Detecting Air Leaks and Mechanical Faults in ATEX Zone 22 with the FLIR Si2x Acoustic Imaging Camera

Why Dust in ATEX Zone 22 Is a Serious Risk

Dust explosions remain a serious threat in industrial settings. Consider the 2008 sugar factory explosion in Georgia: a dust cloud ignited, killing 14 people and injuring 38. The Occupational Safety and Health Administration (OSHA) reported back in 2012 that 130 employees had lost their lives in a period of just over 30 years. During the same period, it reported that 800 more people had been injured due to dust and fine powder fires and explosions.

These tragedies illustrate the devastating consequences of undetected air leaks and unnoticed mechanical faults in dusty environments. In ATEX Zone 22, where explosive atmospheres are rare but possible, reliable tools like the FLIR Si2x-LD acoustic camera are essential for identifying risks before they escalate.

The Dual Threat in Zone 22: Air Leaks and Mechanical Faults

Air Leaks: A Hidden Hazard
Compressed air leaks may seem trivial, but even a small leak can stir up settled dust, creating a combustible cloud. When mixed with air, fine particles like sugar, flour, or chemical powders form explosive atmospheres that can ignite with a single spark.

Mechanical Faults: Ignition Sources
In Zone 22, machinery wear and tear pose a significant risk. Faulty bearings, friction heat, or loose components can act as ignition sources, turning a minor mechanical issue into a catastrophic event.

FLIR Si2x Acoustic Camera: Solving ATEX Zone 22 Challenges
Maintenance managers in Zone 22 environments often face a recurring challenge: pinpointing leaks in compressed air systems within expansive, noisy facilities. These leaks not only waste energy but can stir up dust clouds that pose significant fire risks.

The FLIR Si2x acoustic camera offers an innovative, highly effective solution, combining acoustic imaging technology with ATEX Zone 22 certification to detect and resolve these issues.

Specific Example: Addressing the Pain Point of Hidden Air Leaks in Hazardous Dusty Environments

Imagine a food processing plant where fine flour dust settles near conveyor belts and packaging lines. A minor air leak in a compressed air pipe goes unnoticed, disturbing settled dust and forming a combustible cloud. At the same time, an aging motor begins to overheat due to worn bearings, creating a potential ignition source.

With traditional methods, detecting this leak might require shutting down operations, deploying multiple personnel, and using outdated handheld tools.

Using the FLIR Si2x, the maintenance manager scans the area from a safe distance of up to 200 m (656 ft):

• Acoustic Imaging Mode: Pinpoints the exact location of the air leak on the pipe, visualized as a bright spot on the display.
• Mechanical Fault Detection Mode: Detects abnormal ultrasonic patterns from the overheating motor, identifying worn bearings before they fail.
• Real-Time Data: Displays the severity of both issues and calculates the energy loss from the air leak.

In minutes, the manager has actionable data to prioritize repairs, preventing a potential explosion and costly equipment downtime—all without halting operations.

5 Key Benefits of the FLIR Si2x for ATEX Zone 22 Environments

1. Advanced Air and Gas Leak Detection

Si2x detecting an air leak

The FLIR Si2x uses acoustic imaging to detect leaks in:

• Compressed air systems
• Industrial gases such as ammonia, hydrogen, CO₂ methane, helium, and argon
  

Leaks as small as 0.05 liters per minute can be detected from up to 10 m (32 ft) away, ensuring early intervention.

2. Mechanical Fault Detection

Si2x detecting a mechanical fault

The camera’s mechanical fault detection mode identifies ultrasonic signals from failing components, including:

• Worn or overheating bearings
• Misaligned machinery
• Loose or vibrating parts

Early detection of these issues prevents unexpected breakdowns and reduces the risk of sparks or heat igniting dust clouds.

3. Certified for ATEX Zone 22

Designed for hazardous environments, the FLIR Si2x is fully compliant with ATEX Zone 22 regulations, ensuring safe operation in areas where explosive dust atmospheres may occur briefly.

4. Real-Time Analysis and Cost Estimates

Si2x detecting and quantifying a compressed air leak

The ultrasonic detection camera provides instant feedback on leak size, mechanical fault severity, and potential energy loss, enabling quick decision-making and efficient predictive maintenance planning.

5. Ease of Use

The Si2x's intuitive interface makes it easy for anyone to use

The intuitive interface requires minimal training, making it accessible to all team members, even those with limited technical experience.

Typical Applications of the Si2x Atex Zone 22 certified Acoustic Imaging Camera

1. Food and Beverage Processing

Detects leaks near flour, sugar, or powdered goods, reducing the risk of dust explosions.

2. Chemical Manufacturing

Identifies leaks and mechanical faults in pipelines and equipment handling flammable substances.

3. Pharmaceutical Production

Ensures safety in environments where ultra-fine powders are prevalent.

Why Choose the FLIR Si2x for ATEX Zone 22?

Proactive Risk Mitigation: Prevents hazards by addressing air leaks and mechanical faults before they escalate.

Certified Safety: Complies with ATEX Zone 22 regulations, ensuring reliable performance in hazardous environments.

Operational Efficiency: Reduces downtime and maintenance costs with fast, accurate inspections.

Versatility: Combines air leak detection and mechanical fault identification in a single tool.

FAQs

Conclusion: The FLIR Si2x—A Safety Essential for Zone 22

For maintenance managers in ATEX Zone 22 environments, the FLIR Si2x acoustic camera is an indispensable tool. Its precision, speed, and compliance with safety regulations make it the ultimate solution for detecting air leaks and preventing hazards in dusty environments.

To learn more about the FLIR Si2x, visit the FLIR Si2x-LD product page or contact your local FLIR distributor today.

By adopting the FLIR Si2x, you’re not just investing in cutting-edge technology—you’re prioritizing the safety of your facility, workforce, and operations.