Direct contact ultrasonic testing is a very valuable tool to measure noise output in decibels to determine bearing performance and establish history for future reference. Airborne non-contact ultrasonic testing can be used in multiple areas such as high voltage equipment to detect arcing, tracking and corona discharge. It is also very useful for leak detection in valves, vacuum systems, steam traps, vessels, heat exchangers, gaskets and seals as well as duct work and compressed air systems.
Ultrasonic testing is widely used across manufacturing, energy, and facility maintenance settings to ensure asset reliability and reduce operational risk through early fault detection.
A simple program of leak inspection and repair can go a long way towards reducing excessive energy cost. Here is an example of the cost associated with air leaks: If you are operating your air system at 100 PSIG at $0.22/MCF for 8760 hours per year, a ¼” leak is costing you approximately $11,904.00 per year. How many of these do you have?
What is an ultrasonic survey?
An ultrasonic survey uses high-frequency sound detection to identify hidden equipment problems. It can detect issues like bearing wear, leaks, arcing, tracking, and corona discharge in electrical systems problems that are often invisible until failure occurs.
What is the difference between direct contact and airborne ultrasonic testing?
- Direct contact ultrasonic testing measures noise output in decibels to evaluate bearing performance and create a performance history for trend analysis.
- Airborne ultrasonic testing detects leaks, arcing, and electrical discharge without physical contact, making it ideal for high-voltage equipment, steam traps, vacuum systems, and compressed air lines.
What types of problems can ultrasonic surveys find?
Ultrasonic surveys are effective at identifying:
- Bearing performance issues
- Air, steam, and vacuum leaks
- Transformer and electrical discharge problems
- Faulty steam traps, gaskets, seals, and ductwork leaks
- Compressed air system inefficiencies
How can ultrasonic surveys save money?
Leaks and inefficiencies can add up to major costs. For example, operating an air system at 100 PSIG with just a ¼” leak can cost approximately $11,904 per year in wasted energy. Identifying and repairing leaks through ultrasonic surveys prevents unnecessary profit loss and improves efficiency.
Where are ultrasonic surveys typically used?
They are widely used in manufacturing, energy, marine, and facility maintenance to improve reliability, reduce downtime, and prevent costly failures before they happen.
Do I need to shut down equipment for an ultrasonic survey?
No. Ultrasonic testing is non-invasive and can be performed without shutting down operations, making it safe and efficient for production environments.
Can Reliability Solutions inspect an entire facility?
Yes. We can perform ultrasonic inspections on individual pieces of equipment or design a facility-wide program that includes routine surveys, detailed reporting, and follow-up recommendations.
How do I get started with an ultrasonic survey?
Contact our team at [email protected] or call (251) 490-2999 to schedule an ultrasonic inspection and start reducing waste, improving safety, and saving profit dollars.
HOW WE DO IT
Reliability Solutions Maintenance has the capability to perform inspections on one piece of equipment or set up inspections for an entire facility. We employ both direct contact and airborne ultrasonic testing to test for air leaks and other. Our analysts will perform this ultrasonic survey and compile a detailed report of problem areas.