Energy conservation

and Equipment reliability

using ULTRASOUND TECHNOLOGY

Demo request , please contact :Hà Ngọc Hiếu – 0904 989 904

Mekongtech – Authorized distributor

Today’s Topics

UE Systems Who we are and what we do

Ultrasound technology How the technology works for maintenance

Applications areas Where we use it

Some examples Why companies use it

Ultrasound at YOUR PLANT How it can be implemented

About UE Systems

• Founded in 1973 in Elmsford New York, USA

• 38+ years experience with ULTRASOUND

• We are a global company:Asia UE Systems Asia, based in Hong KongEurope UE Systems Europe, based in the NetherlandsNorth America 11 regional offices in USA, Canada & MexicoSouth America Regional support managers Spanish+ over 200 local distribution partners worldwide!

About UE Systems• UE Systems is world market leader for

Ultrasound instruments

• Continues software development to meet customer demand

• Level I, II & III certified training conducted to ASNT standard

• On-site equipment & software orientation training

• On-site technology implementation training

• 5 year warranty on products

ULTRASOUND TECHNOLOGY

how does it work?

Which Type of Ultrasound?

PULSE ECHO

POWER

AIR & STRUCTURE BORNE

Medical applications

Tickness gauge

Flaw detection in solids

Cleaning

Welding and cutting

AIRBORNE

STRUCTURE BORNESTRUCTURE BORNE

ULTRASOUND

DIVISIONS

Why ultrasound? 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 (Audio Sound) is not directional and penetrates solid materials, making it difficult to locate.

Ultrasound is defined from 20kHz to 100kHzAdvantages are:• 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

Two ways to detect Ultrasound with our instruments:• Airborne medium• Structure borne medium

How does it work?The Ultraprobe 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 theselected frequency!

.

.

PREAMP TRANSDUCER VARIABLE

GAIN AMPLIFIER

HETERODYNE CIRCUIT AUDIO AMPLIFIER

~

DB CONVERTER

PHONES OUTPUT

LINE OUTPUT

DIGITAL I/O

DISPLAY

SENSITIVITY/

STORE BUTTON

GAIN CONTROL FREQUENCY CONTROL

OSCILLATOR 20 - 100 KHz

CPU & DIGITAL CONTROLS

CONVERTER INPUT

MIXER LOW PASS FILTER & AMPLIFIER

FREQUENCY KNOB

APPLICATION AREAS

Where can we use it?

Typical application areas

Leak detection•Pressure or vacuum, any type of gas•Heat exchangers•Tanks and boilers•Window seal inspections

Valve inspection•Valve leak detection•Steam trap inspection

Mechanical inspection•Condition monitoring of bearings•Condition based lubrication•Pumps for cavitations•Conveyor belt systems

Electrical inspectionDischarge testing on:•Switchgears•Power lines & isolators•Transformers•Circuit breakers(Tracking, Arcing, Corona & mechanical looseness)

Speciality solutions for:•Automotive WNWL•Aircraft inspections•Marine hatch testing

LEAK DETECTION

APPLICATION

LEAK DETECTIONGas flow can be divided in:• Laminar flow• Turbulent flowLimitation: Only a turbulent flow will cause sound!

So what can we detect? 0,3 bar with a 0,1mm leak size at 15m distance……(under ideal circumstances)The ultraprobe is a highly sensitive listening device

Works for any type of gas:•Compressed air•Vacuum systems•Specialty gasses Nitrogen, Oxygen, Acetylene, Hydrogen, Propane, Methane, etc..

LEAK DETECTIONConsiderations using Ultrasound for leak detection:-> Pressure difference-> Distance from the leak-> Competing Ultrasound -> Accessibility & isolation materials-> We can only detect turbulent leaks

An alternative method for pressure is the tone generator

LEAK DETECTIONWhy leak detection?-> Economics: leaks cost money-> Environment: CO2 reduction & specialty gasses-> Safety: Flammable gasses

Our digital Ultraprobes can report the cost per leak!1 - find it2 - tag & record3 - report!

VALVE & STEAM TRAP

APPLICATION

VALVE INSPECTIONInspecting valves is as easy as 1-2-3-4Listening 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

A=33 dB B=48 dB D=42 dB

A B C D

C=59 dB

Steam systems, an inefficient but necessary form of energyIt’s expensive to build and operate….

