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Ultrasonic surveys can be used to identify leaks in compressed air systems,
steam systems or any other gaseous distribution system. Ultrasonic surveys compliment any
vibration analysis program by providing a simple means of quickly identifying the
high frequency component of vibration that is typical of the early stages of
many mechanical failures. It also compliments thermographic inspections of
high voltage systems by detecting corona discharge energy.
Key Benefits
 | Cost reduction through the early detection of problems and verification of
findings. |
| Improved efficiency through increased diagnostic certainty prior to
work-order issuance. |
| Reduced downtime through increased equipment reliability and availability. |
Capabilities
Ultrasonic inspections are one of the most versatile
technologies in condition monitoring today. The noise is distinctive and
can be readily used to identify a wide range of problems or potential problems.
It is also a first line of defense in the reliability battle by providing a low cost means
of checking virtually any component in an industrial or power conversion
environment so that further inspections or corrective action can be implemented.
EMP Engineering Services uses the Ultraprobe by UE Systems for our ultrasonic
inspections.
- Compressed Gas Leak Detection
- Did you know that at $0.10 per kilowatt-hour, it costs $39,209 for
electricity to operate a 100 HP fully-loaded compressor with 90% efficiency
for 2 turns per day? According to the Department of Energy, the
electrical cost is 76% of the overall operating cost of the compressor and
up to 30% of that cost is to provide air that is lost through leaks.
That's $11,763 wasted from your budget every year!
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 - These leaks range from pin-holes and bad seals to holes in the pipes.
The evidence is all around anyone who's ever walked through a plant and
listened to the background noise. Unfortunately, fixing the problem
gets lost in the day-to-day maintenance activities and fire-fighting. How do you justify the expense of
dedicating people and resources to fixing leaky flanges when everybody
thinks that there are bigger fish to fry?
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- EMP Engineering Services will provide you with a report documenting your
leaks, the cost for each one and the total cost your facility blows away
every year. We do this by using ultrasonic noise to identify leaks. Ultrasonic noise,
which can be quickly and easily detected with the right equipment, is
created when high pressure gases and steam escape through small holes.
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- Heat Exchanger Inspection and Fault Detection
- Holes in shell and tube heat exchangers can allow serious leakage and
contamination problems. They can be quickly and accurately identified
by placing an ultrasonic noise generator on one side and measuring on the other side.
By using a boot that allows the operator to pinpoint the source of the noise, problems can be narrowed down to a particular tube. This
technique can find even pinholes in large, multi-pass heat exchangers.
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- Bearing Fault Detection and Vibration Confirmation
- There is an ultrasonic component to most common mechanical faults
such as rolling element bearing failures. Although this component is
not as accurate for trending and determining just when a bearing failure
will occur, it is an excellent means for early identification of which
bearings are at risk and need further attention from standard vibration
analysis. Because of this, facilities with large numbers of roller
bearings such as those with roll out tables like to use ultrasonic noise
surveys to monitor their roll bearings. This approach can provide a
level of risk reduction in situations were it simply isn't feasible to
perform vibration monitoring on hundreds of bearings.
Ultrasonic inspections will also identify under and over greasing conditions in
bearings. Over greasing is a common source of bearing problems as the additional
grease causes the bearing to run hot and often ends up in places where it
shouldn't be such as inside of motors. Early identification provides
maintenance people adequate time to remove excessive grease before damage
occurs.
Other mechanical problems ranging from gear lubrication and wear problems
to faulty steam traps to broken valves in reciprocating compressors can also
be identified with ultrasonic inspections.
- Corona Discharge Detection
- Corona discharge occurs is a destructive phenomena that occurs in high
voltage electrical equipment. It generates ultrasonic noise that is
readily detectable with an ultrasonic device. This will work in
outdoor sub-stations or inside enclosures and it is often not not detectable
by other means.
EMP Engineering Services will
provide you with a report detailing the locations and severity of problems
detected in your high voltage equipment.
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- Downloads
- Please take the time to view our sample
ultrasonic leak survey report
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1. Sample Ultrasonic report:
Sample Ultrasonic Report.pdf
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