Compressed air systems are integral to a vast array of manufacturing industries, including paper. Often in continuous use, compressed air systems are a significant drain on energy resources and contribute notably to overhead bills. The ongoing energy crisis means it has never been more important to ensure compressed air systems are leak-free and operating efficiently. This is especially pertinent for paper and pulp mills that rely on compressed air systems at every stage of the manufacturing process. Thankfully, sonic cameras, such as Teledyne FLIR’s Si124 Acoustic Imager, offer an easy, efficient, effective method of pinpointing leaks before they become too damaging and too costly.[1]
Quick Links
- Hidden Cost of Compressed Air Leaks in Paper & Pulp Mills
- Maximising the Energy Efficiency & Profitability of Paper & Pulp Mills with Acoustic Imaging
- Advantages of the Teledyne FLIR Si124 Acoustic Imager
- Further Information
Hidden Cost of Compressed Air Leaks in Paper & Pulp Mills
Typically, compressed air systems employed in manufacturing processes lose about 25-30% of their air through leaks; although some experts estimate this to be higher at around 80%. As compressed air systems are utilised throughout the papermaking process, from separating and cleaning raw pulp fibre to operating pneumatic tools and control valves, running them accounts for approximately 20% of manufacturing costs. This also means that compressed air leaks in pulp and paper mills can be extremely expensive. Resulting in greater energy wastage therefore increased operating costs and CO2 emissions, as well as reduced productivity and poor product quality.
Maximising the Energy Efficiency & Profitability of Paper & Pulp Mills with Acoustic Imaging
Traditional leak detection methods such as sniffers and leak sprays are time-consuming and require specialist training. Conversely, acoustic imagers allow users of all abilities and experiences to pinpoint leaks quickly. This is because sonic cameras detect ultrasonic vibrations and convert them into sound maps which are overlaid onto corresponding digital images. Consequently, users can clearly see where leaks are located and complex analysis is eliminated. Ergo, teams require minimal training to operate acoustic imagers.
Furthermore, incorporating acoustic imaging into maintenance cycles is easy. One advantage of conducting inspections using sonic cameras is that operations do not have to be halted, leaving productivity, and, by extension, profitability unaffected. Additionally, ultrasonic imagers enable safe, convenient inspections from the ground. They provide an easy, efficient, and effective method of scanning large areas to pinpoint even the smallest of leaks before significant, expensive damage is incurred. Using real-time data gathered via acoustic imagers, maintenance teams can address hidden compressed air leaks to minimise energy wastage and, therefore, reduce running costs to maximise profitability.
Advantages of the Teledyne FLIR Si124 Acoustic Imager
Combining an ergonomic design, 124 microphones, and AI-driven analytics, the Teledyne FLIR Si124 Acoustic Imager makes condition monitoring inspections ten times quicker. Ideal for use around paper mills, it supports one-handed operation and can detect leaks from a safe distance negating the need to get close to heavy machinery. Furthermore, production does not have to be halted. The Teledyne FLIR Si124 Acoustic Imager can also be used alongside FLIR’s Thermal Studio Software (with FLIR Si-Series Plugin) or FLIR Acoustic Camera Viewer to determine leak volume and cost.
There are four versions of the Teledyne FLIR Si124 Acoustic Imager available: two are specifically designed for locating compressed air leaks; one for detecting partial discharge (PD); and the fourth combines the capabilities of the others to find both leaks and PD.
Teledyne FLIR Si124-LD Acoustic Imager - Leak Detection
Price: £11 899 (Ex VAT)
- Locate pressurised leaks in compressed air systems
- View leak rate
- Quantify leaks
- Calculate energy loss
- 124 microphones
- Digital Camera
- Lightweight
- Cordless & battery operated
- Automatically uploads images to the cloud
- Compatible with FLIR's Acoustic Camera Viewer
- Suitable for use with FLIR's Thermal Studio Software
Teledyne FLIR Si124-LD Plus Acoustic Imager-Leak Detection
Price: £13 949 (Ex VAT)
- Locate pressurised leaks in compressed air systems
- View leak rate
- Quantify leaks
- Calculate energy loss
- 12x better sensitivity compared to the Si124-LD
- 124 microphones
- Digital Camera
- Auto-distance tool
- Auto-filter automatically selects the best frequency range
- Lightweight
- Cordless & battery operated
- Automatically uploads images to the cloud
- Compatible with FLIR's Acoustic Camera Viewer
- Built-in plugin for the FLIR's Thermal Studio Software
Teledyne FLIR Si124-PD Acoustic Imager - Partial Discharge
Price: £14 349 (Ex VAT)
- Optimised for detecting partial discharge in high voltage electrical systems
- Severity assessment tool for determining the level of danger and type of PD
- 124 microphones
- Digital Camera
- Detection range: 130m
- Lightweight
- Cordless & battery operated
- Automatically uploads images to the cloud
- Compatible with FLIR's Acoustic Camera Viewer
- Suitable for use with FLIR's Thermal Studio Software
Teledyne FLIR Si124 Industrial Acoustic Imager
Price: £17 099 (Ex VAT)
- Locate pressurised leaks in compressed air systems
- Find partial discharge in high voltage electrical systems
- View leak rate
- Quantify leaks
- Calculate energy loss
- Severity assessment tool for determining the level of danger and type of PD
- 124 microphones
- Digital Camera
- Frequency range: 2kHz to 35kHz
- Lightweight
- Cordless & battery operated
- Automatically uploads images to the cloud
- Compatible with FLIR's Acoustic Camera Viewer
- Suitable for use with FLIR's Thermal Studio Software
Further Information
For additional details about using Teledyne FLIR’s Si124 Acoustic Imagers to maintain paper and pulp mills, please download Teledyne FLIR’s application scenario.
Read Teledyne FLIR’s Application Scenario
For more information about our range of acoustic imagers, including Teledyne FLIR Si124 models, please don’t hesitate to contact our Sales team on 01642 931 329 or via our online form.
In the meantime, please browse our range of acoustic imagers here.
[1] The following source provided the information for this blog:
- Teledyne FLIR, Uncovering Compressed Air Leaks in Pulp and Paper Mills with Acoustic Imaging Cameras, last accessed 18 August 2023