Check steam traps regularly to cut energy cost& optimize efficiency in the production process

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 valvesContinuous flow: Float & Thermostatic valves

STEAM TRAP INSPECTION

For evaluating steam traps we can use: Ultrasound & temperature

+

Analyze the condition and report the yearly losses with ourData management software (DMS) & spectralyser software

+

Example: GOOD BAD (note the airflow variation)

STEAM TRAP INSPECTION

Spot 1 311.0

Spot 2 231.6

*>322.8°F

*<212.1°F

220.0

230.0

240.0

250.0

260.0

270.0

280.0

290.0

300.0

310.0

320.0

REPORTINGRoute 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!

ELECTRICAL

APPLICATION

ELECTRICAL INSPECTION>38.5°C

<22.8°C

25.0

30.0

35.0

An electrical emission will cause the air to vibrate and cause a soundWhen 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:1- Ultrasound from a distance2- Open doors and 2nd scan3- IR on resistance problems

Find more and be safe!

The Ultraprobe will find early stages of:-Corona-Arcing-Tracking-Mechanical looseness

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

ELECTRICAL INSPECTION

There are situations IR is difficult to use for getting a visual lineFor Ultrasound all we need is an open air connection

Example enclosed transformer:

ELECTRICAL INSPECTION

Early stages of tracking, evolving into arcing….into catastrophic failure!

$

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

ELECTRICAL INSPECTION

BEARING & LUBRICATION

APPLICATION

PRINCIPLE OVERVIEW

ProactiveDomain

F

PredictiveDomain

FaultDomain

P2P3

P5

P6

P4P1P

Start Failure

Vibration

Oil analysis

Audible noise

Contact heat

Infrared

Structure Borne Ultrasound

EARLY WARNING OF BEARING FAILURE

LUBRICATION DOMAIN

OPTIMIZING BEARING LIFE!

(DMS & GREASE CADDY)

Max time for planning

BEARING MONITORINGUsing ultrasound technology for trending bearing condition:

-> Indicating early warning of failure-> Identifying lubrication condition -> Avoiding over lubrication

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 alarmBaseline +12dB = microscopic damage Baseline +16dB = visual damage

88 dB 70 dB

BEARING MONITORING3 types of testing are used:

1 -> Comparison method - Listening, noting dB and compare2 -> Historical trending - using DMS software to program your test points3 -> Fault frequency analyses - Spectralyser software for identifying faults

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.

Spectralyser: Analyses tool with reporting functionality to document and communicate reports

What about lubrication?.... Seems simple…..

The dilemma: HOW MUCH & WHEN?

LUBRICATION

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 AGPubl.- No. WL 81 115/4 SB “Lubricación de Rodamientos” Pág. 35

A correct period between lubrications depends on many factors. Recommendations can be based only on statistic rules .SKF , México Web page bajo palabra Relubricación

Even if traditional rules and practices can be sometimes correct, it is evident that sometimes it doesn't work.Noria Corporation, Lube-Tips Newsletter

Condition based lubrication -> avoiding over lubrication!The right amount of grease based on the condition of that moment

1- Getting your lubrication report from DMS, go out and perform lubrication2- The Grease Caddy 201 will help you to perform condition based lubrication

What does a bearing sound like?Good BadLubricatedAfter 5 min.

LUBRICATION

CAVITATION EFFECT IN A PUMP DRASTICALLY AFFECTS LIFESPAN!

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 airbubbles to damage the propeller blades to destruction 2 methods of inspection:1- Cancel out or minimize the cavition effect by listening for the air bubbles 2- Trend the dB values in DMS software to periodically monitor the condition

Here is a sound example of cavitation in a waterpump

PUMP INSPECTION

Get the most out of technologies available to you!

Many multinational companies have found Ultrasound to redefine the bearing monitoring strategy:

Define lubrication standards and filter the need for detailed analyses:1-> Identifying lubrication issues2-> Proper lubrication => extending bearing life!3-> Identifying at the same time first failure indication4-> Filtering need for root cause analysesAn Ultraprobe helps you to collect information fast and accurate

Time = Money

TECHNOLOGY STRATEGY

NONE

Vibration

Ultrasound+

Lubrication

Vibration

CONCLUSION

on

ULTRASOUND TECHNOLOGY

CONCLUSION-> Easy to use and quick to learn!-> 1 instrument for many applications-> Training and support available to you at all times-> Regular updates on enhancing software reporting-> We are a supplier of solutions: no service contracts needed-> DMS & Spectralyser software update & license free!-> 5 year factory warranty

The Ultraprobe series will produce results and be highly cost effective for you!Ultraprobe 15,000

Ultraprobe 10,000

Ultraprobe 9000

Grease Caddy 201

WWW.UESYSTEMS.COM

Ultraprobe 3000