaks and inefficient equipment early and to fix them immediately. However, conventional inspection methods such as the soap bubble test are time-consuming and make it difficult to find air leaks. Acoustic cameras, on the other hand, are powerful tools for industry. They can be used for routine inspection of the systems and speed up the process considerably.
FLIR cameras produce a precise acoustic image that overlays ultrasonic signals on a digital camera image in real time. This allows you to visually locate the source of the noise and therefore the leak. Some FLIR models, such as the FLIR Si124, are also very effective at detecting partial discharges in high-voltage systems.
Using acoustic cameras in a predictive maintenance routine ensures that power systems, compressed air and gas lines and other systems are running optimally.
Another advantage is that the inspectors can carry out the inspection from a safe distance and without shutting down production. This means that any leaks can be quickly located before they can cause costs or downtime. In addition, the acoustic cameras have integrated analysis functions that enable the measurement of the leak size and the associated costs. With FLIR products, your trouble-free and efficient production is guaranteed.
The acoustic cameras can also make a significant contribution to reducing operating costs, as their use is particularly worthwhile for companies in energy-intensive industries. FLIR’s Si124, Si124-PD and Si124-LD acoustic imaging cameras detect compressed air leaks in an extended frequency range of 2 to 65 kHz, a significant improvement over the previous 35 kHz bandwidth. This seemingly small change leads to significant cost savings and increased reliability in industrial applications. Every leak that goes undetected can cost companies high four-figure sums with increased energy prices. Now consider that in large production plants, multiple leaks can often develop unnoticed over time. This then leads to enormous operating costs, which can therefore easily be saved.
In addition to ensuring smooth operations and saving on operating costs, the acoustic cameras can cover another important function: ensuring safety standards. Compressed air is used in many production processes, for example in food production or in pharmaceutical companies. Here, leaks can have far-reaching effects, such as reducing quality or even contamination of products. Regular inspection of compressed air systems is therefore essential for consumer safety and the use of acoustic imaging cameras makes a significant contribution to ensuring legal regulations.
Below, the advantages of each model are explained in more detail so that you can find the camera that best suits your application.
Finding compressed air and gas leaks
The FLIR Si124-LD Plus is an advanced acoustic imaging camera that serves as a standalone system for locating and quantitatively assessing pressure leaks in compressed air systems. Equipped with 124 microphones, it captures ultrasonic information extremely precisely, even in noisy industrial environments. This information is superimposed on a digital image in real time so that air leaks can be located quickly and accurately. The system offers user-friendly functions such as the Auto-Filter, which automatically selects the optimal frequency range, and the Auto-Distance function, which detects the distance to the leak to increase accuracy. Despite its compact and lightweight design that allows one-handed operation, the camera is powerful enough to detect leaks up to ten times faster than conventional methods.
For post-processing and detailed analysis, acoustic images can be imported into the FLIR Thermal Studio suite using a plug-in or edited via the FLIR Acoustic Camera Viewer cloud service. It is important to note that the FLIR Si124-LD Plus does not offer partial discharge detection, but is specifically optimized for leak detection in compressed air systems.
Early detection of partial discharges
The FLIR Si124-PD is an advanced acoustic imaging camera specifically designed to detect partial discharges in high voltage systems. It is also equipped with 124 microphones, producing precise acoustic images that detail ultrasonic information even in noisy industrial environments. This information is overlaid on a digital image in real time, allowing the origin of the partial discharges to be precisely located.
The FLIR Si124-PD is specifically designed for design professionals and offers an easy-to-use, one-handed solution. Its advanced features include the FLIR Advanced Severity Assessment analysis, which makes it possible to classify the severity of partial discharges and suggest targeted measures to solve the problem. For post-processing and comprehensive analysis, the acoustic images can either be imported into the FLIR Thermal Studio Suite via a plug-in or edited via the FLIR Acoustic Camera Viewer cloud service. These powerful features not only support the rapid identification of partial discharges, but also the optimization of maintenance strategies and the reduction of energy costs.
