For this application history, which includes the FLIR Si124 industrial acoustic camera, we interviewed Mr. Soichi Yagyu, President of Minalco Co., Ltd .; Mr. Yamaguchi, General Manager of Production; and Mr. Iwade, General Operations Manager.

FLIR: Why were you worried about air leaks?

Mr. Yagu: Whenever I took regular tours of the factories, I was concerned about the hissing sounds at the production sites. We couldn’t identify where the air was leaking, but we could hear hissing sounds. Our Mie plant (Iga City, Mie Prefecture) uses many air compressors to generate aluminum dust. Typically, about 20 to 30 percent of electricity costs are related to air in manufacturing plants. But in our case the rates are about 50 percent. Air leakage directly leads to additional costs, so we considered countermeasures; but leaks are difficult to locate because they are not visible. If air leaks occur in a quiet environment, it is possible to determine where they are by hearing them; but in the factory loud and small noises prevented this. We have heard that FLIR Si124 can help us identify leak points even in noisy environments. Since the air duct networks at the Mie plant work for free, we knew it was not an easy task to completely eliminate the leaks, but we wanted to solve the problem.

Many air ducts are installed in ancillary facilities as well as in major production facilities.

FLIR: What was your impression after using FLIR Si124?

Mr. Yagu: At first I felt that use and operation are very easy. It is only possible to look at the points where there is a suspicion of air leakage with the camera, without the need for special training or knowledge.

During this inspection, we found air leaks in a place where we did not expect, which led to the visualization of a loss of electricity costs. What is good about FLIR Si124 is that it shows the number of air leaks and the annual cost of loss in real time, which raises our awareness of costs at our production sites. In addition, it turned out that the air leaks, which we were unable to identify, were in fact difficult to detect by sound, which led to many new conversions.

The number of leaks and the annual cost of loss shown in real time.

Visual image of a place where air leaks can be heard.

FLIR Si124 can easily identify leak points that would not otherwise be detected.

Mr. Yamaguchi, Managing Director (General Manager of Production): In our production sites there are places with loud ambient noise such as burners. I had some doubts about the actual detection of leaks with a camera that can be handled with one hand. However, when I toured the factory with FLIR Si124, I was surprised that we could detect leaks more accurately and easily than we expected. It also detects enough air leaks from distant pipes in the ceilings.

Check the air pipes in the ceiling.

Mr Iwade, General Operations Manager: When tracking pipes with the camera, there are narrow spaces due to the presence of surrounding equipment. But the FLIR Si124 camera can easily enter these spaces. When I heard that the Si124 is smaller than half of the total acoustic cameras, I immediately realized the advantage of its compact size.

FLIR Si124 is designed for comfortable one-handed operation.

How reflections appear.

Leaks can be identified with simple Si124 settings, such as changing the angle or changing the mode for higher visibility.

FLIR: What would you say to someone who is thinking of using FLIR Si124?

Mr. Yagu: As carbon neutrality has been very important in recent years, FLIR Si124 can detect leaks with minimal load on the production site, thus reducing energy costs and helping to reduce CO2 emissions. An eye to see a hand to touch! Why not try air leak checks in your factories? FLIR: Every time we join a customer for verification, we discover something new.

Mr. Yagyu: What was most impressive this time was the ability to find pipe leak points with Si124, which we couldn’t detect by sound alone. We usually deal with reflected ultrasonic waves as subjects that need to be excluded, but this time we had a unique experience in finding leak points by tracking reflections. Thank you very much.

Minalko Co., Ltd.

Minalco Co., Ltd. is the only manufacturer in Japan that specializes in atomized aluminum powder, created more than 104 years ago. By improving its own production system for the Japanese market, Minalco has experienced increased demand due to the level of evaluation of the functionality of its products in addition to the flexibility in terms of supply.

Soichi Yagu, President of Minalco. Ltd.

Questions and Answers

Question: What is the average training period?

A: For operations and manipulation, this will take about five minutes. It takes about 15 to 30 minutes (for three leak points) to effectively use the OJT camera on site.

Question: What are the subjects of diagnostics?

A: This is the air, steam, nitrogen, etc. pipeline. The types of air do not matter. However, the pressure must be above a certain level (min. 0.3 Mpa or more.)

Question: How about the effects of cost reduction?

A: Based on a provisional calculation with a flow point size of 1.5 mm and a pressure of 0.7 MPa, about 100,000 yen per year (72,000 [email protected] Mpa). If the size of the drain point is 12 mm, the effect will be 600,000 [email protected] MPa.

In most cases, a tour of a production plant in about 30 minutes will result in the detection of five or more leak points.

For demonstrations:

We offer on-site demonstrations and OJTs that are free. If you are interested, please contact us with information about the subject of diagnosis and the level of pressure in the pipes. (Please note that the camera cannot detect slow leaks.)

In addition, it is possible to carry out simplified diagnostics of electrical equipment with the help of thermal imaging cameras. Learn more by visiting FLIR Si124 Industrial Acoustic Imaging Camera Teledyne FLIR

FLIR Si124 Application Story: Can air leaks be visualized? @flir #Camera #Imaging

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