Sustainable Leak Detection
One of SKF’s key customers based in Cape Town, who depends on steam systems for its production processes, was facing costly challenges related to high energy consumption and excessive maintenance hours. The maintenance team was having to frequently replace gaskets and seal kits across all steam traps and valves, which incurred avoidable costs while unnecessary time was spent on labour.
“Their Engineering Manager sought a solution that could effectively monitor the integrity of their steam traps and valves, enabling easy and precise identification of leaks,” notes Darrin Cardoso, SKF Application Engineer / Key Account Manager Cement. “This would ensure smarter, more targeted maintenance efforts that focus only on faulty components. The customer was offered a highly complex solution, prompting the company to reach out to SKF for a simpler solution.”
Customer’s criteria
SKF recommended the TKSU 10 ultrasonic leak detector as a more streamlined, user-friendly alternative. “Engineered for fast and precise leak detection, the cutting-edge device perfectly aligns with all the customer’s criteria, presenting the ideal solution,” notes Darrin. In addition to steam traps, the instrument’s advanced ultrasound sensor can accurately identify leaks in applications such as pneumatic brake and vacuum systems, pressurised gas storage, etc.
SKF, in partnership with its Cape Town Authorized Distributor, Zhous, organised a demo of the TKSU 10 for the Engineering Manager and his team. “Within the first five minutes of their leading us to a particularly challenging asset, the unit identified three leaks in a set of six traps whereas they usually end up repairing all six hoping to solve the issue,” Darrin asserts.
No operator training
“The lightweight, handheld instrument requires no operator training. After all the team members tested the demo unit. They were so impressed by its accuracy, ease of use and overall robust build quality that the customer decided to place an order there and then.”
“The unit works like a microphone, but is sensitive only to high-frequency ultrasound, which is inaudible to the human ear,” explains Darrin. “This is then translated into an audible sound or frequency through a passive industrial noise reduction headset worn by the operator.” The headset also includes volume control and independently adjustable sensor sensitivity.
Sensitivity settings
The built-in colour LED display shows the measured ultrasound noise from leaking air, allowing leaks to be quantified and repairs to be prioritised. Sensitivity settings can be easily adjusted via the display. Designed to withstand harsh conditions, the ultrasonic leak detector functions effectively in extreme temperatures ranging from –10°C to +50°C. The device operates seamlessly even in noisy industrial environments while the flexible probe allows for leak detection in hard-to-reach areas.
The TKSU 10 will enable the customer to accurately identify issues and improve the efficiency of their steam system and maintenance planning, helping to reduce running costs, maintenance hours and spare parts consumption.
