The ultrasonic generator converts the supplied alternating voltage of 50 Hz or 60 Hz to a frequency that corresponds to the operating frequency of the transducer.
The transducer then converts the released electric energy into mechanical acoustic oscillations causing the surrounding fluid to oscillate.
Each oscillation leads to an over-pressure phase or low-pressure phase in the fluid, depending on whether the transducer expands or contracts.
During the low-pressure phase, due to the fluid's limited tensile strength, small cavities form in the fluid; these so-called cavitation bubbles implode during the over-pressure phase.
When the cavitation bubbles implode at the surface to be cleaned, dirt particles are removIt is important at this stage to draw attention to the very important and significant difference between 6dBµV and 6dB. 6dBµV is another way of expressing a voltage measurement 0f 2µV. 6dB however is merely expressing a ratio – stating that one number is 6dB higher than another indicates that the first number has double amplitude of the second. So if the decibel is dimensionless, i.e it does not have a specific reference attached to it, then that decibel reading is not telling anything. To say this is double is quite meaningless without a reference – it must be double compared with something else.
It is very important to keep in mind that decibels should not be multiplied or divided. They are dB and should only be added or subtracted. To say for example that 36dBµV is twice as big as 18dBµV is in correct. The difference between these two values is 18dBµV which correspond to a ratio of 7.9. So the voltage amplitude of a signal of 36dBµV is not 2 times higher than the voltage amplitude of a signal of 18dBµV, its in fact, 7.9 times higher!
Lets apply this to the bearing:
In January, bearing “A” was measured with an ultrasound detector and the value was 10dBµV
In April, that same bearing measured 62dBµV.
62dBµV - 10dBµV = 52dBµV (factor of 400)
Therefore, from January to April, the ultrasonic signal from bearing “A” increased by a factor of 400 – probably the has already failed.
It is important at this stage to draw attention to the very important and significant difference between 6dBµV and 6dB. 6dBµV is another way of expressing a voltage measurement 0f 2µV. 6dB however is merely expressing a ratio – stating that one number is 6dB higher than another indicates that the first number has double amplitude of the second. So if the decibel is dimensionless, i.e it does not have a specific reference attached to it, then that decibel reading is not telling anything. To say this is double is quite meaningless without a reference – it must be double compared with something else.
It is very important to keep in mind that decibels should not be multiplied or divided. They are logarithmic values and should only be added or subtracted. To say for example that 36dBµV is twice as big as 18dBµV is in correct.
Sound waves propagate mechanical wav
2. Company Overview
Our story began about 40 years ago, when founding directors Lesley and Wally Crawford, and Gary Brown set up oil analysis
operations in 1976 in a home laboratory.
Their initial test portfolio comprised six elements - viscosity, water, fuel, sludge and debris analysis, with no automation. The
company employed 10 people and processed less than 500 samples per month.
From those humble beginnings, the company has flourished and grown, and today Wear-Check is one of the leading condition
monitoring specialists on the African continent, processing in excess of 600 000 samples per annum.
We have evolved into a one-stop-shop for a vast range of reliability solutions services across many industries, and we are
proud to be a member of the prestigious International Wear-Check Group (IWG).
The IWG is an association of independent laboratories around the globe, dedicated to oil and wear particle analysis.
Wear-Check’s relationship with the IWG allows for the ongoing exchange of advanced technical information, and the ability to
offer a worldwide service.
3. WHY USE WEARCHECK?
One of WearCheck’s fundamental goals is to save money and time for customers by improving the availability, reliability and
efficiency of their machinery through regular maintenance and tailored condition monitoring programmes.
The development of WearCheck’s reliability solutions division embraces the latest approach to proactive maintenance - the
search for ways to extend the life of components to prevent premature failure, thereby boosting general plant health. The
underlying philosophy is that any good proactive maintenance programme boosts both plant availability as well as plant
reliability.
WHO USES CONDITION MONITORING?
Using results from the scientific analysis of used oil, fuels, coolants and greases from components for plant maintenance
decisions, many industries benefit from WearCheck’s services, among them mining, earthmoving, industrial, transport,
shipping, aviation and electrical operations.
WHERE CAN I FIND WEARCHECK?
Wear-Check’s expansive network of 13 laboratories spans the African continent and beyond, including Isando in Gauteng,
Pinetown in KwaZulu-Natal, Middelburg, Lumwana mine and Kitwe in Zambia, as well as Ghana, Mozambique, DRC,
Zimbabwe, Namibia, India and Dubai (in partnership with Precision Machinery), with additional offices in Cape Town,
Rustenburg, Steelpoort and Port Elizabeth
Wear-Check has a unique achievement – we are the only oil analysis company in Africa with ISO 9001 quality certification
and ISO 14001 certification for our environmental management programme, as well as being accredited with the ISO 17025
laboratory centric quality management programme.
4. OIL ANALYSIS SERVICES
Oil analysis is as important for maintenance engineering as blood testing is for medicine.
It is the scientific analysis of all types of lubricants and transformer oils, coolants, greases and filters and is an established
method for predictive and preventive maintenance.
Preventive maintenance programmes are essential for optimising operational efficiency, reliability and performance of
mechanical and electrical systems.
WearCheck offers many services for predictive and preventive maintenance, including competitive pricing and short
turnaround time.
Analyses are carried out at state-of-the-art, custom built, automated laboratories with interpretation and reports being
completed by our highly-qualified diagnosticians.
The company's services include: Viscosity Distillation Density Flashpoint Water (by Karl
Fischer)
Appearance /
colour
Particle contamination
Dissolved gases Wear metals Total acid and
base numbers
Moisture Dielectric
strength
Visual colour PCB analysis
RULER test Copper and silver
corrosion
Air release
5. RELIABILITY SOLUTIONS SERVICES
• Machinery Health Services
• Non Destructive Testing
• Oil Analysis
• Alignment/Balancing and Thermography
• Sensors (Poseidon Wi-Care, Emerson, SPM and MVA)
• Quality Verification - Fuel and Diesel
• Remote Analysis with data package deals
• Package deals for Customers to rent equipment
6. COURSE TOPICS
AIRBONE ULTRASOUND
ULTRASOUND TECHNOLOGY
APPLICATIONS AREAS
SOME EXAMPLES
ULTRASOUND AT YOUR PLANT
Principles
How the technology works for maintenance
Where we use it
Why companies use it
How it can be implemented
WEARCHECK Who we are and what we do
9. PULSEECHO–MEDICALAPPLICATION
Imaging probes for diagnostic ultrasonography are devices that generate a pressure field into the human body, according to an
electrical signal. The differences in acoustic properties of different types of tissue allow the scanner to generate an image of a
part of the body, based on the received echo signals. The quality of the resulting image is strictly related to the materials
involved in the transducer manufacturing and the understanding of their interactions.
