See sounds and save thanks to the reduction energy losses

How to reduce industrial production costs despite rising energy prices? New Sonel KUS-100 and KUS-200 acoustic cameras come to the rescue, enabling the detection of damage and achieving significant savings by reducing energy losses.

Because of the continuous increase in energy prices, optimisation and reduction of losses in industrial processes are becoming ever more important aspects of production. Among the elements that are the most vulnerable to increases in electricity prices are compressed air installations. Any loose connection, damage to the piping or leak in the tank generates losses, which is in turn a source of increases to the company’s operating costs.

This may be avoided by way of early detection and quick countermeasure implementation on the part of maintenance departments. The high-class Sonel KUS-100 acoustic camera and the more advanced Sonel KUS-200 model are perfect for this purpose.

Photo 1. The Sonel KUS-100 acoustic camera

Leak detection with Sonel KUS-100 and KUS-200 cameras

The Sonel KUS-100 camera is equipped with a grid of 64 microphones that detect sounds in the range from 2 to 100 kHz, enabling effective leak detection. The combination with a visual camera allows for live leak observation as well as saving photos and videos, which significantly facilitates the work of specialists conducting industrial line inspections. Thanks to high image resolution (800 x 480 pixels), it is possible to obtain high-quality materials that are helpful in precisely determining the location of the leak.

When testing an installation, it is important to pay attention to unwanted reflections by changing the viewing angle of the potential leak source. If the point moves along with a change in the observation angle, it indicates that we are dealing with an acoustic wave reflection.

In the case of more demanding applications, such as large industrial installations, extensive compressed air networks, or facilities with high background noise levels, the Sonel KUS-200 camera provides even greater effectiveness. This model is equipped with 136 microphones, which translates to higher acoustic image resolution, better sound source separation, and the ability for more precise leak localization. An additional advantage of the KUS-200 is its increased detection range – up to 150 meters, which allows for inspections from a greater distance, increasing work safety and operator comfort. Higher system sensitivity also enables the detection of smaller leaks, which in the long run generate significant energy losses.

The leak mode also includes a loss calculator, which – after entering data regarding unit costs in the installation – can calculate the cost of every minute of leakage of a given substance from our installation. This is a very useful tool, as it helps not only to justify the incurred costs of repairs and modernization but also to estimate the potential economic benefit resulting from the work undertaken.

Photo 2. Detection of leakage using the Sonel KUS-100 camera

Partial discharge detection

The second mode equipped in the Sonel KUS-100 and KUS-200 cameras is the partial discharge mode. Thanks to this, the device is able to detect and analyze the acoustic wave emanating from electrical micro-discharges in the tested object.

Along with the partial discharge mode, an analysis module is launched that helps the operator determine whether they are dealing with a partial discharge or regular background noise. This mode also allows for the differentiation of individual types of partial discharges: internal, surface, and corona, which supports the assessment of the type of partial discharge being encountered and helps in drawing correct and appropriate conclusions from the analysis of the data obtained as a result of the measurement.

Ergonomics and comfort of use

The Sonel KUS-100 camera is equipped with a 4.3-inch touchscreen, which enables high-quality image display and ensures precise touch operation. The device can be operated with one hand thanks to practical buttons that allow for easy access to every menu element, changing the frequency range, taking a photo, and starting or stopping video recording. This functionality eliminates the need to remove gloves or use the other hand, which is a significant advantage from the point of view of occupational health and safety (OHS) and ergonomics guidelines.

Analogous ergonomic solutions were used in the Sonel KUS-200 model, which, despite more advanced measurement capabilities, retains the same intuitive operation and interface layout. Thanks to this, users can use both models without additional training, regardless of the level of advancement of the measurements performed.

The cameras come with the free Sonel Analyzer Acoustic software, used to analyze the results obtained and enabling the generation of a report from the conducted tests.

Sonel KUS-100 and KUS-200 acoustic cameras are ideal tools for specialists in the HVAC industry, working in industrial plants with systems using compressed gases. They also perform excellently in the professional power industry when working with high and medium voltage installations.

Author:
Marcin Magierowski
Sonel S.A.