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Ultrasonic surveys can be used to identify leaks in pressurized systems such
as steam and HP air. Ultrasonics also compliments 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, yet least used
technologies in condition monitoring today. It provides 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
- It isn't uncommon for a medium size industrial facility to throw away
thousands of dollars in wasted electricity and machine wear compressing air
so that it can be blown out through pin-holes and bad seals. Most
maintenance people know this but it gets lost in all of the other fire
fighting. How do you justify the expense of fixing a leaky flange?
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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, 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. While this component is readily identified
with our vibration analysis services, it is possible to survey a far greater
number of bearings in a given time period using ultrasonic inspections than
with routine vibration monitoring. Therefore some customers with large
numbers of bearings prefer to use periodic ultrasonic monitoring until a
problem is identified, then to invoke routine vibration testing to assess
severity. This approach can provide a significant cost savings.
Ultrasonic inspections will also identify over greasing conditions in
bearings. This is a common source of bearing problems as the additional
grease causes the bearing to run hot. 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
- Although we recommend thermographic inspection as a primary means of
fault detection in high-voltage equipment and sub-stations, ultrasonic
inspections can provide valuable additional information when inspecting
high-voltage installations by revealing corona discharge.
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