How do I Use Ultrasound to Reduce Energy Consumption (Compressed Air & Steam Traps)?
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What Is Ultrasound Analysis (UA)?
Ultrasound analysis (UA) is a predictive maintenance tool that uses sound to identify potentially failing assets.
How do I incorporate predictive maintenance without sensors?
Almost by definition, predictive maintenance uses sensors, but the core principle of PdM doesn’t necessarily depend on them.
Leak Detection & Repair (LDAR)
Leak detection & repair (LDAR) refers to EPA regulations designed to help reduce volatile organic compounds (VOC) & volatile hazardous air pollutants (VHAP).
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You can use ultrasound technology to reduce energy consumption, especially in compressed air and steam trap applications. Ultrasound condition monitoring will "listen" for leaks and help companies detect and locate them more efficiently and completely. Leaks with a rate above 1×10-3 std. cc/sec will generate a turbulent flow and, therefore, a detectable ultrasound. Ultrasound condition monitoring is effective at finding leaks in many types of gas and fluid systems.
Using ultrasound in compressed air systems
When manufacturing companies use compressed air, they are often using a great deal of electricity. Compressed air is frequently used to run machine tools, HVAC controls, material handling equipment, and painting booths. According to UE Systems, the average plants lose nearly one-third of its compressed air to leaks, and the US Department of Energy reported that more than half of all plants have not attempted to identify or resolve the problem.
To address this significant compressed air leakage issue, you should conduct an audit of your equipment and systems. First, you can establish a short-range inspection program using ultrasound technology to address leaks on a quarterly basis. Some other areas you may want to address include over pressurization, overestimating the level of compressed air needed, outdated pipes and obsolete restrictions. Be sure you have sufficient storage for the receiver and related piping as well as an appropriate, monitored use for compressed air. Instituting a regular preventive maintenance program will help you identify compressed air leaks more quickly.
Using ultrasound in steam traps
When it comes to steam traps, many organizations find that leaks can increase their operating expenses by one-third. This makes testing steam traps a high priority in terms of reducing energy and cutting operating costs.
Many experts estimate that a lack of steam trap testing and repair protocol usually means that half of all steam traps are wasting energy. On the other hand, companies that implement preventive maintenance programs with monthly inspections and immediate resolution find this figure drops to under 3 percent.
Companies may use a combination of infrared technology and ultrasound technology to effectively detect flow leaks. Typical areas that lead to wasted energy and steam traps include oversized traps, withdrawn control valves, high-back pressure, and low steam temperatures. Leaks around fittings, valves, and steam traps are the perfect candidates for ultrasound detection.
What are some ultrasound certifications?
Two levels of certifications are available from SDT Ultrasound Solutions and UE Systems, both providers of ultrasound technology solutions. These certifications are designed for professionals looking to advance in their careers or obtain further education in the area of ultrasound technology.
SDT Certifications
SDT Ultrasound Solutions offers two levels of certification based on 40 years of experience as a partner who has helped many customers monitor the health of their facilities, as well as a shift from a reactive maintenance mentality to a more proactive one.
The courses are designed to help inspectors gain confidence, develop a deeper understanding of ultrasound technology, instill a standard level of expertise, and uphold the role that ultrasound inspection should play in predictive and preventive maintenance programs.
Students will learn ultrasound principles, as they relate to predictive maintenance, the properties of leaks and how to find them, sound-based techniques related to lubrication and mechanical failures, and how to detect electrical faults. The first level focuses on theory and practical experience, while the second covers evolutionary advancements in ultrasound technology and how to conduct expert evaluations.
UE Systems Certifications
A manufacturer of portable ultrasonic instruments, UE Systems offers a two-level certification program for professionals as well.
Level One covers theory, principles, and practices of airborne ultrasound technology. Students will learn about the theory and basic physics of sound, amplitude, velocity, typical applications, integration, and reporting inspection guidelines. In addition, leak detection, amplification and inspection methods using ultrasound technology, as well as electrical, steam trap inspection, and detection procedures will be covered.
Level Two introduces advanced theories of airborne and structure-borne ultrasound. It covers compressed gas leaks, as well as electrical and mechanical systems, including valves, steam traps, lubrication, and bearings. Students will learn advanced inspection logistics, condition monitoring, best practices of data collection, data and sound analysis, and procedure and program implementation.