Ultrasound applications in predictive maintenance

1. Energy conservation
and
Equipment reliability
using
ULTRASOUND TECHNOLOGY
Demo request , please contact :
Hà Ngọc Hiếu – 0904 989 904
Mekongtech – Authorized distributor

2. Today’s Topics
UE Systems
Who we are and what we do
Ultrasound technology
How the technology works for maintenance
Applications areas
Where we use it
Some examples
Why companies use it
Ultrasound at YOUR PLANT
How it can be implemented

3. About UE Systems
• Founded in 1973 in Elmsford New York, USA
• 38+ years experience with ULTRASOUND
• We are a global company:
Asia UE Systems Asia, based in Hong Kong
Europe UE Systems Europe, based in the Netherlands
North America 11 regional offices in USA, Canada & Mexico
South America Regional support managers Spanish
+ over 200 local distribution partners worldwide!

4. About UE Systems
• UE Systems is world market leader for
Ultrasound instruments
• Continues software development to
meet customer demand
• Level I, II & III certified training
conducted to ASNT standard
• On-site equipment & software
orientation training
• On-site technology implementation
training
• 5 year warranty on products

5. ULTRASOUND TECHNOLOGY
how does it work?

6. Which Type of Ultrasound?
PULSE ECHO
POWER
AIR & STRUCTURE
BORNE
Medical applications
Tickness gauge
Flaw detection in solids
Cleaning
Welding and cutting
AIRBORNE
STRUCTURE BORNESTRUCTURE BORNE
ULTRASOUND
DIVISIONS

7. Why ultrasound?
Sound definition: Vibrations transmitted through an elastic solid, a liquid or gas, with
frequencies in the approximate range of 20 to 20,000 hertz, able to be perceived by humans
Sound (Audio Sound) is not directional and penetrates solid materials, making it difficult to
locate.
Ultrasound is defined from 20kHz to 100kHz
Advantages are:
• Very directional
• Reflects on solid materials and does not penetrate
• Reduces in strength, making source locating easy
• We can use the information for condition evaluation
Two ways to detect Ultrasound with our instruments:
• Airborne medium
• Structure borne medium

8. How does it work?
The Ultraprobe instruments have the capability to adjust frequency
between 20 kHz up to 100kHz
Ultrasound signals are picked up by the sensors and filtered at the
selected frequency
The high frequency sound is heterodyned down to audio sound so we
can hear it via the headset.
Result:
We only hear sound at the
selected frequency!
.
.
PREAMP
TRANSDUCER VARIABLE
GAIN
AMPLIFIER
HETERODYNE CIRCUIT
AUDIO AMPLIFIER
~
DB
CONVERTER
PHONES OUTPUT
LINE OUTPUT
DIGITAL I/O
DISPLAY
SENSITIVITY/
STORE BUTTON
GAIN CONTROL FREQUENCY
CONTROL
OSCILLATOR
20 - 100 KHz
CPU & DIGITAL CONTROLS
CONVERTER
INPUT
MIXER
LOW PASS
FILTER
& AMPLIFIER
FREQUENCY KNOB

9. APPLICATION AREAS
Where can we use it?

10. Typical application areas
Leak detection
•Pressure or vacuum, any type of gas
•Heat exchangers
•Tanks and boilers
•Window seal inspections
Valve inspection
•Valve leak detection
•Steam trap inspection
Mechanical inspection
•Condition monitoring of bearings
•Condition based lubrication
•Pumps for cavitations
•Conveyor belt systems
Electrical inspection
Discharge testing on:
•Switchgears
•Power lines & isolators
•Transformers
•Circuit breakers
(Tracking, Arcing, Corona
& mechanical looseness)
Speciality solutions for:
•Automotive WNWL
•Aircraft inspections
•Marine hatch testing

11. LEAK DETECTION
APPLICATION

12. LEAK DETECTION
Gas flow can be divided in:
• Laminar flow
• Turbulent flow
Limitation: Only a turbulent flow will cause sound!
So what can we detect?
0,3 bar with a 0,1mm leak size at 15m distance……
(under ideal circumstances)
The ultraprobe is a highly sensitive listening device
Works for any type of gas:
•Compressed air
•Vacuum systems
•Specialty gasses
Nitrogen, Oxygen, Acetylene, Hydrogen, Propane,
Methane, etc..

