Steam Trap Testing & Maintenance

Description

When steam traps leak or fail, it can be extremely costly in terms of product quality, safety and energy loss. There are great differences in the way particular steam traps work (for example, inverted bucket trap versus float and thermostatic trap). The UltraProbe makes it easy to adjust for these differences and readily determine operating conditions while steam traps are on-line.

How Ultrasonic Leak Detection Works

Steam traps can either be defined as continuous (or modulating continuous) flow and on-off types. UE Systems’ Ultraprobe series helps an inspector readily identify the trap operation in all types of environments.

Inspectors can choose from simple “point and shoot” analog instruments to sophisticated digital instruments with on-board sound recording and data logging features. UE Systems unique frequency tuning feature enables users to literally tune into the trap sound and clearly identify leaking or blowing traps.

Leak Detection Method

Inspection methods vary depending on the type of steam trap. Therefore the primary rule is to know the details of your system, for example the way a specific trap may work under specific conditions. In order to determine trap condition such as leakage or blockage: touch upstream of the steam trap and reduce the sensitivity of the instrument until the meter/display panel reads about 50% of scale. If the instrument has frequency tuning, you may also use this feature to hear the trap sound quality more clearly. Simply tune the frequency (usually 25 kHz) until the sound you would expect to hear becomes clear. It's that simple.

Next, touch downstream of the steam trap and compare intensity levels. If the sound is louder down stream, the fluid is passing through. If the sound level is low, the trap is closed. Ultrasonic steam trap inspection is considered a "positive" test in that an operator can instantly identify sound quality and intensity differentials and thereby determine operating condition accurately. A steam trap troubleshooting guide is available from the factory upon request.

A steam trap troubleshooting guide is available from the factory upon request.

Valve Testing Instruments

DESCRIPTION

When valves leak or fail, it can be extremely costly in terms of product quality, safety and energy loss. Valve operation effects the way fluids will flow through a system. There are great differences in the way particular valves work (for example, control valve versus safety valve). The UltraProbe makes it easy to adjust for these differences and readily determine operating conditions while valves are on-line.

How Ultrasonic Leak Detection works

As fluid moves from the high pressure side of a valve through the seat to the low pressure side, it produces turbulence. This turbulence generates ultrasound which is detected by the Ultraprobe and translated, via heterodyning, down into the audible range. The translated ultrasounds are heard through headphones and seen as intensity increments, usually decibels on a display panel. High frequency tuning allows users to adjust for differences in fluid viscosity (i.e. water vs. steam) and reduce any interference from stray pipe noises.

Leak Detection Method

Inspection methods vary depending on the type of valve. Therefore the primary rule is to know the details of your system, for example the way a specific valve may work under specific conditions. In order to determine valve condition such as leakage or blockage: touch upstream of the valve and reduce the sensitivity of the instrument until the meter/display panel reads about 50% of scale. If the instrument has frequency tuning, you may also use this feature to hear the valve sound quality more clearly. Simply tune the frequency (usually 25 kHz) until the sound you would expect to hear becomes clear. It's that simple.

Next, touch downstream of the valve and compare intensity levels. If the sound is louder down stream, the fluid is passing through. If the sound level is low, the valve is closed. Ultrasonic valve inspection is considered a "positive" test in that an operator can instantly identify sound quality and intensity differentials and thereby determine operating condition accurately.

ULTRASONIC TRANSPORTATION APPLICATIONS

The most common areas for ultrasonic inspection in the transportation industry are: wind noise, water leaks, air brakes, and emission systems (especially as it relates to IM240). Until the advent of ultrasound, water leak and wind noise detection involved many hours of trial and error with a water hose and flashlight. Often a few trips around the block, listening with a doctor's stethoscope for a wind noise captured two people for many hours. Air brake leaks and emission leaks can take hours to locate using conventional soap and water bubble testing. Not only can service shops benefit from Ultrasonic Inspection, so can Quality Assurance departments by providing accurate, fast and simple testing.