10. PULSEECHO-THICKNESSGAUGE
Pulse-echo in measuring the thickness of the material, is a technique where a source emits a pulse, then that pulse gets
reflected (echo), and a search unit detects the echo. By measuring the time between the transmission of the transmit
pulse and the reception of that echo, the ultrasound machine can calculate the distance between the probe and the
structure that caused that echo. This is essentially the same principle used by bats to catch insects through echo-location
When using the pulse-echo technique,
thickness is the product between the
velocity of sound and half the transit
time.
12. Industrial Ultrasonic Cleaning with High-Power Ultrasound
For micro-level cleaning systems, it is a challenging task not to damage tiniest structures on the surface to be
cleaned.
Ultrasonic systems that work at operating frequencies between 700 kHz and 3 MHz are best suited for this.
With these systems, dirt particles can be removed reliably in the nanometer range without damaging the sensitive
surfaces by a too high pressure or too high temperatures.
This is why the ultrasonic cleaning process is ideal for microsystems technology and semiconductor production.
Power Ultrasound for Cleaning
The functional principle of ultrasonic cleaning is easy to understand: The ultrasonic system basically consists of
three components:
The electronic ultrasonic generator, the ultrasonic oscillator (transducer), a piezo element, and an appropriate
cleaning fluid, selected according to the cleaning task.
13. Industrial Ultrasonic Cleaning with High-Power Ultrasound
Operating Principle
The ultrasonic generator converts the supplied alternating voltage of 50 Hz
or 60 Hz to a frequency that corresponds to the operating frequency of
the transducer.
The transducer then converts the released electric energy into mechanical
acoustic oscillations causing the surrounding fluid to oscillate.
Each oscillation leads to an over-pressure phase or low-pressure phase in
the fluid, depending on whether the transducer expands or contracts.
During the low-pressure phase, due to the fluid's limited tensile strength,
small cavities form in the fluid; these so-called cavitation bubbles implode
during the over-pressure phase.
When the cavitation bubbles implode at the surface to be cleaned, dirt
particles are removed.
14. Alternative joining technologies - Ultrasonic welding
Ultrasonic welding has become a well-accepted method
for joining high-volume, relatively small plastic parts.
In this process, an ultrasonic generator is used to
produce oscillations of one substrate against a
stationary second substrate.
This, in turn, causes intense frictional heating between
the two substrates, which is sufficient to rapidly
generate a molten weld zone. With pressure and
subsequent cooling, a strong bond can be obtained.
The ultrasonic-welding process consists of four phases.
Phase 4: the holding phase, the vibration ceases,
maximum displacement is reached, and a high joint
strength occurs as the weld cools and solidifies.
Phase 3: steady-state melting occurs, as a constant
melt layer thickness is maintained in the weld
Phase1: the horn is placed in contact with the substrate,
pressure is applied, and vibratory motion is started. Heat
generation due to friction melts points of direct contact,
and the molten material flows into the joint interface.
Phase 2: the melting rate increases, resulting in increased
weld displacement, and the part surfaces fully meet.
15. ULTRASOUNDTECHNOLOGYHOW DOES IT WORK?
• Audible Spectrum – 20Hz – 20kHz (Omnidirectional, penetrates solid objects)
• Ultrasound Spectrum – 20kHz onwards (Directional, does not penetrate solid
objects, easily locatable)
• Generated by Turbulence & Friction
• Airborne & Structure borne mediums
• Mechanical Inspection – Predominantly Structure Borne
• Technology is highly sensitive – Early diagnosis of any potential issue
16. 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.
HOW DOES IT WORK?
ULTRASOUND TECHNOLOGY HOW DOES IT WORK?
17. ULTRASOUNDTECHNOLOGYHOW DOES IT WORK?
• Sound waves propagate mechanical energy causing periodic vibration of particles in a continuous, elastic medium.
• Sound waves cannot propagate in a vacuum since there are no particles of matter in the vacuum.
• Sound is propagated through a mechanical movement of a particle through compression and rarefaction that is
propagated through the neighbor particles depending on the density and elasticity of the material in the medium.
• The velocity of the sound in
• Air: 331 m/sec;
• Water at 0°C: 1430 m/sec; Water at 20°C: 1481 m/sec; Water at 100°C: 1543 m/sec;
• Metal: Copper 4600 m/s; Iron 5130 m/s; Steel 6100 m/s; Stainless Steel 5700 m/s
• Soft tissue: 1540 m/sec; Fat: 1450 m/sec
• Ultrasound medical imaging: 2MHz to 10 MHz
• 2 MHz to 5 MHz frequencies are more common.
• 5 MHz ultrasound beam has a wavelength of 0.308 mm in soft tissue with a velocity of 1540 m/sec.
18. Infrasound can be caused by many different sources—storms, winds, earthquakes, animals, and even wind turbines can
produce infrasound. Elephants use infrasound to communicate over long distances; since low frequency sounds travel farther than
high frequency ones, infrasound is ideal for communicating from far away.
DIFFERENT SOUND LEVELS
19. 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 is not directional and
solid materials, making it difficult to
locate.
WHY ULTRASOUND?
Sound is not directional and penetrates solid
materials, making it difficult to locate.
ULTRASOUND IS DEFINED FROM 20KHZ TO 100KHZ
ADVANTAGES ARE:
Two ways to detect Ultrasound with our instruments:
AIRBORNE MEDIUM - STRUCTURE BORNE MEDIUM
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
20. HOW DOES IT WORK?
The Ultra probe 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!
21. UNDERSTANDING THE PROPERTIES OF DECIBEL
Decibel Scale
Sound is measured in units called decibels
(dB). The higher the decibel level, the louder
the noise. On the decibel scale, the level
increase of 10 means that a sound is actually
10 times more intense, or powerful.
