Many factories use timely preventive maintenance to minimize machine failures, scale plant availability and save costs on energy.
Multipurpose ultrasonic testing devices let you perform many of these operations efficiently and promptly.
With ultrasonic devices in effect, you can detect leakages in the air or vacuum systems, inspect bearings, check on how the valves function, and analyze the electrical partial discharges.
In this blog, let’s know everything about Ultrasound testing devices and how Ocean stands out in delivering the best devices to ensure your plant functions remain reliable and smooth.
Read more about:
- Frequent Causes of Piping Vibration and their Repercussions on Piping Systems
- What Is Reliability Centered Maintenance? A Simple Guide
- How to Consider Machine Alignment to Avoid Equipment Failures
What does Ultrasound Testing mean?
Ultrasound testing refers to the process of measuring and recording ultrasound waves.
The waves are said to be ultrasound if their frequencies exceed 20KHz.
Through ultrasound testing, you analyze these waves that propagate along the solid and liquid medium to ultimately determine the inaccuracies due to air/gas leakages and friction from bearings.
Many industries including Aluminium, steel, oil and gas, manufacturing, automotive, aerospace, and power, utilize this testing method to enhance the overall functioning of the plant.
Let’s dig further into the devices used for Ultrasound Testing.
How does this process work?
The testing requires an ultrasound transducer— a device that transforms the ultrasound energy into electrical energy.
Diagnostic equipment aids in the inspection of the machine to ensure the plant works efficiently.
Here are the two types of transducers based on their uses:
- Air-borne transducers:
Airborne inspection is usually performed to identify the air and gas leakages that occur in critical industries.
These leakages not only degrade the plant’s efficiency but also challenge personal protection due to the toxic emissions.
In this type of testing, the transducer doesn’t have to be in contact, and the inspection can occur even at a 15-meter distance with sensors such as parabolic sensors.
Air/gas leakage generally produces ultrasound noise with turbulence in the area of leakage.
The sensor generates adequate noise levels in the diagnostic instruments to let you evaluate the annual cost loss.
The SONOTEC leak calculator can help to make this analysis based on the data the manufacturer provides.
- Structure-borne transducers:
With structure-borne inspection, you can understand the irregularities that bear damages and malfunction in the steam trap in the industries.
The critical rotating machinery should function properly to improve the lifetime efficiency of the machine components.
This testing involves placing the transducer on the surface of the component.
Irregularities present in the roller bearing cause friction between components and the sensors to produce ultrasound noise.
The sensor thus builds a spectrum that remains proportional to the abnormalities in the system.
Significant Features of Ultrasound analysis
The early detection of faults in the bearing and appropriate diagnosis are essential to monitoring the conditions of the machine you use.
With high sensitivity, you can detect even the smallest abnormalities that occur in the machines.
This method is the best and most accurate compared to any other non-destructive method since it assesses the effect of internal defects and analyzes even minor gas/air leakages.
It also predicts the extent of leakages based on the data from the manufacturer.
The testing method is non-hazardous to any other functioning of the plant, and the surrounding workforce, keeping the equipment and materials undisturbed.
The portable and completely automated operations produce immediate results, while you can also deploy corrective measures right after the inspection.
Core Industrial applications of ultrasound examination
Ultrasound analysis involves a non-destructive examination process which is ideal to locate the leaks and defects in the machine without causing any damage to it.
Periodic ultrasound analysis can also be helpful to test the condition of bearing health, manage lubricant, and inspect steam traps and compressor air leakage.
It offers the following industry-specific applications:
1. Lubrication management
Ultrasound lubricates the machine bearings to deploy condition-based maintenance instead of a time-based maintenance process.
2. Keep a track of the bearings & Steam trap condition
The ultrasound keeps track of the health of the bearing and steam trap regularly. This helps to plan maintenance which triggers plant reliability.
3. Air and gas leakage detection
Ultrasound inspects and records the gas or air leakages at every compressed pipeline joint. It also improves the entire plant’s efficiency and offers cost-effectiveness.
Ultrasound Testing Devices & Equipment from Ocean
SONAPHONE Pocket is a compact Ultrasonic testing device you can use to conduct preventive maintenance promptly.
Minimize energy loss and boost operational safety while you use the SONAPHONE series.
The device fits the following applications:
- Condition monitoring
- Leak detection in the air compression systems
- Tightness testing and analysis
- Detection of partial discharge.
This ultrasonic digital testing device combines the software and most advanced sensors to conduct preventive maintenance.
In this current era of Industry 4.0, optimizing processes, enhancing energy efficiency, and improving operational security play a crucial role.
Ocean offers brand new SONAPHONE from the signature of SONOTEC to let you operate with intuitive web and app features.
This offers an optional PC-enabled software platform to conduct route planning trend identification, measurement point organization, and documentation.
Apart from the above benefits, you’ll also get:
- Bundle significant information on the measuring points;
- Test reports in a few clicks;
- Broadband ultrasonic evaluation;
- 5-inch display and multi-touch screen
- Realization of maintenance 4.0
3. SONAPHONE® E
Being ATEX certified, it can be used effectively even in areas where there is a risk of explosion.
Since it adopts an intrinsically safe construction, SONAPHONE E can be ideally used in potentially hazardous environments.
The ultrasonic testing devices address the concerns of air or gas leaks, tightness of the systems, and wear in rotating machinery, and offer reliable solutions with proof of electrical discharge in case of insulation defects.
Another breakthrough of the testing is the analysis of steam traps and valves, with the help of a handheld device.
The core applications of the device include:
- Integrated Data Logger
- Used in potentially explosive surroundings
- Easy handling of equipment
- Multi-functional testing process
Why Choose the Ultrasonic Solutions from Ocean?
SONOTEC Ultrasonic solutions are the leading manufacturer of the finest ultrasonic testing devices you can rely on for preventive maintenance.
Ocean has been the trusted distributor of SONOTEC ultrasound testing devices in Oman since way back in 2017.
The SONOTEC Ultrasonic Solutions produce various Ultrasonic Testing Devices to ensure quick, precise, and easy detection of faults in the machinery or material to secure the smooth functioning of the plant.
Ocean has successfully sold numerous ultrasound testing solutions to customers spread across industrial plants and manufacturing sectors.
The Parting Shot
Ultrasound testing monitors the equipment’s condition and warns industries that work with costly equipment and machinery to identify whether repair or maintenance is necessary.
Ocean provides a great range of non-destructive ultrasonic testing machines to improve machine life, protect against system failure, and minimize the expenditure on frequent equipment replacement.
Ultrasound assessment is a significant, practical, and economic method that helps to test equipment with an insight into the internal structure of a material or equipment.