Electrical Leak Detection
Case Background
Client: A domestic electrical and electrical equipment group

Requirement: Currently, leak detection at welds is performed by spraying soapy water onto the joints; the goal is to enhance detection efficiency by employing an industrial acoustic imaging device.
Testing Procedure
01.
Preliminary Preparation
·The engineer performs electrostatic discharge at the entrance, then powers on the thermal imager and runs a self-test.
·Quickly set the detection frequency band and sound pressure range, insert the SD card, and the device is ready.
02.
On-site testing
·Walk at a steady pace along the inspection route, keeping the camera focused on the equipment and maintaining a safe distance.
·Real-time imaging on the screen: a red acoustic speckle suddenly appears, with its location simultaneously marked on the visible-light image.
03.
Re-test results
·Close-range scanning: the red-dot range has narrowed, and positioning accuracy verification has been passed.
· Soap solution verification: Bubbles form and rupture rapidly, indicating a minor leak that meets the inspection criteria.
Test Record
1
Acoustic signatures were detected at two air-gun muzzle connection leaks, and these were immediately marked.
2
Two connections inside the electrical box were loose; immediate on-site location and re-tightening were performed upon opening the box.
3
The vacuum pump valve continuously displays a red indicator; after replacing the sealing ring, retesting shows it has returned to zero.
4
A minor leak at the threaded connection produced a sonographic “speckle” pattern, indicating on-site that a gasket is missing.
5
Side flange air leak: fine soap bubbles disappear within 3 seconds yet are still detected, with a stable red highlight.
6
Top flange trace leak detection with 2-second imaging, eliminating the need for climbing to verify.
Test Results
·The noisy welding area R1 is free from interference, with second-level imaging, and can replace soap-and-water testing.

· Leak detection at elevated locations can be performed from the ground without the need for an aerial work platform, thereby improving work efficiency.
·For “ultra-micro leaks” (<0.1 L/min), it is recommended to increase the pressure or perform a close-range re-inspection.

·It is recommended to incorporate thermographic imaging into routine inspection procedures to reduce energy losses due to leaks and mitigate safety risks.
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