The term bel is derived from the name
of Alexander Graham Bell, inventor of
the telephone. The unit decibel is used because a
one-decibel difference in loudness between two
sounds is the smallest difference detectable by
human hearing.
22. UNDERSTANDING THE PROPERTIES OF
DECIBEL
In order to quantify, compare and trend, we need to be able to measure sound. The chosen measurement unit for
sound, and therefore ultrasound, is the decibel.
A decibel scale scale without a reference value is merely a scalar quantity which cannot be converted back into a actual
physical unit. A decibel scale is relative measurement which compares a measured value with a reference.
I case of an SDT device, the dBµV scale is written as:
dBµV = 20log10(V/𝑉0)
Where 𝑉0 is the reference voltage which says that 0dBµV, the threshold of ultrasound hearing is 1µV
To fully understand decibels and how to handle them, we need to go back to school and remember logarithms. Starting first
with powers:
𝟏𝟎𝟓 𝟏𝟎𝟒
𝟏𝟎𝟑 𝟏𝟎𝟐 𝟏𝟎𝟏 𝟏𝟎𝟎
1
1 0
1 0 0
1 0 0 0
1 0 0 0 0
1 0 0 0 0 0
23. UNDERSTANDING THE PROPERTIES OF
DECIBEL
Using powers simplifies multiplication and division:
103 x 102 = 105 to multiply the numbers together, add the powers
105 x 103 = 102 to divide the numbers, subtract the powers;
Such a system would not be so useful if it only applied to 10. In fact , any number can be expressed as power 0f 10. For
example the number 2 can be expressed as 100.301
.
So by using the same approach to multiplication by addition of powers ,
100.301 x 100.301 = 100.602
Or in other words 2 x 2 = 4
Mathematics naturally contains a lot of symmetry. There symmetrically opposite mathematical operators like + and – or x
and ÷. The symmetrical opposite of 10 x is log. In other words, the log of a number ask the question “what power do I need
to raise 10 to in order to get this number?” Referring to table 3 on the previous slide, it should be clear that
log (1) = 0 log (2) = 1 log (100) = 2 log (1,000) = 3 Similarly, log (2) = 0.301 and log (4) = 0.602
24. UNDERSTANDING THE PROPERTIES OF
DECIBEL
Examples:
• A measurement of 1µV (i.e. 1 times the 1µV reference)
20log10 1 = 20 𝑥 0 = 0𝑑𝐵µV
• A measurement of 10µV (i.e. 10 times the 1µV reference)
20log10 10 = 20 𝑥 1 = 20𝑑𝐵µV
• A measurement of 100µV (i.e. 100 times the 1µV reference)
20log10 10 = 20 𝑥 2 = 40𝑑𝐵µV
• A measurement of 1000µV (i.e. 1000 times the 1µV reference)
20log10 10 = 20 𝑥 3 = 60𝑑𝐵µV
The decibel value is calculated by taking the measured voltage expressed in µV (microvolts), taking the log of that
voltage value and multiplying the answer by 20
Note the additive property of logs:
x 1,000 = x10 x 100 = 20dB + 40dB
• If we were to measure 2µV, then
log10 2 = 0.301
• So doubling of the amplitude of an
ultrasound signal would become:
20log10 2 = 20 𝑥 0.301 = 6𝑑𝐵µV
25. UNDERSTANDING THE PROPERTIES OF
DECIBEL
It is important at this stage to draw attention to the very important and significant difference between 6dBµV and 6dB.
6dBµV is another way of expressing a voltage measurement 0f 2µV. 6dB however is merely expressing a ratio – stating that
one number is 6dB higher than another indicates that the first number has double amplitude of the second. So if the
decibel is dimensionless, i.e it does not have a specific reference attached to it, then that decibel reading is not telling
anything. To say this is double is quite meaningless without a reference – it must be double compared with something
else.
It is very important to keep in mind that decibels should not be multiplied or divided. They are logarithmic values and
should only be added or subtracted. To say for example that 36dBµV is twice as big as 18dBµV is in correct. The difference
between these two values is 18dBµV which correspond to a ratio of 7.9. So the voltage amplitude of a signal of 36dBµV is
not 2 times higher than the voltage amplitude of a signal of 18dBµV, its in fact, 7.9 times higher!
Lets apply this to the bearing:
1. In January, bearing “A” was measured with an ultrasound detector and the value was 10dBµV
2. In April, that same bearing measured 62dBµV.
3. 62dBµV - 10dBµV = 52dBµV (factor of 400)
4. Therefore, from January to April, the ultrasonic signal from bearing “A” increased by a factor of 400 – probably the
has already failed.
27. Sound is produced by vibration of molecules in an elastic medium such as gases,
liquids or solids
Sound travels as wave.
Basics of Sound
Sound works over a range of frequencies. The behavior of sound waves varies
depending upon the frequency.
Sound can be transmitted through material and reflected off them
The amplitude of sound wave varies in relation to the distance between the sound
source and the detector
Basics of
Sound
28. ATTENUATION OF SOUND
Tissue Average Attenuation Coefficient in
dB/cm at 1 MHz
Propagation Velocity of Sound in m/sec
Fat 0.6 1450
Liver 0.8 1549
Kidney 0.95 1561
Brain 0.85 1541
Blood 0.18 1570
29. Wave
Motion
Sound travels as wave
In air sound travels as longitudinal wave. The particle of medium move back and
forth in the same direction as the direction of travel of the wave. Consider the
motion of the worm.
Sound Wave Motion
Another common wave motion is a transverse wave. In a transverse wave, particles
move perpendicularly to the direction of travel of the wave. Consider the motion of
the snake
30. Wavelengt
h
We know that in a sound wave, the combined length of a compression and an adjacent rarefaction is
called its wavelength.
Also, the distance between the centers of two consecutive compressions or two consecutive
rarefactions is equal to its wavelength.
Sound - wave can be described by five characteristics
The minimum distance in which a sound wave repeats itself is called its wavelength.
That is it is the length of one complete wave. It is denoted by a Greek letter λ (lambda).
31. Amplitude
Sound - wave can be described by five characteristics
In fact the amplitude is used to describe the size of the wave. The S.I unit of measurement of amplitude is
meter (m) though sometimes it is also measured in centimeters. Do you know that the amplitude of a wave is
the same as the amplitude of the vibrating body producing the wave?
