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Ultrasonic Monitoring (A New Method For Condition Monitoring)

Ultrasonic monitoring uses ultrasound technology to detect faults in machines and predict failures. It can detect issues in bearings, lubrication levels, and other mechanical components. Ultrasonic monitoring provides early warnings, is accurate at locating problems, and can be used in loud environments. It offers cost savings over other maintenance methods with typical returns on investment of 15:1. Various ultrasonic techniques like backscatter analysis and phased array testing are used to inspect materials and components without damaging them.

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Ankur Kumar
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126 views4 pages

Ultrasonic Monitoring (A New Method For Condition Monitoring)

Ultrasonic monitoring uses ultrasound technology to detect faults in machines and predict failures. It can detect issues in bearings, lubrication levels, and other mechanical components. Ultrasonic monitoring provides early warnings, is accurate at locating problems, and can be used in loud environments. It offers cost savings over other maintenance methods with typical returns on investment of 15:1. Various ultrasonic techniques like backscatter analysis and phased array testing are used to inspect materials and components without damaging them.

Uploaded by

Ankur Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Ultrasonic Monitoring (A New Method for

Condition Monitoring)

INTRODUCITON:-
Ultrasound inspection offers a unique position for condition
monitoring as both a "stand-alone" inspection technology and as an effective screening tool that
can speed up the inspection process and help inspectors determine effective follow-up actions
for mechanical, electrical and leak applications. A new technique called ultrasonic condition
monitoring is now available which can detect even incipient faults in bearings as well as
adequacy of lubricant. IRD measurements are generally not useful for very slow speeds, but
ultrasonic detectors can be used even in slow-speed machines such as APH guide / support
bearings, etc. This technology can be considered an integrating technology since it can be used
with infrared and vibration inspections as well as stand alone to perform a multiplicity of
inspection activities. Instruments based on this technology can monitor a wide range of plant
operations and yet are simple enough to be used with minimal training for basic, effective
inspection routines.
Many failures and repairs that commonly occur in the industrial setting can be prevented with
ultrasonic technology, a highly effective non-destructive, predictive maintenance method.
Ultrasonic leak detection is recommended by entities such as the U.S. Department of Energy as
the best method for detecting the location of leaks in order to minimize energy waste and
improve plant efficiency. Ultrasonic sensors designed with the right technology and software can
be used for condition monitoring and predictive maintenance. This will minimize production
downtime, improve quality control and safety, and decrease man-hours by improving
troubleshooting capabilities.
Consider the following summary from a third-party evaluation team for the integration of
ultrasonic technology in a single organization with more than 500 sites:
 More than 100 applications were identified in use for various equipment at each site,
such as boilers, heat exchangers, compressors, motors, pumps, valves and steam traps.
 The total savings for the organization would be approximately $3.7 million annually.
 The return on investment for the integration of ultrasound with this cost avoidance would
be approximately 15:1.
The basic advantages of ultrasound and ultrasonic instruments are:

1. They are directional and can be easily located.


2. They provide earliest warning of impending mechanical failure.
3. Many problems are only detectable in the ultrasonic range.
4. Audible noise is ignored, increasing the selectivity of the ability to pinpoint. Therefore,
they are more accurate at pinpointing problems.
5. They can be used to locate leaks and potential electric failure conditions.
6. Instruments can be used in loud, noisy environments.
Ultrasonic technology is an excellent option, especially for organizations with lower budgets.
Ultrasonic detectors are capable of accurately interpreting the sounds created by under-
lubrication, over-lubrication and early signs of wear. The right ultrasonic technology is a fast and
effective means of determining such conditions in moving, mechanical components such as
bearings, gearboxes, motors, compressors, etc.
Ultrasound is produced by friction, impact, turbulence and electrical discharge. Friction and
impact are the by-products of mechanical equipment. For example, a roller bearing will produce
friction as the shaft and balls roll around the center. If there is too much friction, however,
problems begin to occur on the equipment due to imbalance, or the bearing might seize, thereby
shutting down equipment altogether.