13. LEAK DETECTION
Considerations using Ultrasound for leak detection:
-> Pressure difference
-> Distance from the leak
-> Competing Ultrasound
-> Accessibility & isolation materials
-> We can only detect turbulent leaks
An alternative method for pressure is the tone generator

14. LEAK DETECTION
Why leak detection?
-> Economics: leaks cost money
-> Environment: CO2 reduction & specialty gasses
-> Safety: Flammable gasses
Our digital Ultraprobes can report the cost per leak!
1 - find it
2 - tag & record
3 - report!

15. VALVE & STEAM TRAP
APPLICATION

16. VALVE INSPECTION
Inspecting valves is as easy as 1-2-3-4
Listening and recording dB levels at 4 test points will give accurate
information if the valve is leaking
A leak in flow direction after the valve will create a turbulence,
fluids or gasses
A=33 dB B=48 dB D=42 dB
A B C D
C=59 dB

17. Steam systems, an inefficient but necessary form of energy
It’s expensive to build and operate….
Check steam traps regularly to cut energy cost
& optimize efficiency in the production process
Testing steam traps while in operation:
•Test for correct operation (modulating valves)
•Test for leakage when in closed condition
•Find out flow direction
•Determine location of sound emission (confirming diagnoses)
•Report the steam loss into yearly cost reporting
Works for all different types of steam traps:
ON/OFF: Inverted bucket, Thermodynamic & Thermostatic valves
Continuous flow: Float & Thermostatic valves
STEAM TRAP INSPECTION

18. For evaluating steam traps we can use: Ultrasound & temperature
+
Analyze the condition and report the yearly losses with our
Data management software (DMS) & spectralyser software
+
Example: GOOD BAD (note the airflow variation)
STEAM TRAP INSPECTION
Spot 1
311.0
Spot 2
231.6
*>322.8°F
*<212.1°F
220.0
230.0
240.0
250.0
260.0
270.0
280.0
290.0
300.0
310.0
320.0

19. REPORTING
Route based data collection is possible with DMS software
For the Ultraprobe 15,000:
With the integration of an IR thermometer
and digital camera it is possible to integrate
everything into 1 report!

20. ELECTRICAL
APPLICATION

21. ELECTRICAL INSPECTION
>38.5°C
<22.8°C
25.0
30.0
35.0
An electrical emission will cause the air to vibrate and cause a sound
When inspecting electrical equipment:
-> InfraRed for RESISTANCE problems
-> Ultrasound for DISCHARGE and
MECHANICAL problems
This applies for any type of equipment and can be detected from a distance!
Inspect switchgears at the air gaps before opening doors
IMPROVING SAFETY STANDARDS FOR THE INSPECTOR:
1- Ultrasound from a distance
2- Open doors and 2nd
scan
3- IR on resistance problems
Find more and be safe!

22. The Ultraprobe will find early stages of:
-Corona
-Arcing
-Tracking
-Mechanical looseness
This applies to any type of equipment and can be detected from a distance of
up to 30 meters with help of the Ultrasonic Waveform Concentrator
ELECTRICAL INSPECTION

23. There are situations IR is difficult to use for getting a visual line
For Ultrasound all we need is an open air connection
Example enclosed transformer:
ELECTRICAL INSPECTION
Early stages of tracking, evolving into arcing….into
catastrophic failure!
$

24. Reporting electrical problems with DMS and Spectralyser:
When a sound source is located & recorded, we can analyze and document it
With the Ultraprobe 15,000 we can:
-> Locate the source of sound found
-> See on board spectrum for a fast first analyses
-> Take a picture for reference (laser pointer)
-> Use spectralyser software for determining which type of electrical problem
(in FFT and time-series view)
-> Report and document your results
ELECTRICAL INSPECTION

