Efficient Plant February 2020 - 24

Genie, Redmond, WA,
used the Fluke ii900
sonic industrial imager
for leak detection in
the company's compressed-air system.
The imager applies
proprietary algorithms
to determine leak
location and presents
results on an LCD
screen in a still image
or real-time video.

feature | solution focus

Find
Invisible Leaks

Manufacturer recovers more than 25% of compressed-air capacity using sonic imager.

WHEN A PRODUCTION line relies
heavily on compressed air to run tools and
processes, even tiny air leaks can multiply product waste, energy costs, and lost
production time. Staying on top of those air
leaks is a priority. Genie, a Terex brand, and
a global manufacturer of aerial lift equipment, recently found a new weapon to help
combat those pesky and costly leaks.
Genie's plant in Redmond, WA, uses
between 1,800 and 2,600 cfm of compressed
air daily. That air runs as many as 200

24

| EFFICIENTPLANTMAG.COM

EP2002fsolfocus.indd 24

torque tools on each line, along with process
equipment used to move large sheets of
half-inch steel and to position parts. If the
tools don't have enough compressed-air
pressure to function properly, the results
are costly.

FINDING INVISIBLE LEAKS
The company is vigilant about finding
and fixing air leaks. Some leaks occur in
hoses and fittings high in the rafters; others
appear on the torque tools on the shop floor.

One or two maintenance technicians would
hunt for air leaks over a weekend. They first
sprayed joints and hoses with a soap-andwater mixture and searched for bubbles that
indicated leaks. Then they fixed the leaks
and retested with soapy water.
"It was very labor intensive," said Josh
Stockert, Genie Maintenance Supervisor,
Terex AWP. "It might take 30 to 45 minutes
to find one leak in the rafters, and then
come back down to get material to fix it,
go back up and fix the leak, and verify with

FEBRUARY 2020

1/28/20 5:55 PM



http://www.EFFICIENTPLANTMAG.COM

Efficient Plant February 2020

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