Airborne Ultrasonics:-
Ultrasonics to hear what you cannot see. Ultrasound detectors sense high-
frequency signals and convert them into corresponding audible sounds while maintaining their
original characteristics and qualities. Ultrasounds are mechanical sound waves with frequencies
above those audible to the human ear (20 kHz). The tools to Airborne Ultrasound, thanks to a
piezoelectric sensor, turn the mechanical waves in electric waves. the wave frequency is
lowered and the operator made audible through headphones or a recorder.

The analysis by ultrasound is a noninvasive technique that can be applied in various field

 Leak Detection of a fluid


 Inspection machines and ball bearings
 Electrical inspections

Ultrasonic backscatter technique:-


Advanced Ultrasonic Backscatter Technique (AUBT) involves a collection of
ultrasonic techniques used for detecting High Temperature Hydrogen Attack (HTHA) in
process equipment. The technique uses conventional UT probes and a digital oscilloscope to
provide both an A-Scan display and frequency analysis.
The backscatter technique is applicable to materials of any geometry with or without
cladding. It is primarily used to determine damage progression through the wall. Spectrum
analysis helps determine the degree of HTHA, is sensitive to fissures and is independent of
the measurement system. The velocity ratio measurement differentiates between fissures and
other internal defects. It is not affected by material geometry, back wall surface condition, or
the measuring system.

Backwall echo attenuation:-


Backwall Echo Attenuation is a flaw detection technique applied in ultrasonics
to identify or confirm the presence of defects by observing a reduction in the amplitude of the
echo reflected from the backwall. A typical example is in the inspection of forgings using a 0°
probe. The amplitude of the echo from the backwall will remain approximately constant in
clean material. The presence of defects between the probe and the backwall reduce the
amount of sound reaching the backwall and, consequently, reduce the size of the backwall
echo.
Planar laminar defects are likely to produce direct pulse-echo responses, which can be
detected as signals observed in the range between the probe and the backwall echo. The
BEA provides confirmation of the presence of such defects. Clusters of small defects, such as
porosity, may not produce a reflected signal of sufficiently high amplitude to be detected by
direct pulse-echo. However, depending on the number and density, they may scatter the
sound sufficiently to be detected by BEA.

Ultrasonic thickness and gauging:-


Ultrasonic thickness gaging is a widely used nondestructive test technique for
measuring the thickness of a material from one side. It is fast, reliable, and versatile, and
unlike a micrometer or caliper it requires access to only one side of the test piece. The first
commercial ultrasonic gages, using principles derived from sonar, were introduced in the late
1940s. Small, portable instruments optimized for a wide variety of test applications became
common in the 1970s. Later advances in microprocessor technology led to new levels of
performance in today's sophisticated, easy-to-use miniature instruments.
Ultrasonic thickness gages can be set up for metals, plastics, composites, fiberglass,
ceramics, and glass. On-line or in-process measurement of extruded plastics and rolled metal
is often possible, as is measurement of individual layers or coatings in multilayer fabrications.
Liquid levels and biological samples can also be measured.
The gage is programmed with the speed of sound in the test material, from which it can then
calculate thickness using the simple mathematical relationship
T = (V) x (t/2)
where
T = the thickness of the part
V = the velocity of sound in the test material
t = the measured round-trip transit time

Phased array testing:-


Phased array ultrasonic testing (PAUT) probes are composed of several
piezoelectric crystals that can transmit/receive independently at different times. To focus the
ultrasonic beam, time delays are applied to the elements to create constructive interference of
the wavefronts, allowing the energy to be focused at any depth in the test specimen
undergoing inspection.
Phased arrays are used for a wide variety of inspection and measurement applications,
and they can be used for any job done by conventional ultrasonics. For example, phased
arrays are used to detect and image defects including cracks, voids, and pits caused by
corrosion. They are used to measure material and coating thickness and to detect changes in
material properties. Another common application is to assess the quality of welds and rivets.
Phased arrays are also used to inspect joints and interfaces, for example, to detect and map
adhesive.

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