When a wave passes through a medium, the particles of the medium get displaced temporarily from their
original undisturbed positions. The maximum displacement of the particles of the medium from their original
undisturbed positions, when a wave passes through the medium is called amplitude of the wave.
32. Time
Period
Sound - wave can be described by five
characteristics
So, we can say that the time taken to complete one vibration is known as time-period. It is denoted by letter T.
The unit of measurement of time-period is second (s).
The time required to produce one complete wave or cycle or cycle is called time-period of the wave. Now, one
complete wave is produced by one full vibration of the vibrating body.
33. Frequency
Velocity or Speed.
Sound - wave can be described by five characteristics
Sometimes a bigger unit of frequency is known as kilohertz (kHz) that is 1 kHz = 1000 Hz. The frequency of a
wave is denoted by the letter f.
The frequency of a wave is the same as the frequency of the vibrating body which produces the wave
For example: if 10 complete waves or vibrations are produced in one second then the frequency of the waves
will be 10 hertz or 10 cycles per second. Frequency of a wave is fixed and does not change even when it
passes through different substances?
The number of complete waves or cycles produced in one second is called frequency of the wave. Since one
complete wave is produced by one full vibration of the vibrating body, so we can say that the number of
vibrations per second is called frequency. The S.I unit of frequency is hertz or Hz. A vibrating body emitting 1
wave per second is said to have a frequency of 1 hertz. That is 1 Hz is equal to 1 vibration per second.
34. Sound – wave can be described by five characteristics
Velocity = Distance travelled/ Time taken
Let v = λ / T
Where T = time taken by one wave.
v = f X λ
VELOCITY OF SOUND
This formula is known as wave equation.
Where v = velocity of the wave
f = frequency
λ = wavelength
Velocity of a wave = Frequency X Wavelength
The distance travelled by a wave in one second is called velocity of the wave or speed of the wave. It is represented by
the letter v.
The S.I unit for measuring the velocity is meters per second (m/s or ms-1).
The velocity of a sound wave in a medium, c, is related to its wavelength l and frequency n by c=ln
36. 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)
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
VALVE INSPECTION
Valve leak detection
Steam trap inspection
TYPICAL
APPLICATION AREAS
38. LEAK DETECTION
Gas flow can be divided in:
LIMITATION:
only a turbulent flow will cause sound!
LAMINAR FLOW
TURBULENT FLOW
So what can we detect?
The ultra probe is a highly sensitive listening device
0,3 bar with a 0,1mm leak size at 15m distance……
(Under ideal circumstances)
COMPRESSED AIR
VACUUM SYSTEMS
SPECIALTY GASSES
PRESSURE
LEAK
VACUUM
LEAK
Works for any type of gas:
Nitrogen, Oxygen, Acetylene, Hydrogen,
Propane, Methane, etc..
39. LEAK DETECTION
Considerations using Ultrasound
for leak detection:
An alternative method for
pressure
is the TONE GENERATOR
WE CAN ONLY DETECT TURBULENT LEAKS
COMPETING ULTRASOUND
DISTANCE FROM THE LEAK
ACCESSIBILITY & ISOLATION MATERIALS
PRESSURE DIFFERENCE
40. LEAK DETECTION
WHY LEAK DETECTION?
ECONOMICS:
Leaks cost money
ENVIRONMENT:
CO2 reduction & specialty gasses
SAFETY:
Flammable gasses
Our digital Ultra probes can report the cost per leak!
FIND IT TAG, RECORD & PICTURE REPORT!
THERE IS A FREE APP FOR THAT
42. Valve Inspection
Valves are extremely important part of the operating assets of most plants. Failures of valves can cause many problems
and may even prevent plant operation. The frequent assessment of valve condition should therefore be an important part
of the work of condition monitoring. Valves are used in many applications: control valve and non-return valves for
example.
Blocked
If there should be flow through a valve and there isn’t , the valve is said to be blocked. The lack of flow will be
accompanied by lack of ultrasound both in the valve it self and the pipe work both upstream and particularly down stream.
Passing
If a valve is supposed to be shut and there is still some flow through the valve, then it is possible that the valve is said to be
passing. In this case there will be a constant residual ultrasound signal present irrespective of valve position.
Cavitation and Flashing
If there is a drop in hydrostatic pressure across the valve, then it is possible that the valve will be driven into cavitation.
Cavitation will produce quite distinct intermittent clicks and pops which can be detected on the valve and a small distance
downstream of the valve as the pressure recovers.
If there is no improvement downstream, it is probable that the valve is flashing.
43. Valve Inspection – Measurement Methods
When developing a strategy for valve inspection there are many things to think about.
• What types of valves are out there and what are their failures?
• Are they all clearly and correctly identified? Is there a database?
• Is the direction of flow correctly established?
• Are all valves installed the right way around?
• What are the impacts of process variations? What will be operating and when?
44. A = 33 dB B = 48 dB D = 42 dB
A B C D
C = 59 dB
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.
45. STEAM TRAP
INSPECTION
CHECK STEAM TRAPS
REGULARLY TO CUT
ENERGY COST &
OPTIMIZE EFFICIENCY
IN THE PRODUCTION
PROCESS
Steam systems, an inefficient but necessary form of energy
IT’S EXPENSIVE TO BUILD AND OPERATE….
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
46. STEAM TRAP INSPECTION
For evaluating steam traps we need ULTRASOUND &
TEMPERATURE
Analyze the condition
and report the yearly
losses with our
SOFTWARE
EXAMPLE
GOOD
BAD
(note the airflow variation)
Data management software (DMS) Spectralyser software
47. 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!
48. REPORTING STEAM TRAP ENERGY LOSSES
Report your SAVINGS
OPPORTUNITY using
dB & Temperature
measurement
50. ELECTRICAL INSPECTION
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
Ultrasound
from a distance
Open doors
and 2nd scan
IR on resistance
problems
FIND MORE AND
BE SAFE!
51. Electrical Inspections
P
D
PD Occurs: Anywhere there is a junction between two electrical components.
Examples are within solid insulation, across the surface of insulation material, within
gas bubbles in liquid insulation and around an electrode surrounded in gas.
