Compressed air leak detection in compressor rooms: Gooseneck and Ultrasound Camera in practical use

A look behind the scenes: Our tests in the new compressor station

Our 20 years of experience in Compressed air / gases leak detection has taught us that no system is perfect - neither during installation and even less during operation. For compressed air systems, perfection means first and foremost that it is 100% free of leakages.

We continuously test all our products in order to constantly improve them. We carry out thorough tests under real-life conditions to ensure that our customers always achieve the best results. A recent example is our new compressor station in our compressor room, which was recently installed. The new installation gave us the ideal opportunity to use our latest Leak Detectors and accessories (in this case the Gooseneck and the Ultrasound Camera) ourselves.

Surprisingly, leakages occurred in three different places immediately after installation:

  • The shut-off valve on the Desiccant dryer next to a pressure gauge and various other lines was leaking (Fig. 1).
  • One of the two filters was also affected (Fig. 2).
  • We were also able to detect a leak with our system at a thread in the existing pipework, which had been modified (illustrated in the following video). As you can see and hear, the loud noise of the compressors is not affecting the ultrasonic leak detection.

Balancing Non-Stop Production and Leak Repairs: Best Practices for Energy Management

The compressed air leakages mentioned above are typical examples of transient installation defects, highlighting the demanding challenge of ensuring the tightness of compressed air systems. Even the smallest gaps can lead to significant compressed air loss.

Another known leak occurred in the main line of the catalytic converter (see following video). As the catalytic converter is in operation around the clock, the leakages shown in the video below could not be repaired immediately. This shows a common problem in compressed air technology: the uninterrupted supply of compressed air to production usually has the highest priority, which means that leakages cannot be repaired immediately despite known problems.

Common causes of leakages in compressed air systems

1. Errors during the initial installation

Leakages can already occur during planning and installation. Common causes are

  • Volatile installation faults: seals are not fitted correctly or connecting elements are not tightened to the correct torque.
  • Material defects: Production defects such as micro-cracks or inferior seals and pipes mean that the components leak right from the start.
  • Incorrect choice of components: Materials not matched to Pressure, Temperature or medium favour leaks.
  • Unfavourable installation conditions: Tight installation space or hard-to-reach places make the quality of the installation more difficult, e.g. inadequately connected pipes.

2. Faults during operation

Even a perfectly installed and tested system will leak over time under operating conditions:

  • Material fatigue: Seals and hoses lose their elasticity due to continuous contact with compressed air, metal parts are weakened by corrosion.
  • Temperature fluctuations: Severe temperature changes stress materials and lead to shrinkage or expansion, which favours Leakages.
  • Vibrations: Mechanical vibrations loosen screws, flanges and other connecting elements, leading to leaks in the long term.
  • Pressure surges: Sudden Pressure changes put a lot of stress on the system and make weak points visible.
  • Mechanical damage: Pipes and hoses are damaged by external influences such as impacts or improper handling.

Ultrasound Camera vs. Gooseneck

The weak points of an Ultrasound Camera

  • Accessibility: In confined or hidden areas, such as behind pipes or in dense systems, the ultrasonic camera is often too large to carry out precise measurements. The reach of the arm that has to guide the device and carry its weight is also limited.
  • Unclear visualisation: If components are installed close together or deep in the system, the two-dimensional display on the screen can lead to misinterpretation of ultrasonic signals. This makes it difficult to identify exactly which component is actually affected.
  • Interfering ultrasound: In areas such as compressor rooms or automated systems, other ultrasound sources can make Leak detection considerably more difficult and distort the visualisation.

How the Gooseneck solves these problems

The Gooseneck offers a precise and flexible addition to the Ultrasound Camera:

  • Improved accessibility: Its slim and flexible design reaches even hard-to-reach areas that are inaccessible to the camera and checks them with pinpoint accuracy.
  • Minimisation of background noise: The Gooseneck enables targeted measuring thanks to its direct placement at the leak, effectively blocking out interfering ultrasound. In addition, its sensitivity can be adapted to the environment.

The advantages of the Gooseneck at a glance

  • Maximum precision: Even the smallest Leakages in complex systems are reliably detected.
  • Time saving: Quick localisation of Leakages without time-consuming spraying of all connecting elements with leak detection spray.
  • Efficiency: Reduced energy losses and lower operating costs thanks to precise elimination of Leakages.
  • Flexibility: Perfect for noisy or difficult to access environments.

Conclusion: Precision and efficiency for your Leak detection

Our tests in the new compressor station have impressively demonstrated how effective the combination of Ultrasound Camera and Gooseneck is. While the camera provides a quick overview, the Gooseneck enables precise inspection in hard-to-reach areas. This practical experience emphasises the importance of regular inspections - both immediately after installation and during operation.

Reduce energy losses and lower your operating costs. Contact us for a no-obligation consultation!