Ultra Sound
One of the more useful technologies is airborne ultrasound. Airborne ultrasound instruments provide information two ways: qualitatively, due to the ability to "hear' ultrasounds through a noise isolating headphone, and quantitatively, via incremental readings on a meter.
Some of the most common plant applications are:
Leak Detection:
Leak detection in pressure and vacuum systems
- boilers
- heat exchangers
- condensers
- chillers
- vacuum furnaces
The costs of an Air Leak (Examples)
- In a 75 p.s.i. system with a production cost of $0.14/m cu. Ft., a number of leaks totaling 1/4" will cost $5,734.15 in a year. Double that to 1/2" and the cost of wasted air will be $22,940.25.
- In a 100 p.s.i. system, based on nozzle coefficient of .65, and a production cost of $0.10 per thousand cubic feet, a number of leaks totaling 1/8" will result in the loss of 740,210 cubic feet of air per month, at a cost of $74.01 per month. Triple that to 3/8" and the waste will be 6,671,090 cu. Ft. per month and $667.19.
Electrical Inspection:
There are three basic electrical problems that can be detected:
- Corona: When voltage on an electrical conductor, such as an antenna or high voltage transmission line exceeds threshold value, the air around it begins to ionize to form a blue or purple glow.
- Tracking: Often referred to as "baby arcing", follows the path of damaged insulation.
- Arcing: An arc occurs when electricity flows through space. Lightning is a good example.
Mechanical Inspection:
- Bearing inspection
- Pump cavitations
- Gear train inspections
- Lack of lubrication
- Over lubrication
- Steam trap inspection,
- Valve blow-by,
The costs of a Steam Leak (Examples)
Indiana University-Perdue University Campus at Indianapolis has three to four thousand steam traps. Technicians using the Ultraprobe to monitor steam traps and by-pass valves estimate they are saving $300,000 per year.
All operating equipment and most leakage problems produce a broad range of sound. The high frequency ultrasonic components of these sounds are extremely short wave in nature and tend to be fairly directional.Therefore as subtle changes begin to occur in mechanical equipment, the nature of ultrasound allows these potential warning signals to be detected early before actual failure.
Ultra-Sound Inspections: Uncovering the hidden costs!!