How To Detect PD: PD is most often detected by ultrasound testing devices that pick
up the sound emissions given off by the discharge. Alternately, Transient Earth Voltage
(TEV) detection may be appropriate on some equipment.
Effects of PD: Damage caused by PD can be mechanical, thermal or chemical. If PD
goes undetected, catastrophic damage to electrical equipment may occur and may
cause serious safety issues in the workplace such as Arc Flash.
Classification of PD: There are three distinct types:
1. Corona – ionization of fluid or air surrounding a conductor.
2. Tracking – surface tracking over contaminated insulation
3. Arcing – electrical breakdown of a gas producing a plasma discharge.
Physical Signs of PD: Odors (ozone, burning, metallic), discolored lines or carbon
track
52. ELECTRICAL INSPECTION
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
THE ULTRAPROBE WILL FIND EARLY STAGES OF:
CORONA TRACKING
ARCING MECHANICAL LOOSENESS
53. ELECTRICAL INSPECTION
There are situations IR is difficult to use for getting a visual line.
For ULTRASOUND all we need is an open air connection.
EARLY STAGES OF TRACKING, EVOLVING INTO ARCING…. INTO CATASTROPHIC FAILURE!
EXAMPLE
ENCLOSED TRANSFORMER
54. 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
59. BEARING MONITORING
USING ULTRASOUND TECHNOLOGY FOR TRENDING BEARING
CONDITION:
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
SEVERE Failure +35 SEVERE FAILURE
Indicating early warning of failure
Identifying lubrication condition
Avoiding over lubrication
88
dB
70
dB
60. Action Levels for Alarms
• 8 dB Lubrication
• 12 dB Microscopic Damage
• 16 dB Damage - Visual Faults
• 35+ dB - Severe Failure
(Above Baseline levels)
Lack of
Lubrication
Microscopic
Damage
Damage
(visual)
Severe
Failure
61. BEARING MONITORING
COMPARISON METHOD - Listening, noting dB and compare
HISTORICAL TRENDING - Using DMS software to program your test points
FAULT FREQUENCY ANALYSES - Spectralyser software for identifying faults
3 TYPES OF TESTING
ARE USED
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.
ROUTE BUILDER APP: Build routes quick & easy with your smartphone or tablet
SPECTRALYSER:
Analyses tool with reporting functionality
to document and communicate reports
62. LUBRICATION
WHAT ABOUT LUBRICATION?.... SEEMS SIMPLE…..
The dilemma: HOW MUCH & WHEN?
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
A correct period between lubrications depends on many
factors.
Recommendations can be based only on statistic rules .
SKF
Even if traditional rules and practices can be sometimes
correct, it is evident that sometimes it doesn't work.
Noria Corporation
THE MAJORITY (60%) OF PREMATURE BEARING
FAILURES ARE LUBRICATION RELATED!
63.
64. LUBRICATION
Condition based lubrication
AVOIDING OVER LUBRICATION!
THE RIGHT AMOUNT OF GREASE BASED
ON THE CONDITION OF THAT MOMENT
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?
Lubricated
After 5 minutes
1 2
Good
Bad
65. PUMP INSPECTION
THE RIGHT AMOUNT OF GREASE BASED ON THE CONDITION OF THAT MOMENT
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 air bubbles to damage the
propeller blades to destruction
HERE IS A SOUND EXAMPLE OF CAVITATION IN A WATERPUMP
2 METHODS OF
INSPECTION
Cancel out or minimize the cavitation effect by listening for the air bubbles
Trend the dB values in DMS software to periodically monitor the condition
66. ACCESS ISSUES TESTING BEARINGS?
MACHINES CAN BE SHIELDED
OR TEST POINTS NOT ACCESSED
DURING NORMAL OPERATION
A fixed installed sensor with BNC connector to be
able to test or lubricate a bearing during
operation.
The Instrument is connected to the sensor cable
directly or via the switchbox.
67. TECHNOLOGY STRATEGY
DEFINE LUBRICATION STANDARDS AND FILTER THE
NEED FOR DETAILED ANALYSES:
Identifying
lubrication issues
Proper lubrication >
extending bearing life!
1 2
3 4
Identifying at the
same time first
failure indication
Filtering need
for root cause
analyses
AN ULTRAPROBE HELPS YOU TO COLLECT INFORMATION
FAST AND ACCURATE
TIME
MONEY
Get the most
out of technologies
available to you!
MANY MULTINATIONAL
COMPANIES
HAVE FOUND ULTRASOUND TO
REDEFINE THE BEARING
MONITORING STRATEGY
NONE
ULTRASOUND
+
LUBRICATION
VIBRATION
VIBRATION
v
v
v
69. A growing demographic of qualified and skilled ultrasound inspectors is poorly represented in the mobile maintenance shop
where the technology is virtually unknown, and sadly, many cost saving applications have not been revealed
Internal combustion engines burn fuel and regardless of size they require air; preferably clean. The air we breathe is the
same air engines breath.
No matter where we are on the planet air contains particles in suspension. Some of these particles are harmless but others
represent a serious danger.
Silica ranks as one of the hardest elements on earth, only surpassed by topaz, corundum, and diamond. Silica is very
damaging if it reaches the inside of the engine.
Silica also ranks as one of the most abundant elements on earth and ever present in dirt and dust which is made airborne in
the conditions where mobile machines operate.
Engines are therefore equipped with high efficiency filtration systems to prevent silica and other contaminants from reaching
the combustion chamber.
Diesel Engines
70. All diesel engines have primary and secondary filters fitted between the air intake vents and the turbocharger
(Image 2).
When the engine is operational a negative pressure is created in the air intake system and any leaky orifice
(loose clamps, cracked hoses, thinned metal, pin holes) downstream of the filters means the engine is
breathing without filtration.
This means air full of silica can reach the pistons, rings, sleeves and other engine components causing
damage and premature failure.
Depending on how much silica is ingested, the life of the engine is dramatically reduced, sometimes lasting
only a few days!
Oil analysis is used as a predictive tool comparing the metal content and silica in parts per million (PPM) found
in the oil sample against limit values set according to the engine manufacturer.
Diesel Engines
71. The acceptable silica content is very low ranging from 15-50 PPM.
When a sample shows values over the limit the source of the contamination needs to be found quickly and the mobile asset
must be removed from service to avoid further costly damage.
