Ultrasonic

Condition Monitoring
Alan Bandes
UE Systems, Inc.
 Ultrasonic Condition Monitoring
Alan Bandes
UE Systems, Inc

Ultrasound inspection offers a unique position for condition monitoring as both a “stand-
alone” inspection technology and as an effective screening tool that can speed up the
inspection process and help inspectors determine effective follow-up actions for
mechanical, electrical and leak applications.

Whether you refer to proactive inspections as “predictive maintenance” or “condition

monitoring”, the goal is the same; to note a deviation from a normal or baseline condition
in order to determine whether or not to take corrective action in a planned orderly manner
and to prevent an unplanned incident.

The ideal end result is to maintain asset availability, reduce maintenance overhead and
improve safety conditions. Not one technology can cover everything. The
recommendation is to incorporate as many technologies as possible into inspection
procedures to assure reliable results.

This paper will review the basics of ultrasound technology, what is new to the technology
and how it is used for condition monitoring to locate safety hazards, reduce energy waste
and improve equipment availability.

Ultrasound Technology
Airborne/structure borne ultrasound instruments receive high frequency emissions
produced by operating equipment, electrical emissions and by leaks. These frequencies
typically range from 20 kHz to 100 kHz and are beyond the range of human hearing. The
instruments electronically translate ultrasound frequencies through a process called
heterodyning, down into the audible range where they are heard through headphones and
observed as intensity and or dB levels on a display panel. The newer digital instruments
utilize data management software where information is data logged on the instrument and
downloaded to a computer for analysis. Some instruments contain on board sound
recording to capture sound samples for spectral analysis.

What makes airborne ultrasound so effective? All operating mechanical equipment,

electrical emissions (arcing, tracking, corona) and most leakage problems produce a
broad range of sound. The high frequency ultrasonic components of these sounds are
extremely short wave in nature. A short wave signal tends to be fairly directional and
localized. It is therefore easy to separate these signals from background plant noises and
to detect their exact location. In addition, as subtle changes begin to occur in mechanical
equipment, the subtle, directional nature of ultrasound allows these potential warning
signals to be detected early, before actual failure.
Most of the sounds sensed by humans range between 20 Hertz and 20 kilohertz (20
cycles per second to 20,000 cycles per second). The average human high frequency
threshold is actually 16.5 kHz. These frequencies tend to be relatively large when
compared with the sound waves sensed by ultrasonic translators. The lengths of low
frequency sound waves in the audible range are approximately 1.9 cm (3/4") up to 17 m
(56'), where-as ultrasound wave lengths sensed by ultrasonic translators are only 0.3 cm
(1/8") up to 1.6 cm (5/8") long. Since ultrasound wave lengths are magnitudes smaller,
the "ultrasonic environment" is much more conducive to locating and isolating the source
of problems in loud plant environments.

The high frequency, short wave characteristic of ultrasound enables users to accurately
pinpoint the location of a leak, electrical emission or of a particular sound in a machine.

The basic advantages of ultrasound and ultrasonic instruments are:

1. Ultrasound emissions are directional
2. Ultrasound tends to be highly localized
2. Ultrasound provides early warning of impending mechanical failure
3. The instruments can be used in loud, noisy environments
4. They support and enhance other PDM technologies or can stand on their own
in a maintenance program

When used as part of a condition monitoring program, ultrasound instruments help

improve asset availability and save energy.

Once established, ultrasound can be used as the “first line of defense” to:
• Inspect equipment fast
• Screen out anomalies
• Set up alarm groups for detailed analysis and further action

With the most recent advances over the past few years, Ultrasonic Detectors have become
much more sophisticated and have gone from just a listening device that is quite
subjective, to a system that can store test data, record sound samples and analyze both the
data through data management software and the recorded sound samples with spectral
analysis software.

With these new advances, using Ultrasound to separate good operating equipment from
bad is as easy as 1,2,3.
1. Listen and observe
2. Note deviations and record the translated ultrasonic signal
3. Analyze and review.
Let’s examine the possibilities of what can be done to save time, locate deviations and
save energy. First listen to the translated ultrasound and observe the decibel level. Note
any deviations from previous readings as you continue your route. Record the data and
any sound anomalies. Then analyze the data and sounds to consider if additional action is
necessary. All of this can be accomplished very quickly.