25. BEARING & LUBRICATION
APPLICATION

26. PRINCIPLE OVERVIEW
Proactive
Domain
F
Predictive
Domain
Fault
Domain
P2
P3
P5
P6
P4
P1P
Start Failure
Vibration
Oil analysis
Audible noise
Contact heat
Infrared
Structure Borne
Ultrasound
EARLY WARNING OF
BEARING FAILURE
LUBRICATION DOMAIN
OPTIMIZING BEARING
LIFE!
(DMS & GREASE CADDY)
Max time for planning

27. BEARING MONITORING
Using ultrasound technology for trending bearing condition:
-> Indicating early warning of failure
-> Identifying lubrication condition
-> Avoiding over lubrication
Works also on slow moving bearings or sloe bearings!
Friction between mechanical components will cause a sound energy
The dB levels can be used to evaluate condition in the route-based data colletion
principle with help of DMS software:
Baseline +8dB = Lubrication alarm
Baseline +12dB = microscopic damage
Baseline +16dB = visual damage
88 dB 70 dB

28. BEARING MONITORING
3 types of testing are used:
1 -> Comparison method - Listening, noting dB and compare
2 -> Historical trending - using DMS software to program your test points
3 -> Fault frequency analyses - Spectralyser software for identifying faults
Key for our Ultraprobe instruments:
It is quick to learn and data collection goes fast!
DMS software: Reporting functionality designed for ease of use on collecting the
data, to communicate results and produce work orders.
Spectralyser: Analyses tool with reporting functionality to document and
communicate reports

29. What about lubrication?.... Seems simple…..
The dilemma: HOW MUCH & WHEN?
LUBRICATION
The lubricant used for a bearing is extremely reduced
compared to what is usually needed.
An excess of lubricant in the bearing can be harmful.
FAG Kugelfischer Georg Schäfer AG
Publ.- No. WL 81 115/4 SB “Lubricación de Rodamientos” Pág. 35
A correct period between lubrications depends on many
factors. Recommendations can be based only on statistic
rules .
SKF , México Web page bajo palabra Relubricación
Even if traditional rules and practices can be sometimes
correct, it is evident that sometimes it doesn't work.
Noria Corporation, Lube-Tips Newsletter

30. Condition based lubrication -> avoiding over lubrication!
The right amount of grease based on the condition of that moment
1- Getting your lubrication report from DMS, go out and perform lubrication
2- The Grease Caddy 201 will help you to perform condition based lubrication
What does a bearing sound like?
Good
Bad
Lubricated
After 5 min.
LUBRICATION

31. CAVITATION EFFECT IN A PUMP DRASTICALLY AFFECTS LIFESPAN!
Typical problems when installing and monitoring pump operation is to
adjust pressures for optimal operation conditions
Cavitation is caused by uneven pressure differences creating a vacuum
and airbubbles to damage the propeller blades to destruction
2 methods of inspection:
1- Cancel out or minimize the cavition effect by listening for the air bubbles
2- Trend the dB values in DMS software to periodically monitor the condition
Here is a sound example of cavitation in a waterpump
PUMP INSPECTION

32. Get the most out of technologies available to you!
Many multinational companies have found Ultrasound to redefine the
bearing monitoring strategy:
Define lubrication standards and filter the need for detailed analyses:
1-> Identifying lubrication issues
2-> Proper lubrication => extending bearing life!
3-> Identifying at the same time first failure indication
4-> Filtering need for root cause analyses
An Ultraprobe helps you to collect information fast and accurate
Time = Money
TECHNOLOGY STRATEGY
NONE
Vibration
Ultrasound
+
Lubrication
Vibration

33. CONCLUSION
on
ULTRASOUND TECHNOLOGY

34. CONCLUSION
-> Easy to use and quick to learn!
-> 1 instrument for many applications
-> Training and support available to you at all times
-> Regular updates on enhancing software reporting
-> We are a supplier of solutions: no service contracts needed
-> DMS & Spectralyser software update & license free!
-> 5 year factory warranty
The Ultraprobe series will produce results and be highly cost effective for you!
Ultraprobe 15,000
Ultraprobe 10,000
Ultraprobe 9000
Grease Caddy 201
WWW.UESYSTEMS.COM
Ultraprobe 3000