Pillar 3 of 8 · SDT Ultrasound Solutions methodology

Ultrasonic Compressed Air and Gas Leak Detection

Name: KEG TRK
Address: 50 лет Октября, д 60А, Рудный, Костанайская область, 111500, KZ
Telephone: +7 717 264 08 69
Price range: ₸₸₸

20–30%

of compressed air lost at a typical plant

~10%

of a plant's electricity is compressed air

3–12 mo.

typical program payback period

0 shutdowns

inspection without depressurizing

📸 Photo: a technician with a directional ultrasonic detector (parabolic reflector) scanning an air pipeline in a compressor room

Recommended format: 1200×500 px, WebP

Ultrasonic compressed air leak detection identifies energy losses in pneumatic systems. According to the Compressed Air Challenge, leaks account for 20–30% of total compressed air production at a typical industrial plant. Given that compressed air consumes around 10% of a plant's total electricity, eliminating leaks is the fastest way to cut energy costs.

Ultrasonic detectors find leaks by the characteristic high-frequency signal (20–100 kHz) of turbulent flow. The method works for compressed air, process gases (N₂, Ar, CO₂), steam, and vacuum. Inspection is performed on running equipment under operating pressure — with no production shutdown and no depressurizing. The specialized LEAKChecker instrument is purpose-built for leak detection tasks.

KEG TRK supplies SDT Ultrasound Solutions detectors and LEAKReporter software for leak detection across Almaty, Astana, Atyrau, Aktobe, Pavlodar, Kyzylorda, and other cities in Kazakhstan. Training in the leak detection and documentation program is included.

Applications of Ultrasonic Leak Detection

One detector — full control of every gas system in the plant.

Compressed Air and Pneumatic Systems

20–30%

loss at a typical plant

Detects leaks in pipelines, connections, valves, and fittings. The detector localizes the leak source down to a specific fitting — even in noisy shop floors above 100 dB.

Vacuum Systems

100%

without shutdown

Identifies air ingress in vacuum lines, chambers, and seals. The ultrasonic signal of the turbulent flow clearly pinpoints the ingress point.

Natural and Process Gas

1 mm²

min. hole size

Finds leaks of N₂, Ar, CO₂, and natural gas in industrial installations. Safe inspection under pressure without additional gas analyzers.

Steam and Condensate

instant

localization

Detects steam leaks in pipelines and fittings. Ultrasound distinguishes a genuine leak from normal venting by the signal characteristics.

How to Perform Ultrasonic Leak Detection

Three steps from scanning to a savings report.

Scan Pipeline Zones with the Sensor

Use a directional sensor with a parabolic reflector for long-range searches, or a contact sensor for close-range work. Move along the pipeline, noting any rise in signal.

Localize the Leak Point

The ultrasonic signal increases as you approach the source. Move toward the peak dBµV reading — that is the exact leak location.

Document and Calculate the Loss

Tag the leak and log it in LEAKReporter. The software calculates the annual cost of the loss and generates a report with a map for the repair crew.

Benefits of Ultrasonic Leak Detection

Measurable energy savings for plants across Kazakhstan.

Up to 30% Energy Savings

Eliminating leaks reduces compressor load and directly lowers electricity consumption. A single survey route provides the data for a savings plan.

Detection in Noisy Environments

The 20–100 kHz range does not overlap with production noise. Leaks are found in the noisiest conditions — near presses, crushers, and compressors.

Precise Localization

A directional sensor points to a specific fitting or joint — no need to shut down and disassemble piping to find the leak location.

Loss Calculation Reporting

LEAKReporter automatically calculates the volume and annual cost of a leak. A ready-made document for prioritizing repairs and reporting to management.

No Shutdown or Depressurizing

Inspection is performed on running equipment under operating pressure. No downtime, no production loss during the audit.

Fast ROI: 3–12 Months

A single survey of a large plant identifies losses worth hundreds of thousands of tenge a year. A leak detection program pays for itself within the first quarter.