Here are a few case histories of how Ultrasound helped avoid Equipment Breakdown:

COMPRESSOR VALVE LEAK DETECTION

With a shutdown scheduled with very little advanced notice, a major mining operation
had to determine ways to reduce the manpower requirements on their Preventative
Maintenance Schedule. Normally, they changed out all of the valves on their large (
2000HP) compressor, but decided to use ultrasound as a method of determining which
valves to change, and thus reduce the manpower requirements. After checking the
valves, they found that only a small fraction of the valves needed to be changed. Times
series images of a good and a bad valve are below.

Good Compressor Valve Bad Compressor Valve

MAIN POWER TRANSFORMER ANOMALIE

A Main Power Transformer for a large utility began to show signs of heating up with
Infrared Scans on the top of the transformer near two of the three output insulators. It
was decided to investigate the Oil Recirculating Pumps to see if they were possibly the
problem. These pumps had been in service for 7 years with an expected life of over 10
years. An ultrasonic scan of both the inboard and outboard bearings on several
transformer oil pumps of the same age found that most had readings of 20 to 30 dB. 12
of the 14 pumps on the suspect Main transformer had readings in the 50 to 70 dB range.
The 30 to 35 dB increase in only these 12 oil pumps out of over 100 oil pumps tested was
considered to be very unusual, and needed further investigation.
Main Power Transformer Image with Oil

Oil Pump Cutaway

 UE-UT Readings
on
Outboard & Inboard
Oil Pump Bearings
06/29/2005
80

70

60

dB 50

40 OBB IBB

30

20

10

0
Pump Pump Pump Pump Pump Pump Pump Pump Pump Pump Pump Pump Pump Pump
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Ultrasonic Readings on Oil Pump Bearing

These Decibel Readings on the Oil Pump Inner and Outer bearings give the Ultrasound
operator excellent information about what might be causing the higher temperature
readings on the top of the Transformer and subsequent high gas readings. They can be
used to help evaluate risk of going to higher loads.

Below is a Time Series image of the inner bearing wave file. It is very close to the pump
outflow and from the “spikes” that come considerably above the baseline, it is easy to see
that there is a high probability that there is cavitation occurring at the pump output. This
has initiated further action to determine if the high decibel readings were caused by the
pumps being wired incorrectly causing the pump to rotate backwards.

Spectrum of Inner Bearing Cavitation

In another example described below3, an ultrasonic signal viewed through a vibration
analyzer can help isolate faulty gears.

The following time waveforms were taken on identical gearboxes in a tubing

manufacturing facility. There are 6 gearboxes coupled together each driving tooling that
bends steel to form tubing. The inspector was out collecting data with a vibration
analyzer and an ultrasound instrument when they came across the following gearboxes. A
vibration time waveform was taken with an accelerometer. When listening to the
gearboxes with the ultrasonic instrument, most of them had a hissing type sound. One
gearbox had a ticking sound to it and was captured in a time waveform first using an
accelerometer and then with the ultrasonic instrument. These were then compared to the
gearbox right beside it. The following time waveforms show the results.

This is the time waveform of gearbox A using vibration.

This is the time waveform of gearbox B using vibration.

By comparing the two time waveforms, a slight difference in the two gearboxes can be
observed. Note the time waveforms that were captured with ultrasound. The problem
becomes more defined
This is the time waveform of gearbox A using ultrasonics.

This is the time waveform of gearbox B using ultrasonics.

The ultrasonics time waveform shows the broken tooth or teeth in gearbox A. By the use
of ultrasonics this problem was caught in an earlier stage.

Electrical Inspection:
Ultrasound instruments detect ionization produced by arcing, tracking and corona and can
be used to locate problems in all voltages with the majority of applications in the mid to
high voltage range. While infrared is typically used to locate electrical problems, there
are “sound” events that could go undetected when relying on infrared thermography
alone. Enclosed cabinets can be scanned, transformers can be probed and corona can be
detected in high voltage equipment. Sound samples can be recorded for analysis and
spectral or time series views can be placed in reports.