How Ultrasonic Detection Works

Compressed gases, when leaking produce a turbulent flow with strong ultrasonic components. By scanning fittings, a leak will be heard as a distinct "hiss". Due to the high frequency, short wave nature of ultrasound, the sound will be loudest at its point of origin. The ULTRAPROBE translates the ultrasonic leak signals into recognizable audible signals where they are heard through headphones and seen as intensity increment on a meter. A unique test called "Ultratone" incorporates a patented ultrasonic transmitter called a Warble Tone Generator. This device is placed in a cabin, tank or container where it floods the area with an intense ultrasonic signal. The generated ultrasound will deflect off solid seals but will flow through a leak path.

Detection Methods

Leaks produce turbulence with high frequency components. To locate compressed gas and air leaks, simply scan the area while listening for a "hissing" sound and follow it to the loudest point. If it is difficult to discriminate location, reduce the sensitivity and continue to follow to the loudest point. Emissions testing can be performed in the same manner. Cabins, fuel tanks, containers, seals and gaskets, wind noise and water leaks may be tested with the unique patented Ultrasonic Warble Tone Generator. Place the generator in the cabin or container and scan the window, door, floor, seals, etc. for sonic penetration which will have a distinct chirping sound and follow to the loudest point. It's that simple.

ULTRASONIC MARINE INSPECTION

DESCRIPTION

Ultrasonic inspection can be used in practically every phase of the maritime industry. There are application for marine vessels, dry docks, ship repair and shipbuilding. Some of the major areas of inspection cover water tightness integrity of bulkheads, leak detection of hatches vapor recovery systems, condensers, steam systems, pressurized gas systems (including nitrogen blankets), valve leak detection/blockage and steam traps. Mechanical applications include early warning of bearing failure, inspection of motors, pumps, gears, gearboxes and compressors. Dry dock usage not only includes all of the above, but also extremely large energy savings through compressed air leak detection.

How Ultrasonic Detection Works

High frequency sounds are produced by operating equipment and fluid flows. The ULTRAPROBE detects subtle changes in mechanical equipment and turbulence produced by leakage to provide early warning. Ultrasounds are translated into the audible range where the sound quality is easily recognized through acoustically isolating headphones. The headphones are designed to be used in the extremely noisy environment of the engine room. Intensity levels are observed on a display panel and may be data logged for trending, diagnosis and trouble shooting purposes. A patented Warble Tone Generator can be used to test for leaks in lieu of pressure by flooding an area with intense ultrasound. The sound will deflect off a solid surface and penetrate leak sites. UE Systems has a selection of specialized ultrasonic tone generators ideally suited for hatch and bulkhead inspection.

Detection Methods

To locate leaks around pressure or vacuum systems, simply scan the area while listening for a "hissing" sound and follow it to the loudest point. Vapor recovery systems can be checked on-line in this manner. Hatches and bulkheads may be tested with the patented ultrasonic Warble Tone Generator. Place the generator on one side (i.e. of the bulkhead) and scan the other side for sonic penetration which will have a distinctive chirping sound. Scan the area to the loudest point of emission which will indicate the leak site. For valves, touch upstream and reduce the sensitivity to get a mid-line reading on the meter, then touch downstream and compare intensity levels. A more intense reading downstream indicates leakage. No sound indicates blockage. Bearings are checked at 30 kHz. Set a baseline by selecting one test/reference point, touch that point with the contact probe, reduce the sensitivity to obtain a low dB level. An increase of 8 dB indicates "pre-failure" or lack of lubrication, while an increase of 12-16 dB over baseline indicates the beginning of the failure mode. It's that simple.

UE Systems Ultraprobes have type approval from DNV and ABS and are GSA listed.

ULTRASONIC LEAK DETECTION 2

Heat Exchangers, Boilers, Condensers

DESCRIPTION

Leak Detection of heat exchangers, boilers and condensers most often involves inspection of three generic areas: tubes, tube sheets and housings. The Ultraprobe can be used to detect leaks three ways: pressure leaks, vacuum leaks or by utilizing a unique UltratoneTM Ultrasonic Tone transmission method.

While it may be necessary to take a unit off-line to inspect for leaks, with ultrasound, it is often possible to perform an inspection while on-line or at partial load.

How Ultrasonic Leak Detection Works

During a leak, the fluid will flow from high pressure to low pressure producing a turbulent flow at the leak site. This turbulence has strong ultrasonic components which are sensed by the Ultraprobe and translated (via heterodyning) into the audible range where they are heard in headphones and seen as intensity increments on a meter.