This introduces the added cost of downtime and lost productivity.
Finding the leaks calls for an exhaustive visual inspection of the entire air intake system.
This can take several hours to inspect and it’s not uncommon after the inspection to have found nothing.
The next oil sample will still show high silica levels and increasing wear metal values indicating the problem is getting worse.
As a companion to visual inspection, ultrasound testing to find the leak will net results much faster, and is also useful to
confirm the repairs to the leak were done correctly.
Diesel Engines
72. Image 2 - Typical Turbo Charger System
Diesel Engines
74. There are two methods for finding problems in the air intake system with ultrasound
instrument
Inspection with the engine running
Inspection with the engine turned off
Diesel Engines
75. Diesel Engines – Inspection with the engine running
Using this method of inspection is based on the premise that any turbulent flow from a potential leak produces
ultrasonic sound pressure waves which are detected with the ultrasonic detector.
Turbulent flow is produced between two adjacent volumes when those volumes have a) differential pressure, and b)
a leak path. Turbulent flow will exist at the leak path as there is differential pressure between the volumes
Start the engine and leave it to idle. With noise attenuating headphones in place adjust the sensitivity according to
the ultrasound sources near the engine.
Using the flexible sensor for safety (if you have that accessory) inspect the entire intake system starting from the air
breather and ending at the turbocharger. Any air ingress will produce an ultrasonic signal that sounds like the hissing,
swooshing sound you know from a compressed air leak.
A well trained ear will pick this sound quickly despite competing noises that may come from the engine itself.
Additional training teaches ultrasound inspectors how to deal with parasite noise and harsh environments and is
highly recommended for mobile mechanics that are adopting ultrasound testing symbiotically with oil analysis.
Techniques known as “shielding”, “covering”, “blocking”, and “positioning” are learned keys that assist inspectors in
high noise area
76. The air intake system can also be inspected for leaks when the engine is not running.
In fact this may be a more desirable method if the parasite noise from the engine is too much. When the engine is off
there is no differential pressure and consequently no turbulent flow.
No turbulent flow means no natural ultrasound signals are present at any leak sites. In lieu of turbulent flow we can
generate artificial ultrasound signals in the air breather system. This is done by means of Bi-Sonic Transmitter, a small
accessory that generates a 40 kHz signal powerful enough to fill small volumes.
The ultrasound signal can be heard and measured directly through the various membranes that make up the air breather
system. Wherever the possibility of air ingress exists the signal will be significantly louder. This is noted in the headphones
of the, and also in the measured decibel on the ultrasound instrument display.
A large mining company in northern Canada recently shared their experience inspecting the air intake on a LeTourneau
production loader. In Response to very high levels of Silica & Iron from Oil samples on 546 Production Loader an attempt
was made to determine if there were any leaks in the breather system of the loader which would cause severe dusting. A
visual inspection of the breather system failed to produce any definitive results
Finding the leaks was easy the mining company reports. A 200mW Ultrasonic Transmitter was placed inside the inner air
filter. Both air filters were replaced and the breather system was sealed up
Diesel Engines – Inspection with the engine turned off
78. ONLINE BEARING & LUBRICATION
CONDITION MONITORING
PERMANENTLY INSTALLED TRANSDUCERS CONTINUOUSLY MONITOR BEARING CONDITION
24 HOURS A DAY, 7 DAYS A WEEK
All data is stored locally
Once alarm is triggered, a notification is issued via Ethernet
Data transmission based on desired programmed intervals
Continuously
monitor the health
of your asset
24/7
Set alarm levels!
Know when to
lubricate or when
to take repair/replace
action
When an alarm
level is entered,
analyze data and
sounds before,
during, after an
event
Produce reports
with images
and sound
analysis
Prevent
over lubrication
and lack of
lubrication
conditions
MONITOR ALARM ANALYZE REPORT PREVENT
WE’VE GOT YOU
COVERED!
80. STANDARD SENSOR WIRED TO BE CONNECTED
TO YOUR PLC SYSTEMS TO ONLINE MONITOR
BEARING CONDITION
CAVITATION IN PUMPS
LEAKING VALVES
ULTRATRAK 750
Condition monitoring sensor
Output 4-20 mA or power looped to measure changes in condition. Includes a glue stub kit for easy installation.
FOR
81. PLUG-IN MODULES
TRISONICTM SCANNING MODULE. This module is
utilized to receive air-borne ultrasound such as the
ultrasounds emitted by pressure/vacuum leaks and
electrical discharges.
There are four prongs at the rear of the module. For
placement, align the prongs with the four corresponding
jacks in the front end of the pistol housing and plug in.
The TrisonicTM Scanning Module has a phased array of
three piezoelectric transducers to pick up the airborne
ultrasound. This phased array focuses the ultrasound on
one "hot spot" for directionality and effectively intensifies
the signal so that minute ultrasonic emissions can be
detected.
COMPONENT
S
82. STETHOSCOPE (CONTACT) MODULE.
This is the module with the metal rod. This rod is utilized
as a "waveguide" in that it is sensitive to ultrasound that is
generated internally such as within a pipe, bearing
housing or steam trap. Once stimulated by ultrasound, it
transfers the signal to a piezoelectric transducer located
directly in the module housing. The module is shielded to
provide protection from stray RF waves that can affect
electronic receiving and measurement. It is equipped with
low noise amplification to allow for a clear, intelligible
signal to be received and interpreted. For placement align
the four prongs on the back with the corresponding
receptacles in the front of thepistol and plug in.
COMPONENT
S
83. LRM (LONG RANGE MODULE). A cone shaped
scanning module that increases the detection
distance above standard scanning modules. The
LRM-15 is ideal for high voltage inspection and for
locating leaks at great distances.
COMPONENT
S
84. RAM/RAS-MT REMOTE MAGNETIC TRANSDUCER.
The RAS/RAM-MT is a magnetically mountable contact
probe with cable. The probe is applied to a test surface
and the RAM (Remote Access Module) is plugged into the
front end of the Ultra probe.
COMPONENT
S
85. COMPONENT
S
CFM-15. The “Close Focus” scanning module is
used for close proximity, low level leak detection in
pressure and vacuum systems
UWC-15. The UWC-15, Ultrasonic Waveform
Concentrator, substantially increases the detection
distance. The UWC-15 is great for corona, tracking and
arc detection at safe distances.
