SDT Ultrasound Solutions What Industry Listens To Ultrasound

SDT Ultrasound Solutions What Industry Listens To Ultrasound, not just your daddy leak detector anymore. Presented by Paul Klimuc

Defect Detection 101 2 The benefit of ultrasonic is that the energies produced are detectable much earlier in the failure curve.

P-F Interval Condition P F Time

P-F Interval P Condition Vibration Infrared F Time

Static Condition Indicators • • 5 RMS Max RMS Peak Crest Factor

What is RMS? • Acronym for Root Mean Square • Reflects the amount of energy present • Physical unit (we use): d. BµV 6

7

RMS: advantages/disadvantages Positive: • Stable • Repeatable • Suited for trending Negative: • Insensitive to short duration events • So not suited to early stage impact detection 8

Max RMS: advantages/disadvantages Positive: • Stable and repeatable • Comparison with RMS: steady or varying signal • Suited for trending Negative: • Insensitive to early stage impact detection 9

What is Peak? • The highest value detected in the time signal • Physical unit used: d. BµV • The Sampling Rate is 8 K. 10

Peak : advantages/disadvantages Positive: • Very sensitive to any change • Suited for impact detection Negative: • Not going to be repeatable, by the very nature of infrequent transients • Trends difficult to interpret 11

What is Crest Factor? • • 12 The Peak-to-RMS ratio Crest Factor = Peak / RMS No physical unit – it is a numeric ratio Indicates how Peaky the signal is or how many impacts/RMS

What is Crest Factor? • RMS value is 20 d. BµV • Peak is 40 d. BµV • Crest Factor could be expressed in d. B’s – 40 -20=20 d. B • Crest Factor is expressed in linear numbers – Crest Factor is 10 • 40 d. BµV = 100µV, 20 d. BµV = 10µV – Crest Factor is 100/10= 10 13

Condition indicators A guide to choosing RMS Max RMS Peak Leak Steam traps Lubrication Mechanical Electrical 14 Crest Factor

Condition indicators A comparison guide RMS Max RMS Peak and Crest Factor 15 Positive Negative Stable Repeatable Trending Insensitive to short duration events Not suited for early stage bearing failure Steady or fluctuating signal (vs. RMS) Not suited for early stage bearing failure Very sensitive to any change Suited for bearing failure Not stable and repeatable Not suited for trending

Benefits Combining the 4 condition indicators: • Better view of machinery health or performance (steam traps, mechanical) • Better evaluation of the failure severity (lubrication, mechanical, traps) • Better diagnosis capabilities (lubrication vs bearing failure) • Early stage detection (mechanical) 16

Condition indicators and UAS • UAS handles each indicator separately • Select whichever you want for trend display • Alarms are set up individually for each – (3 Absolute, 4 Relative, 2 Safe) x 4 = 36 alarms 17

Condition indicators and UAS Condition indicators: • Simplicity for those who want • Elaborate for those who need 18

Slow Speed Bearings

Rotating Machinery • Slow Speed Condition Monitoring – Difficult with some technologies • Ultrasound does not need 1 minute 20

Singapore Flyer • Ferris Wheel Feng Shui A 21 • Spindle bearing measurements taken one month after rotational direction changed (Feng Shui) • 37 minutes for one rotation. 0004 RPM

Rotating Machinery • Special Applications – Hoist Bearing – Doesn’t operate long enough for some tech. – 14 RPM but for 10 or 20 seconds only – BPFI expected at 2. 88 Hz/173 CPM 22

Time Signal • Time Signal – Impacts can be seen clearly 23

Time Signal • Expand any area of this time signal • Apply a periodic cusor – You get a repetition frequency of 346 cpm – 2 x the inner race defect frequency (173 cpm)

Rotating Machinery • Inner Race Defect Discovered – Spalling across the length of the raceway 25

Bearing failure example Healthy bearing: • RMS = 24. 4 d. BµV, Peak = 43. 1 d. BµV, CF = 8. 6 26

Bearing failure example Defective bearing: • RMS = 47. 7 d. BµV, Peak = 75. 4 d. BµV, CF = 21. 9 27

What’s the problem? • Over lubrication is – A huge killer of bearings – Consumes far too much grease – Consumes far too much time – Reduces reliability 28

Applications Lubrication: • Lubrication is friction • Correctly greased: regular and pleasant signal (low RMS value) • Under or over greased: friction, and so signal is increasing • RMS is the suited indicator, throw in Peak to detect possible early stage damage 29

The horror stories 30

Lubrication example Healthy bearing being lubricated: • Correctly greased: RMS = 51. 2 d. BµV • Under-greased: RMS = 57. 8 d. BµV 31

On-condition lubrication • Bearing needed grease: 32

On-condition lubrication • Bearing already overgreased: 33

On-condition lubrication • Using trending: 34

Using an accelerometer Vibration Motor Current Analysis Oil Analysis 35 Ultrasound Thermal Imaging

Keeping it simple • The 270 has IR temperature measurement – But it is not an IR camera • The 270 has vibration measurement – But it is not a vibration data collector – That’s not the intention 36

Using an accelerometer • Adds one extra tool to the powerful SDT 270 • Means that users can make diagnosis that bit easier – Don’t need to go back to office to change tools – Don’t need to ask somebody else to do it 37

What can I measure? Velocity in ips or mm/s 10 -1, 000 Hz Acceleration in g 10 -10, 000 Hz RMS and Peak calculated Dynamic measurement (Time) of both now possible with the Raw option instead of Ht. • All options controlled inside UAS Sensor Options • Supports 100 m. V/g ONLY • • 38

This should get your attention

Electrical Applications • Use ultrasound to find electrical faults – Arcing – Tracking – Corona – Special areas • Flow • Loose part monitoring

Measurement Cycle • Find it, Fix it, Check it BEFORE CLEANING AFTER CLEANING

42

Valve Inspections 1. Do a comparison method before and after the valve. OR 2. Contact the valve and listen.

Valves and Hydraulics • Find internal leakage and passing valves • Perform inspections without disassembly • Save hours or even days from complicated repairs Ultrasonic Inspection of Hydraulics: 44

Valve Body Inspection • Checking valve for flow – Upstream and downstream – Works for any gas or liquid

Valve Inspections • Identify the difference between a closed and 10% open 60 cm bypass recycle valve – Dynamic measurements captured downstream – Time signals identically scaled Valve closed Valve opened 10%

Steam Trap example Good trap: • Max RMS (43. 3 d. BµV) is higher than RMS (29. 7 d. BµV) Peak (51. 7 d. BµV) Max RMS 47

Trap example Failed closed: • RMS is low (9. 4 d. BµV) • Max RMS (11. 5 d. BµV) is close to RMS Max RMS 48

Trap example Failed open: • RMS is high (39. 5 d. BµV) • Max RMS is close to RMS (41. 9 d. BµV) Max RMS 49

THANKS!