Leak Detection Method

Most often leak detection is concerned with tube leaks. In heat exchangers and condensers, there are situation where the end plates (headers) are removed or water boxes are isolated while the unit is still on-line or at partial load. The tube sheet are scanned while listening for a distinct "hissing" or "rushing" sound of a leak. By adjusting the sensitivity of the instrument to help discriminate direction, move in the direction of the tube with the loudest sound.

Should the unit require off-line inspection, it is possible to use the Ultratoneô Ultrasonic Tone transmission method. Using ultrasonic transmitters such as UE Systems' patented Warble Tone Generators, the heat exchanger is flooded with intense ultrasonic sound waves on the shell side and the tube sheet is scanned for a distinct high pitched warbling sound coming from the leak. As above, adjust the sensitivity to discriminate direction and follow the sound to the loudest point which will be the leaking tube.

While under pressure or vacuum, fittings and casings may also be checked for leakage in a similar manner.

Electric Arc Flash

Electric Arc Flash can severely burn or kill anyone exposed to it.

There are a reported 5-10 arc flash incidents occurring daily. According to the NFPA, arc flash is “a dangerous condition associated with the release of energy caused by an electric arc.” When an arc flash occurs, there may be 1 to 2 explosions within milliseconds, which can generate temperatures between 5,000 and 35,000° F. The pressure wave from an arc blast can be very similar to an explosion from a hand grenade.

When it is necessary to understand whether or not an arc flash condition is present, a multi technology approach is recommended. Integrating Infrared and ultrasound can be useful in determining equipment condition. If there are no scan ports in the equipment, it will be difficult to detect arcing, tracking or corona with infrared.

Incorporating ultrasound to scan around door seals and air vents can help detect the presence of arc flash hazard potential in enclosed, energized electrical equipment.

ULTRASONIC LEAK DETECTION

DESCRIPTION

Ultrasonic leak detection is extremely broad based. Sensing ultrasounds generated by a leak, the ULTRAPROBE can be used to locate leaks in pressurized systems regardless of the type of gas used. This is especially beneficial in areas where there is a saturation of gases or where a wide variety of gases, pressurized vessels and vacuum processes exist.

Time and convenience are also improved with ultrasonic detection since equipment may be tested while on-line.

How Ultrasonic Leak Detection Works

During a leak, a fluid (liquid or gas) moves from a high pressure to a low pressure. As it passes through the leak site, a turbulent flow is generated. This turbulence has strong ultrasonic components which are heard through headphones and seen as intensity increments on the meter. It can be generally noted that the larger the leak, the greater the ultrasound level.

Leak Detection Method

Ultrasound is a high frequency, short wave signal. The intensity of the ultrasound produced by a leak drops off rapidly as the sound moves away from its source. For this reason, the leak sound will be loudest at the leak site. Ultrasound is considered fairly "directional" and therefore, locating the source (i.e. the location) of the leak is quite simple.

For detection, scan the general area of a suspected leak and listen for a hissing sound (similar to the sound you hear when you fill a tire with air). Move in the direction of the loudest sound. If it is hard to determine the direction of the noise, reduce the sensitivity until direction can be established. Follow the sound and continue to reduce the sensitivity to determine the direction of the leak. In order to confirm the leak site, move the scanner back and forth over the suspect area. The sound level should increase as you pass over the leak. In some loud factory environments, frequency tuning may be required.

ULTRASONIC ELECTRICAL INSPECTION

DESCRIPTION

When electrical apparatus such as switchgear, transformers, insulators or disconnects and splices fail, the results can be catastrophic. This is just as true in industrial plants as it is in the power transmission and distribution side. Electrical discharges such as arcing, tracking or corona are all potential for equipment failure. In addition, the problems of RFI and TVI impact on our valuable communication networks. If left undetected, these conditions can become a source of an arc flash incident, which can result in severe injury or death. Arcing, tracking and corona produce ultrasound and are detected with an Ultraprobe.