86. COMPONENTS
TFSM. Telescoping Flexible Scanning Module.
A flexible scanning probe that is bent to
accommodate odd scanning angles. The telescoping
action helps scan hard to reach areas.
TFCM: Telescoping Stethoscope (Contact) Module. A
contact probe for structure borne inspection that can be
extended for hard to reach areas.
87. SET UP MODE 15000
Before using the instrument, become familiar with the various features and modes of operation. The user can
customize the instrument to meet plant specific inspection demands. This is accomplished in the SETUP Mode.
• Turn the instrument on.
• Locate the Setup icon on the Home Screen.
• Touch the Icon to enter the Setup mode.
NOTE: To select or change a setting; touch the selection box or circle on the screen. In some instances, it will be necessary to use
the UP/DOWN arrows on the right side of the screen to display choices.
NOTE: When changing preferences or settings, touch the “OK” icon to save the changes. Touch “Exit” to exit without saving
changes.
To enter the set up mode:
FEATURES
88. Inspector ID: There are three empty fields that can be used to identify the inspector.
Bluetooth: There are two options; “Enable” or “Disable”. This option allows for connection of the audio feed to be
connected to a Bluetooth headphone or earbuds. If this is enabled, a Bluetooth icon will appear in the Setup
screen.
Module type: This field allows the inspector to choose the module to be used in the inspection. (Ex: SCM, LRM
etc.)
NOTE: Changing module type in this section, does NOT change the frequency settings.
Disp (Display) Response: There are three options, the inspector can control the speed at which the bar graph
moves in relation to the meter responds to reflect a Db level. There are three choices: Slow, Medium, Fast. The
instrument defaults to Slow.
PREFRENCE
S
SET UP MODE
15000
89. PREFRENCE
S
SET UP MODE
15000
Alarm Enable: There are two options: “Enable” and “Disable”. Enabling this feature will have the instrument alert
the user if the monitored asset has moved into an alarm state. This will present itself my colouring the dB reading
red.
Alarm Rec (Record) Time: There are four options: The selection will include a time value of from 5 seconds up to
30 seconds. The user may also select MANUAL. When MANUAL is selected, press the REC (recording) box in the
Spectral Screen. To stop recording, Press STOP.
Headphone Vol (Volume): There may be situations in which the sound level in the headphones is uncomfortably
high and the sensitivity level must remain in a high level. To make this comfortable for the user, the volume of the
headphones can be
adjusted for 100% of volume to as low as 0% of volume.
Turn Off Time: The Turn-off time can be set to 5, 10 or 15 minutes. Or it can be disabled. In disable, when the
instrument is turned on, it will stay on until either it is turned off, set in suspend or the battery charge is depleted.
90. To adjust
sensitivity and
volume:
SET UP MODE
9000
Look at the meter. If the instrument is within range, the dB decibel indicator must blink. The kHz ( frequency ),indicator must be
steady and not blink.
If the frequency indicator is blinking, click in the sensitivity control dial until the frequency indicator is steady and the decibel
indicator blinks.. This indicates that you are now able to adjust the sensitivity.
Once in the Sensitivity mode, turn the Sensitivity control dial clockwise to increase the sensitivity and counter clockwise to
decrease the sensitivity.
The Sensitivity control dial increases/decreases the sensitivity of the instrument simultaneously with the sound level in the
headphones NOTE: the instrument needs to be in range for accurate testing.
If the sensitivity is too low, a blinking arrow pointing to the right will appear and there will be no numeric decibel visible in the
display panel. If this occurs, increase the sensitivity until the arrow disappears (in low level sound environments the arrow will
blink continuously and It will not be possible to achieve a dB indication until a higher intensity level is sensed).
If the sensitivity is too high, a blinking arrow pointing to the left will appear and there will be no numeric decibel visible on the
display panel. Reduce the sensitivity until the arrow disappears and the numeric decibel value is shown.
NOTE: The blinking arrow indicates the direction in which the Sensitivity Control Dial is to be turned.
The Sensitivity Control Dial controls the bar graph display.
Each click of the sensitivity dial changes the sensitivity / volume by 1 dB
91. Adjust frequency and
store a reading:
SET UP MODE
9000
Look at the meter. The kHz indicator must blink to be able to tune the frequency. If it is not blinking, “Click” in the Sensitivity
control dial one time and the kHz indicator in the display panel will blink
When the kHz indicator blinks, change the frequency by rotating the Sensitivity dial up (clockwise) or down (counter
clockwise).
Yellow store button To store a reading:
“click” / press the yellow Store Button. This puts the instrument in the data storage mode. In the data storage mode the
display panel changes.
The Storage Location is shown in the upper left corner. There are 400 Storage Locations numbered 001 to 400. If the Storage
Location has no data in it, the display will show: “NOT USED”.
If there has been information stored in the selected location, the upper section of the display will indicate that information.
The text field (if previously selected), Time, Date, Decibel, Frequency and Operation Mode “R”, “S”, “P” (RO, SO, or PO with
offset Value in the Offset Mode) will blink and alternate (scroll). The text field, if previously selected in the Set Up Mode, may
be used to record notes or codes.
The lower left corner of the display indicates the current decibel level selected for storage.
The lower right of the display indicates the current frequency selected for storage.
92. SET UP MODE
9000
1. Make sure the Ultra-probe is off.
2. Press (click) both the Yellow Store button and the Sensitivity dial at the same time, then squeeze and hold the trigger.
3. When in the first Menu Selection : “Data Transfer” (Menu 01), you may move to any of the other Menu Selections by
spinning the Sensitivity Control up or down (clockwise or counter clockwise).
4. Spin to “Set Time and Date” (Menu 02 blinks) and click in (EXIT Blinks), .
5. Spin to desired month or day or year and Click (selected number will blink rapidly). Spin to select a new value. Click to set.
6. Spin to TIME setting and click on either Hour or Minute (the displayed number will blink rapidly).
7. Once an hour or minute has been selected, spin to select a new value. 10.Click to set.
8. When through, Spin the Sensitivity Control until EXIT flashes.
9. Click the Sensitivity Control again and return to the Set Up Mode.
10. Spin to Exit to PGM (Exit to Program) Menu 10 blinks. Click to enter Operation Mode.
Data transfer –
Time & Date:
93. P-F CURVE AND ITS
IMPACT
The P-F curve has become an essential component to any reliability centred maintenance program, and being able to understand it can help
extend the lifespan of your machines by more than you might think.