The following demonstrate the effectiveness of ultrasound when used with infrared. An
inspector who utilizes both ultrasound and infrared technologies was inspecting
switchgear. Some of the doors could not be opened. There were no IR ports on the
closed cabinets and therefore this switchgear could not be tested with infrared. By
scanning the door seams and air vents with the ultrasound instrument, the inspector heard
a very distinctive arcing sound. He recorded the sound and after the cabinets were
opened he took visual and infrared images. Below are the results.

This is the spectral image of arcing. Below is the time series view of arcing.
The infrared image shows that this failure condition could have resulted in flashover at
any monent which would have produced a catastrophic event.

>38.5°C

35.0

30.0

25.0

LEAK DETECTION

The category of leak detection covers a wide area of plant operations. It can be looked on
as a way of keeping a system running more efficiently. Some plants include leak
detection as part of an energy conservation program while others perform leak detection
for safety purposes or to reduce an environmental impact. No matter what, leaks can cost
money, effect product quality and can reek havoc with the environment.

The reason ultrasound instruments are so versatile is that they detect the sound of a leak
and are not limited to just one type of leak. Leakage can occur in liquid or gas systems,
pressurized and vacuum systems, internally such as in valves or behind walls, or
externally such as through exposed piping.

For those instances where no pressure or vacuum can be created, an ultrasonic tone test
can be used. An ultrasonic transmitter is placed in one side of a test item to flood an area
with ultrasound. By scanning on the other side for sonic penetration, a leak can be
located. As an example, this is used in the transportation industry to locate wind noise
and water leaks around windshields.

The most common leak detection applications are used to save energy by locating
compressed air and steam leaks. The US Department of Energy has programs to help
industry reduce energy loss through three “challenges”: Compressed Air Challenge,
Steam Challenge and Motor Challenge. Information on these challenges can be found on
their web site: www.eere.energy.gov/industry/bestpractices.

Compressed air is one of the most costly utilities in plants today. The Department of
Energy has estimated that upwards of 30% of all compressed air produced in the US is
lost to leaks. An ultrasonic compressed air leak survey can offer fast pay back.

It is not uncommon to read of reports demonstrating savings in the tens of thousands and
hundreds of thousands of dollars from compressed air leak surveys, a recent survey at a
manufacturing plant is a typical example. This plant averaged an electric cost of
$1,760,000 to generate compressed air. The survey identified 3,561 leaks totaling 6,340
CFM at an annualized cost of $597,000 of energy waste. A program of leak detection
and repair can have a dramatic effect on the profitability of a company such as this.

Steam is another costly utility. Leaks in a steam system add to the energy cost. In fact,
leaking steam traps not only waste energy, they can cause water hammer which can
damage steam system components and add the operating costs. One steam trap can leak
an average of 43 tons of steam per year. A steam leak and steam trap survey can provide
substantial savings. One chemical company reported that the results of a steam trap
survey in one of their plants demonstrated a savings of $1,000,000.

With escalating energy costs, the impact is effecting not only the bottom line but jobs. A
recent National Association of Manufacturing newsletter1 reported that many companies
are forced to cut jobs due to the high cost of energy. They mentioned “Energy prices
have been a primary factor in the loss of 100,000 jobs in the chemical industry alone.”1

Conclusion:
Ultrasound condition monitoring provides many opportunities to improve asset
availability, keep production on schedule and save energy. Applications for mechanical
analysis, electrical inspection and leak detection cover just about all plant equipment.
The basic ultrasonic instrument is relatively easy to use while advancements in the
technology have helped improve data management, analysis and reporting. With
escalating energy costs ultrasonic technology can provide a cost-effective approach to
reducing energy waste in compressed air and steam systems.

1. “NAM Advancing Nine-Point Energy Security Plan” Just In Time, Special Issue: Energy Costs January, 2006

©2006 UE Systems, Inc., all rights reserved

14 Hayes Street Elmsford, NY 10523 USA

914-592-1220 [email protected] www.uesystems.com