Detecting the undetectable: Ultrasound solutions for industrial asset health monitoring
Inaudible indicators of compromised asset health provide invaluable insights into maintenance needs. Ultrasound technologies increase site safety, productivity, and cost savings by detecting conditions such as compressed air and gas leaks, vacuum leaks, fugitive emissions, partial discharge, bearing faults, and lubrication and flow problems. The latest ultrasonic instruments and solutions improve upon their predecessors with earlier and more precise condition monitoring results.
Acoustic cameras
Locating and analyzing leaks and partial discharge are the focus of the new H-series high-performance acoustic camera from FOTRIC. It is designed with heightened sensitivity enabled by up to 162 digital MEMS microphones and provides built-in analysis for on-site decision making. Acoustic Focus Mode filters out background noise and interference to better diagnose subtle and localized issues while Leak Evaluation Mode quantifies the financial impact of leaks to improve maintenance prioritization.
The H-series camera “is compact, yet the sensitivity is absolutely remarkable,” says Fernando Rico, regional manager at FOTRIC. “What really sets it apart are the advanced features like partial discharge diagnosis and leak cost evaluation, which typically come at a steep price with other brands.”
SonaVu+ is the newest model in SDT Ultrasound Solutions’ SonaVu line of acoustic imaging cameras. It includes improvements to performance, quality, UI design, and reporting. SonaVu uses 112 digital MEMS sensors and an optical camera to detect and visualize sources of airborne ultrasound signals produced by turbulence.
“One of my key focuses is finding quick and easy wins for reliability teams. The SonaVu+ speeds up finding leaks with its ability to scan large areas for the specific ultrasonic turbulence frequency we are targeting, while filtering out background noise. Improvements to its multipoint detection allow us to accurately sweep over larger zones, without worrying about competing signals,” explains Robert Schell, reliability program manager at SDT Ultrasound Solutions.
The Si2-series of acoustic cameras from FLIR, offered in partnership with UE Systems, is built to accurately detect and measure the most sensitive equipment issues, even in the noisiest areas. Improved picture quality and battery life and new on-screen gas leak quantification are among the advancements.
Aside from air, gas, and vacuum leak detection, “using the camera’s 'mechanical mode' feature, the Si2-series easily distinguishes potentially faulty bearings at a distance and measures the sound pressure level (SPL), sound crest, and kurtosis,” notes Rob Milner, global business development director at Teledyne FLIR. “The Si2’s new Mechanical Sound Indicator analyzes and confirms the slightest sounds from mechanical faults, empowering plant professionals to evaluate conditions, identify problems, and implement solutions rapidly.”
The FLIR and UE Systems partnership combines their respective strengths for the benefit of reliability maintenance programs and energy conservation across the world, starting with the Si2-series of acoustic imaging cameras, according to UE Systems VP Blair Fraser.
The SONASCREEN 2 acoustic camera from SONOTEC is distinguished by its high number of microphones and fast acoustic framerate. “Its 176 microphones allow for finding even smaller leaks than before, while the 100 frames-per-second acoustic refresh rate makes it easy to quickly scan areas for leaks and partial discharges. It is also the first device with a built-in GPS and has a laser range finder and thermal camera included,” says Brian Kavanagh, product manager at SONOTEC US.
With its sealed, encapsulated microphones, SONASCREEN 2 is IP54 rated for protection against water and dust, making it suitable for industrial environments.
Ultrasound solutions
To better detect bearing and lubrication faults, the new UDK-CM Ultrasound Condition Monitoring Kit from Wilcoxon Sensing Technologies includes an ultrasound receiver, solid probe set, headset, one-year subscription to a cloud-based condition monitoring app, and an industrial carrying case. It is differentiated by its ease of use and expansion capability, according to Senior Applications Engineer Peter Eitnier.
“With no complex tuning requirements, the receiver is a simple point-and-shoot device that will immediately provide feedback on nearby sources of ultrasound, with the twist of a knob enabling easy gain adjustment for low- or high-amplitude signals,” observes Eitnier. The kit can also be combined with additional accessories to detect other sources of ultrasound, such as gas or compressor leaks, electrical hazards, or to perform valve and steam trap inspections.
The new 39DL PLUS ultrasonic thickness gauge from Evident saves time in precision and corrosion thickness inspections. With its 60 Hz update rate, it delivers the scanning speed of a flaw detector in a more affordable instrument. The gauge’s high signal quality, stable waveforms, optimized algorithms, and rugged design enable accurate, reproduceable measurements in industrial environments.
"By integrating Wi-Fi and Bluetooth capabilities directly into the handheld gauge, we're empowering inspectors to work smarter and faster than ever before," says Steve LaBreck, director of global product management for NDT portable ultrasonics at Evident.