RELIABILITY CENTERED MAINTENANCE
94. P-F CURVE AND ITS IMPACT
Reliability
Domain
Functional Failure
+
Collateral Damage F
Predictive
Domain
Corrective
Domain
P2 P3
P5
P6
P4
P1
P
Point were
Failure Begins
Vibration Changes
Wear in Oil Analysis
Audible Sounds
Heat by
Contact
Thermography
Ultrasonic Changes
RELIABILITY CENTERED MAINTENANCE
96. TURN-KEY SUCCESSFUL ULTRASOUND
PROGRAM
YOU NEED
ULTRAPROBE
3000
ULTRAPROBE
9000
ULTRAPROBE
15,000
ULTRAPROBE
10,000
GREASE CADDY
401
The right
ONGOING
SUPPORT
The right
TRAINING
to ensure good
implementation
The right
INSTRUMENT
for the job
99. The Historical Approach allows for:
• Trending
• Baselines & Alarms
• Reporting & Documentation
• Knowledge of asset health
• Aids in RCA events
Historical Approach
100. Action Levels for Alarms
• 8 dB Lubrication
• 16 dB Damage - Visual Faults
• 35+ dB - Severe Failure
(Above Baseline levels)
Lack of
Lubrication
Microscopic
Damage
Damage
(visual)
Severe
Failure
101. Slow Speed Bearing Case Study
Source: Ultrasound World XI 2015 Ron Tangen
Bearing reliability:
• Optimizing Bearing Life
• Correct Bearing
• Correct Operation
• Correct Maintenance
• Reducing Catastrophic Failure
• Correct Pdm Technology(s)
• Correct Frequency
102. Slow Speed Bearing Case Study
Source: Ultrasound World XI 2015 Ron Tangen
Analyzing the data
(Time Series Spectrum)
103. Slow Speed Bearing Case Study
Source: Ultrasound World XI 2015 Ron Tangen
Visual Inspection
104. Slow Speed Bearing Case Study
Source: Ultrasound World XI 2015 Ron Tangen
New bearing Time Wave Form
105. Case Study – Slow Speed Rollers in coarse environment
110. Case Study – Oven Motor Drives (Slow)
Alarm Levels decreased over time to
investigate levels of damage. This
presented at 18dB above baseline.
111. Case Study – Oven Motor Drives (Slow)
Results: 7-10rpm (6 Months old)
Damage to outer race
Cage Damaged
One rolling element turned by 90 degrees (Noticeable on Time series)
116. 116
Experience gained
Acoustic impedance of a magnet vs. a quick
disconnect coupler
Acceptance testing of motors and newly
installed drives.
Fault findings using ultrasound.
117. 117
Equipment :
GFF Filter NDE Bearing
• Rotational Speed Rotation speed 0.016 Hz
(0.96 RPM)
• Bearing type NCF 18/800V
• Lubrication Engen Resista Sulfonate Grease
• Load zone of bearing is on the top
118. 118
Quick disconnect coupler
To mount the ultrasound sensor with the quick disconnect coupler:
Press the two half's of the coupling together (2)
To connect turn the female half of the coupling clock wise. (3)
To disconnect turn the female half of the coupling anti clock wise to
disconnect
119. 119
Quick disconnect coupler installation
Due to very low ultrasound signals from a magnetic coupler a
decision was made to install “quick disconnect” couplers on
the filter bearings.
To accommodate the installation a 6mm hole was drilled
and tapped 5mm into the housing.
A 6 mm stud was then used to screw the quick disconnect
coupler half onto the housing.
The other half of the “quick disconnect “coupler was
screwed onto the ultrasound sensor.
120. 120
Quick disconnect results (Static trend)
Two ultrasound measurements
where taken one with a magnet
and the other with a quick
disconnect coupler.
See above trend indicating that the
quick disconnect coupler gives
much better response than the
magnet.
121. 121
Quick disconnect results (Dynamic)
Above measurements
was taken on the same
bearing 1 min apart with
a magnet and a quick
disconnect coupler
respectively.
With the quick
disconnect coupler some
bearing noise can be
seen on the time signal
and heard on the
recorded sound file but
with the magnet the
response was very low
123. 123
Acceptance test of motor at supplier
• Electrical noise (50Hz) was picked up
on the overhauled motor
• An MCA test was recommended and an
uneven air gap was confirmed.
125. 125
Acceptance test of motor at supplier
• Motor DE bearing noise increased from 2.3 to 8.8 dB𝜇V RMS after running 15 min.
• The bearing was greased 2 pumps of grease and the value dropped to 3.9 dB𝜇V RMS
• It was recommended to approach the bearing supplier for further investigation.
• The motor bearing was replaced.
• Follow up readings indicated that the bearing ran at a much lower value and stabilised at 0.3dB
𝜇V RMS.
126. 126
Acceptance test after new motor installation
After new motor installation ultrasound readings taken on the bearings revealed that the new motor
is in order but that the pump DE bearing had some bearing noise. (Click on the blocks to listen to the
sound files.)
127. 127
Acceptance test after new compressor installation
After new compressor installation the
ultrasound measurement on the NDE bearing
was 46.4 dB𝜇V RMS and the temperature
measured 83.6 deg C
It was recommended to change the grease from
EP 42 to Polyrex EM. The temperature decreased
to 64.8 deg C and the ultrasound decreased to
37.7 dB𝜇V RMS
130. 130
Motor was inspected at
different speeds.
• Ultrasound inspections revealed no bearing noise on the motor or the pump.
• Noise related to slip frequency could only be heard at the center of the motor at speed 5 and 6.
• Vibration data did not give any indication for concern.
131. 131
Motor was inspected
uncoupled
• Motor was uncoupled and data was taken again at speed 5 and 6.
• The noise related to slip frequency could not be heard uncoupled and the ammeter
readings was stable.
132. 132
Conclusion
• Ultrasound was the only way
to detect and measure the
deviation
• An arrangement has been
confirmed with a MCA
company to spend a day for
a survey.
Notas do Editor
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