Airborne & Structure-Borne Ultrasound as a key component to Predictive Maintenance Christopher Hallum, CMRP Regional Manager UK & Ireland UE Systems UK & Ireland
ULTRASOUND TECHNOLOGY HOW DOES IT WORK?
WHICH ULTRASOUND? ULTRASOUND DIVISIONS PULSE ECHO POWER AIR & STRUCTURE BORNE MEDICAL APPLICATIONS TICKNESS GAUGE FLAW DETECTION IN SOLIDS CLEANING WELDING AND CUTTING AIRBORNE STRUCTURE BORNE
WHY ULTRASOUND? 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 SOUND DEFINITION Vibrations transmitted through an elastic, be it solid, a liquid or gas, with frequencies in the approximate range of 20 to 20,000 hertz, able to be perceived by humans. Sound is not directional and penetrates penetrates solid materials, making it difficult to locate.
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!
APPLICATION AREAS WHERE CAN WE USE IT?
TYPICAL APPLICATION AREAS LEAK DETECTION Compressed air systems Compressed gas systems Heat exchangers Tanks and boilers ELECTRICAL INSPECTION DISCHARGE DETECTION ON: Switchgear Power lines & insulators Transformers Circuit breakers (Tracking, Arcing, Corona & mechanical looseness) VALVE INSPECTION Valve leak detection Steam trap inspection MECHANICAL INSPECTION Condition monitoring of bearings Condition based lubrication Cavitation effect in pumps Conveyor belt systems ONLINE MONITORING Electrical cabinet monitoring Fixed sensors for Valve monitoring Fixed sensors for bearing monitoring Ethernet compatible bearing monitoring systems
LEAK DETECTION APPLICATION
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.. PRESSURE LEAK VACUUM LEAK
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! FIND IT TAG, RECORD & PICTURE REPORT! THERE IS A FREE APP FOR THAT
VALVE & STEAM TRAP APPLICATION
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 B C D A = 33 db B = 48 db C = 59 db D = 42 db
STEAM TRAP INSPECTION For evaluating steam traps we need Analyze the condition and report the yearly losses with our SOFTWARE Data management software (DMS) ULTRASOUND & TEMPERATURE Spectralyser software EXAMPLE GOOD BAD (note the airflow variation)
ELECTRICAL APPLICATION
ELECTRICAL INSPECTION AN ELECTRICAL EMISSION WILL CAUSE TURBULENCE IN THE AIR 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 FIND MORE AND BE SAFE! Ultrasound from a distance Open doors and 2nd scan IR on resistance problems
ELECTRICAL INSPECTION THE ULTRAPROBE WILL FIND EARLY STAGES OF: CORONA TRACKING ARCING 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 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
BEARING & LUBRICATION APPLICATION
PRINCIPLE OVERVIEW
88 db 70 db 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 slow 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
Condition based lubrication AVOIDING OVER LUBRICATION! LUBRICATION THE RIGHT AMOUNT OF GREASE BASED ON THE CONDITION OF THAT MOMENT 1 2 Getting your lubrication alarm report from DMS, go out and lubricate The Grease Caddy will help you to decide when to stop adding grease WHAT DOES A BEARING SOUND LIKE? Good Lubricated Bad After 5 minutes
TECHNOLOGY STRATEGY DEFINE LUBRICATION STANDARDS AND FILTER THE NEED FOR DETAILED ANALYSES: 1 2 Identifying lubrication issues 3 4 Identifying at the same time first failure indication Proper lubrication > extending bearing life! Filtering need for root cause analyses AN ULTRAPROBE HELPS YOU TO COLLECT INFORMATION FAST AND ACCURATE TIME MONEY MANY MULTINATIONAL COMPANIES HAVE FOUND ULTRASOUND TO REDEFINE THE BEARING MONITORING STRATEGY NONE VIBRATION VIBRATION ULTRASOUND + LUBRICATION Get the most out of technologies available to you!
ONLINE BEARING & LUBRICATION CONDITION MONITORING
DATA
CONCLUSION ON ULTRASOUND TECHNOLOGY