Search for leaks of toxic and explosive gases
Remote inspection of a chemical plant with the NACEx-PU camera: leak localization, gas loss assessment, and report generation in Aura SVS.
These are approximate estimates from case materials, compiled using publicly available data. They do not represent losses or savings at the customer's site. Actual costs depend on the substance, the scale of the leak, and production conditions.
About the project
- Client
- Production of ammonia, urea, phosphorus mineral fertilizers and feed phosphates
- Industry
- Chemical Industry
- Object
- Pipelines and process equipment
- Format
- Walk-arounds with a portable ultrasound camera
- Equipment
- NACEx-PU
- Software
- Aura SVS
The task: to find leaks from a distance
A chemical plant needed a non-invasive method for detecting toxic and explosive gas leaks. Much of the equipment was located outdoors, which, according to the project specifications, complicated the use of gas analyzers and thermal imaging.
It was necessary to accurately determine the leak's location from as far away as possible. This information was required to plan repairs, including access control and the construction of auxiliary structures.
An additional challenge is to quickly inspect a large amount of different equipment with a minimum number of devices.
Hazardous gas leaks pose a threat to personnel and the environment and can lead to production shutdowns. Accurate containment helps identify areas requiring priority attention.
Solution: Portable Ultrasound Camera
The NACEx-PU camera was used for the examination in conjunction with Aura SVS software for analysis of stored data and automated report generation.
Under the project's conditions, the camera detected leaks from tens of meters away. Visualization of ultrasound sources made it possible to locate leaks on equipment images and inspect a significant portion of the facility in a short period of time.
How was the examination conducted?
Inspection of production areas
The operator inspected pipelines, furnaces, reactors, compressors and cleaning systems using NACEx-PU.
Real-time source search
The camera displayed leak locations on the equipment image, helping to identify areas for subsequent repair.
Service priorities
The operator used the gas loss estimate to prioritize maintenance and added notes to the saved acoustic data files.
Processing in Aura SVS
The saved data and notes were used to automatically generate a report on the results of the inspection.
Result: production inspection in a few hours
The inspection of a large production facility took several hours. The camera allowed for remote localization of leaks on various process equipment and the recording of the results for future work.
Localizing the sources and assessing gas losses provided information for prioritizing maintenance and preparing repairs. Operator notes can be used to generate reports in Aura SVS.
Where applicable
Ultrasound detection for gas leaks can be used at various industrial facilities. The inspection conditions and camera design are tailored to the specific task.
Oil, gas and petrochemicals
Pipelines, compressor seals and process units for gas processing and transportation.
Chemical plants
Gas communications, connections and equipment in production chains with hazardous substances.
Fertilizer production
Technological areas with ammonia and other gaseous substances.
Metallurgy and coke chemistry
Gas pipelines and equipment using coke and other process gases.
Pulp and paper industry
Gas communications and equipment for technological processes of cellulose processing.
Industrial refrigeration
Piping, connections and equipment for ammonia refrigeration plants.
Logistics and storage
Gas communications of terminals, pumping, storage and loading/unloading areas.
Equipment and Software
Portable camera for examinations and software for working with saved results.
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