How SoundCam Ultra 3 has changed the way leaks and anomalies are detected in plants by integrating with vibration analysis and predictive maintenance
Over a three-year period, a large international group in the chemical and automotive sectors installed 12 SoundCam Ultra 3 systems at its production and maintenance sites with a very specific goal in mind: to quickly identify compressed air leaks and acoustic anomalies that cause energy waste, inefficiency, and potential risks to plant reliability. For maintenance and safety teams, it has become an everyday tool: in a matter of seconds, they can locate the source of the problem, document the case, and decide on the intervention, without having to "trial and error."
In Italy, SoundCam Ultra 3 is distributed by Aesse Misure, a company specializing in industrial vibration monitoring and critical machinery protection, which supports power plants, utilities, and large process plants with predictive maintenance and condition monitoring solutions.
The problem: invisible leaks, visible costs
In the initial phase, the problem was not "finding a tool," but rather involving maintenance technicians and department managers in the right way to test it in the field. Once the right people (maintenance, energy managers, HSE) were seated at the table, the need was clear: to identify leaks, defects, and acoustic anomalies before others do, which today escape traditional controls but which over time translate into costs and plant downtime. There were three basic requirements:
- A fast and intuitive tool for leak detection (compressed air, gas, vacuum) and acoustic troubleshooting on machines and lines.
- A partner capable of accompanying the company from initial analysis to field training.
- A solution that can be sold internally, i.e., easy to adopt across multiple departments and plants.
For a company that depends on service continuity, such as a power plant or a facility with critical rotating machinery, this means being able to transform part of its maintenance from reactive to truly predictive.
From theory to practice: the demo that speaks the language of maintenance technicians
Instead of starting with slides and specifications, the project began directly in the field: SoundCam Ultra 3 in the hands of operators, in front of real pipes, skids, and panels.
The approach was deliberately simple: "press an icon and see where the problem originates, " showing the acoustic map superimposed on the image of the plant in real time, with the source of ultrasonic noise immediately highlighted.
During the tests, the teams were able to:
- Identify compressed air leaks and ultrasonic interference in seconds, without searching by ear or using spray.
- Automatically generate comprehensive reports (approximately 20 pages) ready to be shared with energy managers and safety officers.
- Take advantage of the integrated thermal camera, slow-motion playback, and acoustic imaging at up to 100 frames per second to clearly distinguish transient events and stationary signals.
This "demo effect" broke down many barriers: those who use vibration analyzers, sound level meters, or thermal imaging cameras on a daily basis found themselves in a familiar environment, but with an added capability— the ability to "see" ultrasound and transform it into a maintenance decision.
Why it won the comparison: performance, features, and time saved
Alternative systems were also considered during the evaluation, but certain technical and usage aspects made the difference. SoundCam Ultra 3 uses 176 microphones with 200 kHz sampling and covers the 2–100 kHz range, generating 100 acoustic images per second: this allows even small leaks to be detected in noisy environments and weak sources to be clearly visualized alongside very intense sources.
For the customer, the strengths were in particular:
- Long-term measurements with trigger functions, preset profiles, and frequency comparisons for repeatable analysis over time.
- Versatile applications: from leak detection to machine diagnostics, structural noise analysis, and environmental noise analysis.
- Continuous software evolution, with updates and new features available without replacing the hardware.
In the discussion on costs, the ability to quickly quantify the potential energy savings associated with the identified losses—and to document them with clear reports—made the return on investment a concrete, rather than theoretical, argument.
What has changed in the plant: routine, energy, safety
Today, the system is mainly used for periodic compressed air leak detection campaigns and routine checks as part of preventive maintenance. Over time, the customer has developed actual "inspection routines" that are integrated into the maintenance plan, reducing compressed air waste and intervening before acoustic anomalies turn into failures
The benefits highlighted are mainly qualitative:
- Reduction of losses and related energy costs.
- Faster diagnoses, greater efficiency of maintenance teams, fewer unplanned downtimes.
- Internal "word of mouth" effect: a satisfied department leads other departments and plants to request the same tool.
For power plants and large facilities with critical rotating machinery, this logic naturally integrates with existing activities (vibration analysis, thermography, electrical checks), adding an extra perspective on phenomena that were previously difficult to locate.
The role of Aesse Misure: from testing to standardization
A decisive element that emerged from the project was the "internal champion": a figure who was the first to adopt the system, measured its benefits, and promoted it to colleagues and management. Alongside this internal role, the support of a specialized partner made it possible to move from a single demo to a true multi-site adoption program. Aesse Misure, with its extensive experience in vibration monitoring and condition monitoring of critical machinery, can accompany Italian customers through all phases:
- Preliminary analysis of applications (power plants, turbines, compressors, process lines).
- Field demonstrations and pilot projects on existing plants.
- Training for maintenance technicians, operations managers, and HSE managers, with a focus on integrating SoundCam Ultra 3 into predictive maintenance routines.
For those who manage facilities where an "invisible" leak can turn into costs, downtime, and risks, introducing an ultrasonic acoustic chamber such as SoundCam Ultra 3 means giving maintenance and safety teams an extra ally: fast, visual, and easy to share with those who decide on investments.
Contact the Aesse Misure team to request a field demo or a discussion about your applications.
Download the SoundCam Ultra 3 technical data sheet below
SoundCam Ultra3 Brochure English.pdf