All-round package with a wide range of functions
In addition to the specialized cameras, FLIR also has some models that identify both leaks in compressed air systems and partial discharge problems in high-voltage systems.
FLIR SI2-LD
The FLIR Si2-LD is characterized by its ability to precisely detect compressed air and gas leaks from up to 200 meters away, as well as partial discharges and bearing defects. The camera offers integrated measurements and cost analysis for a variety of industrial gases, including hydrogen and CO2, based on leak rates. With its 8x digital zoom and one-handed operation, the FLIR Si2-LD enables detailed inspection and easy handling. The 12 MP digital camera and 5-inch screen provide high-resolution images for precise problem analysis. Two integrated LED lamps improve visibility in dark areas. On-device partial discharge severity analysis enables fast and informed decision-making. With its comprehensive leak and fault detection and cost analysis functions, the FLIR Si2-LD makes a decisive contribution to efficient maintenance and cost reduction in industrial environments.
FLIR SI2-PD
The FLIR Si2-PD is specialized in the identification of electrical partial discharge faults in high-voltage systems. It precisely detects, locates and classifies faults from up to 200 meters away and assesses their severity, which supports decision-making for maintenance actions. In addition to detecting partial discharges, the Si2-PD can also detect compressed air and gas leaks and detect bearing defects early. With a 12 MP digital camera, 8x digital zoom and a 5-inch screen, it delivers detailed images.
FLIR SI124
The FLIR Si124 is a powerful acoustic imaging camera optimized for both detecting compressed air leaks and identifying partial and corona discharges in high voltage systems. With 124 microphones, it delivers precise acoustic images and detects problems up to ten times faster than conventional methods. The camera provides an instant real-time display of the leak rate and estimated annual energy loss. Its digital image displays ultrasonic signals in real time and enables precise localization of noise. Integration with the FLIR Thermal Studio Suite allows leak reporting and thermal imaging inspection to be combined. The FLIR Si124 is lightweight, can be operated with one hand and offers a 5-inch touchscreen. Their features help reduce energy costs and delay the need for new compressors.
FLIR SI2-PRO
The FLIR Si2-Pro is the most comprehensive acoustic imaging camera in the FLIR Si2 series and is ideal for the precise detection of partial discharges, compressed air leaks and mechanical failures. Equipped with a 12 MP digital camera and 8x digital zoom, it offers detailed imagery to identify potential hazards from up to 200 meters away. The camera enables severity assessment and identification of partial discharges directly on the camera or via the software, which speeds up decision making. In addition, industrial gas quantification offers a comprehensive analysis of leak rates and costs for various gases such as methane and hydrogen, which increases efficiency in maintenance actions.
Conclusion: Choosing the right FLIR acoustic imaging camera
FLIR offers a diverse selection of acoustic imaging cameras tailored to different industrial needs. The FLIR Si124-LD Plus is ideal for the precise and fast detection of compressed air leaks and offers comprehensive leak assessment features. The FLIR Si124-PD is specifically designed to identify and assess the severity of partial discharges in high voltage systems, with additional support for maintenance strategies. The FLIR Si2-LD combines leak and bearing defect detection with integrated cost analysis for various industrial gases. The FLIR Si2-PD offers specialized partial discharge capabilities, complemented by the ability to detect leaks and mechanical faults. The FLIR Si124 combines compressed air leak and partial discharge detection, with real-time leak rate display and integration with the FLIR Thermal Studio Suite for comprehensive analysis. Finally, the FLIR Si2-Pro offers a comprehensive solution for precise fault detection and severity assessment, complemented by industrial gas quantification for efficient maintenance planning. All models feature the integrated MECH mode for quick detection and measurement of bearing and other mechanical problems that could lead to production interruptions. Likewise, two LED lamps improve visibility in dark areas, while simple one-handed operation and minimal training requirements make it easy to use.
Images: Adobe Stock