How Ultrasonic Electrical Detection Works

Arcing, tracking and corona all produce some form of ionization which disturbs the air molecules around it. The Ultraprobe detects the high frequency noise produced by this effect and translates it, via heterodyning, down into the audible ranges. The specific sound quality of each type of emission is heard in headphones while the intensity of the signal is observed on a meter. Normally, electrical equipment should be silent, although some may produce a constant 60 cycle hum or some steady mechanical noises. These should not be confused with the erratic, sizzling frying, uneven and popping sound of an electrical discharge.

Detection Method

Before beginning any inspection of mid or high voltage equipment, be sure to review your plant or company's safety procedures. Essentially, as in generic leak detection, the area of inspection is scanned starting at a high sensitivity level. To determine the location of the emission, reduce the sensitivity and follow the sound to the loudest point. If it is not possible to remove covers, or plates, scan around the seams and vent slots. Any potentially damaging discharges should be detected.

When it is not possible to get close to the test equipment, such as for safety reasons or while inspecting over-head power lines, use a parabolic microphone. UE Systems has two models, the Ultrasonic Waveform Concentrator (UWC) and the Long Range Module (LRM). These highly sensitive, directional sensors double the detection distance of a standard scanning module and provide pinpoint accuracy.

ULTRASONIC BEARING & MECHANICAL INSPECTION

DESCRIPTION

Inspection of mechanical equipment with ultrasonic instruments such as the Ultraprobe has many advantages. Ultrasound inspection provides early warning of bearing failure, detects lack of lubrication, prevents over lubrication and can be used on high as well as low speed bearings. In addition, since ultrasound is a high frequency, short wave signal, it is possible to filter out stray, confusing background noises and focus on the specific item to be inspected. Basic inspection methods are extremely simple and require very little training.

Ultrasonic condition analysis is straightforward. Users can observe sound levels while simultaneously listening to sound quality and record both sound and data for analysis through specialized software. Digital instruments provide many possibilities for a comprehensive bearing condition program including sound sample recording, data logging, trending, alarm groups, sound (spectral) analysis and reporting.

How Ultrasound Bearing and Mechanical Inspection Works

Mechanical movements produce a wide spectrum of sound. By focusing on a narrow band of high frequencies, the Ultraprobe detects subtle changes in amplitude and sound quality. It then heterodynes these normally undetectable sounds down into the audible range where they are observed on a meter (for trending and comparison purposes) and heard through headphones.

Based on research by NASA, it was established that ultrasonic monitoring provides early warning of bearing failure. Various stages of bearing failure have been established. An 8 dB gain over baseline indicates pre-failure or lack of lubrication. A 12 dB increase establishes the very beginning of the failure mode. A 16 dB gain indicates advanced failure condition while a 35-50 dB gain warns of catastrophic failure.

Ultrasonic Bearing Inspection Method

There are two basic methods for ultrasonic bearing monitoring: comparative and historical. In order to trouble shoot bearings or to establish a baseline, it is necessary to compare similar bearings for potential differences in amplitude and sound quality. To do this, make a permanent reference point on a bearing housing or use the grease fitting, tune to 30 kHz and adjust the sensitivity to read the intensity/decibel level on the display panel. Then compare this base reading to other similar bearings. An 8 dB gain over a baseline, with no change in sound quality will indicate possible lubrication starvation. Levels, such as 12 dB or higher can signify a potential failed condition. Once a series of bearings have been tested, and a base line set, data is recorded and then compared to future readings for historical trending and analysis. Alarm levels can be set to note any bearings in need of corrective action. Sound anomalies can be recorded for spectral analysis.

Ultrasonic inspection works extremely well with vibration technology. In fact the two technologies complement each other and enhance any PDM, (Predictive Maintenance) program.

Additional information regarding vibration data logging connection is available from the factory.

Testing an Air Compressor

Testing with the Airometrix LP Flow Meter is simple, quick, and repeatable. The ideal meter tie-in location is after the aftercooler and moisture separator and as close to the output of the compressor as practical. This can be on a bung in a receiver, at a drop leg or tap in the compressor room, or at a service port where a portable compressor is typically connected. The main requirement is that the compressor is capable of being isolated from the system with the full flow of the compressor going to the LP Meter. Note the installation diagram below:

Testing the Compressor Performance

Once the meter has been plumbed in and the compressor has been isolated from the rest of the system, the compressor is started and the different orifices on the meter are opened and closed until the compressor can just barely keep up at system pressure. Add the valves which are open and this is the Free Air Delivered (FAD) of the compressor at the test pressure. In order to build a performance curve for the compressor, flow tests are performed at various pressures to determine the compressor output over a span of loads. This is accomplished by opening or closing more or less orifices and noting the changes in pressure with flow. It is recommended to take simultaneous true power readings (kW) on the compressor at each load point to get a full picture of compressor performance (flow, pressure, and power).

