Title of Session

Energy Conservation and Equipment Reliability with Ultrasound Technology

Summary of Session

Airborne and structure-borne ultrasound technology has certainly become a major player in condition monitoring. Once considered just a leak detector, more maintenance and reliability professionals are realizing the benefits associated with using ultrasound for reducing energy waste and improving asset availability in plants. They expand the concept of” Condition Monitoring” to include much more than basic mechanical fault inspections. Since these instruments detect friction, ionization and turbulence, their inspection capabilities range from trending bearing condition to determining lack of lubrication, locating compressed air leaks and detecting arcing, tracking and corona emissions in both open and enclosed electric equipment.

Energy Conservation using Ultrasound Technology:

High energy prices and global competition dictate a need to reduce energy waste and improve system efficiencies whenever possible. Compressed air, gas & Steam aside from being one of the costliest utilities in plants, is an essential component to product quality in many processing industries. A major contributor to waste and inefficiency is leaks both to atmosphere and through valves and steam traps. Ultrasound technology is used by maintenance and reliability professionals around the world to identify Airborne leaks & also in steam traps and valves inspection.

Electrical Inspection:

Airborne ultrasound has become a necessity for inspecting energized electrical equipment. The primary driver of this application is safety. In most cases, airborne ultrasound inspection can be done without opening energized electrical cabinets that helps reduce the risk the inspector faces from potential exposure to arc flash hazards. Ultrasound can be used to listen for electrical abnormal conditions such as corona, tracking, and arcing. Each anomaly has a distinct sound, and can easily be identified and confirmed using ultrasound spectral imaging.

Ultrasound technology for Bearing Monitoring & Improve Lubrication Practices:

Ultrasonic inspection and monitoring of bearings is by far the most reliable method for detecting incipient bearing failure and conditions such as lack of lubrication. The ultrasonic warning appears prior to a rise in temperature or an increase in low frequency vibration levels. Ultrasonic inspection of bearings is useful in recognizing the beginning of fatigue failure, Brinelling of bearing surfaces, Flooding of or lack of lubricant.
As the most common cause of bearing failure, lubrication is serious business. For many years, this “serious business” has been conducted in a way that makes perfect sense on the surface but in fact borders on being haphazard. Relying on time-based, periodic lubrication assumes bearings need to be greased at defined time periods will lead to the risk of under and over lubrication. By using ultrasound technology along with normal practices, you can combine standard time-based maintenance with condition-based predictive maintenance, gaining in the process both a clearer picture of what’s really going on in your machines to improved availability and reliability.

Practical problem solving with data involves more than just visualization or applying the latest technologies. Our aim is to deliver a successful model. Let’s dive into some ultrasound best practices extracted from real world case studies that illustrate how come up with creative solutions.

References: Application Guides from UE Systems Inc., USA & Ultrasound Level 1 Training Manual.

Presenter Short Biography

• Airborne/Structure borne Ultrasound ISO Category I and LEVEL I
• Airborne/Structure borne Ultrasound ISO Category II and LEVEL II
• Vibration Analyst ISO Category II and ASNT Level II – Reliability Improvement and Condition Monitoring

Education & Expertise:

• Bachelor’s degree, Mechanical Engineering.
• More than 8 years’ Experience in the field of Condition Monitoring and Reliability.
• Conducted more than 250 Ultrasound Technology case studies, training courses and workshops in different plants & Industries all over the Middle East Region during the last 4 years.