The performance data obtained from the test can be used to diagnose control function and other hard to measure performance information. It can also be used to chart inlet valve control, and accurately determine compressor power and flow turndown.

Testing for Leak Volume

Additional testing can be performed to determine system leak volume and consumption of equipment and processes. To test a system for leaks, the system is brought on-line without any equipment operating (usually performed on lunch breaks, off shifts, maintenance shifts, or annual shutdown), and a second flow test is performed on the compressor at the previously tested system pressure. The results for the second test with the system pressurized will be a lower air flow through the meter, the difference in the two tests is the leak volume in the system. For instance, if an isolated compressor is tested at 100psig at 1000cfm, and then retested at 100psig with the system pressurized and a flow of 600cfm through the meter, then the leak volume in the plant is 400cfm. If areas of the plant can be isolated, a leak test for each section can be administered and effort focused in the sections with the greatest volume of leaks.

Consumption Testing

Consumption tests can be performed using the same approach as the leak test which is to test before and after equipment is turned on and off. The difference in flow readings between the on and off conditions is the consumption of that piece of equipment. The same procedure can be used to test building consumption, process lines, or any other end use which can be isolated. A similar procedure can be used to find overall system consumption plus leaks when the plant is fully operational by testing each compressor off line one at time to determine the flows at full load. With the plant running, the compressors are brought to full load by opening orifices on the LP meter and the flow through the meter is subtracted from the known maximum capacity of all the on-line compressors. This is the consumption plus leaks for the entire system. If the leak volume has already been determined, the leak volume can be subtracted as well and the remainder is the consumption of the plant equipment.

In most facilities, only one meter is required to test all of the compressors for the system. The meter can be quickly disconnected from one location and moved to test another compressor as long as the meter is sized large enough to accept the compressor flow. Actual testing time is limited by how fast the compressor can react to a load change. Typical test time for positive displacement compressors is 10 minutes or less,  and one hour or less for dynamic machines.

ULTRASONIC AIRCRAFT INSPECTION

DESCRIPTION

Aircraft have many systems that can be checked ultrasonically. Some of the more common applications include: testing leaks in fuel cells, oxygen systems, hot air ducts, cabin pressure, tire leaks, floatation devices, hydraulic valves and actuators. It is also used to locate leaks in cockpit windows as well as to identify potential problems with bearings, pumps, motors and gears.

How Ultrasonic Detection Works

Operating systems such as compressed gas systems, valves, motors, pumps, etc., all produce ultrasound. Some high frequency sounds are generated from turbulence, others from friction. As components begin to wear, fail or leak, there is a change in the normal ultrasonic pattern. This can be detected as an increase in amplitude, a change in sound quality or a change in sound pattern. Due to portability, ease of use and flexibility any Ultraprobe may be used all around the aircraft.

The Ultraprobe detects minute changes in ultrasound and converts these signals so that they may be heard through headphones, and observed as intensity increments, usually decibels, on a display panel. By using plug-in modules for either a scanning mode or a contact mode, equipment may be inspected for leakage or for mechanical problems.

Digital instruments with on-board sound recording and data logging help inspectors record sound samples and data for accurate condition analysis. There are instruments rated intrinsically safe for those conditions that require such ratings.

Detection Methods

For general leak detection, in a scanning mode, move along the area to be tested using a slight waving motion, listen for the loudest "hissing" sound and follow the sound to the loudest point, making adjustments with the sensitivity dial as needed. Use the patented Warble Tone Generator to test for cabin pressure and cockpit window leaks in the same manner. For valves and actuators, touch upstream and reduce the sensitivity to a mid-line reading. Compare with the downstream reading. Test bearings and mechanical equipment by setting a baseline sound level and sound quality conditions. Compare readings and sound samples over time for trending. It's that simple.

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