Ultrasonic Inspection

A Helpful Maintenance Technology for the

Hydrocarbon Processing Industry

Summary
Maintaining banks of heat exchangers, pumps, motors,
compressors, and thousands of valves and steam traps to ensure
the integrity of a final product is a daunting task. Luckily,
ultrasonic technology is available to make the job manageable.
The challenge for plant operators is to facilitate equipment-
condition analysis, detect leaks and make repairs as quickly as
possible. In this article, we will focus on airborne/structure borne
ultrasound and leak detection methods using state-of-the-art
ultrasonic instruments.

UESystems_03002
Alan Bandes
UE Systems, Inc
8 pages
November 2003

SKF Reliability Systems

@ptitudeXchange
5271 Viewridge Court
San Diego, CA 92123
United States
tel. +1 858 496 3554
fax +1 858 496 3555
email: info@aptitudexchange.com
Internet: www.aptitudexchange.com

Use of this document is governed by the terms

and conditions contained in @ptitudeXchange.

Introduction
Every day leaks of all shapes and sizes, as
well as mechanical problems, take their toll on
the operation of a facility. Such problems
squander costly energy, damage product runs
and waste thousands of dollars each year. The
challenge for plant operators is to facilitate
equipment-condition analysis, detect leaks and
make repairs as quickly as possible. In this
article, we will focus on airborne/ structure-
borne ultrasound and leak detection methods
using state-of-the-art ultrasonic instruments.
What is Ultrasound?
Ultrasound is defined as high-frequency sound
waves, which are above the range of human
perception. Usually they start at 20 kilohertz
(kHz) and go up into the megahertz range.
Airborne/ structure borne ultrasound covers
frequencies from 20 kHz up to 100 kHz.
All operating equipment and most leakage
problems produce a broad range of sounds.
The high-frequency ultrasonic components of
these sounds tend to be fairly directional.
Using ultrasound instruments, it is easy to
separate such signals from background plant
noises and to detect their exact location. In
addition, as subtle changes occur in
mechanical equipment, ultrasound inspections
enable early detection of potential warning
signals before actual failure.
How Does the Instrumentation
Work?
Airborne/structure-borne ultrasound
instruments, often referred to as “ultrasonic
translators,” provide information through
multiple paths: qualitatively through their
ability to hear ultrasounds through a noise-
isolating headphone, and quantitatively via
incremental readings on a meter/display panel.
Digital instruments provide on-board data
storage for data logging and for viewing
baseline data. Some newer versions of the
© 2004 SKF Reliability Systems All Rights Reserved
Ultrasonic Inspection
instruments also include on-board sound
recording for spectral analysis.
The instruments allow inspectors to confirm a
diagnosis on the spot because they clearly
discriminate among various equipment
sounds. An electronic process called
"heterodyning" accurately converts
ultrasounds sensed by the instrument into the
audible range where users can hear and
recognize them through headphones. This
process enables users to record sound events
through conventional recording devices.
Most of the sounds sensed by humans range
between 20 Hertz and 20 kilohertz (20 cycles
per second to 20,000 cycles per second). The
average high-end human threshold is16.5 kHz.
The wavelength sizes of these frequencies
tend to be relatively gross when compared
with the sizes of sound waves sensed by
ultrasonic translators. The wavelength of low-
frequency sounds in the audible range are
approximately 1.9 cm (3/4") up to 17 m (56')
in length (when using the high-frequency
average of 16.5 kHz), whereas ultrasounds
sensed by ultrasonic translators are only 0.3
cm (1/8") up to 1.6 cm (5/8") long. Since
ultrasound wavelengths are magnitudes
smaller than those in the audible range, they
have characteristics that are conducive to
condition analysis. One advantage is that the
amplitude of a generated ultrasound falls off
exponentially from the source, making the
emission localized and easily isolated for
detection and analysis.
Most manufacturers will provide on-the-job
training in the use of the ultrasonic
instruments, and the equipment is
maintenance free.
Leak Detection
Leakage can occur in any fluid system. Thus,
the greatest advantage of ultrasonic detection
is that it can be used in a variety of leak
situations and environments since it is sound
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 Ultrasonic Inspection

sensitive and not "gas" specific. When a leak
occurs, the fluid (liquid or gas) moves from
the high-pressure side of a leak through the
leak site to the low-pressure side where it
expands rapidly and produces a turbulent
flow. This turbulence has strong ultrasonic
components that ultrasonic instruments detect.
The intensity of the ultrasonic signal falls off
rapidly from the source localizing the leak
signal and enabling an inspector to isolate the
exact leak site.
Leaks may be located while a system is under
pressure in a vacuum or offline, since pressure
and vacuum leaks produce a turbulent flow,
which has strong ultrasonic components. For
offline systems, a special tone test uses an
ultrasonic transmitter to produce an ultrasonic
sound source.
Inspecting for Leaks in Heat
Exchangers
In hydrocarbon processing facilities,
ultrasound inspections often are made on two
major types of heat exchangers: straight shell-
in-tubes and U-tubes. Whether they are under
pressure or in a vacuum, tubes can be easily
inspected with ultrasonic translators. Headers
are removed so inspectors have access to the
tube sheets. In both vacuum and pressure
conditions, inspectors listen to the tubes that
are carrying a loud rushing sound produced as
fluid flows from the high- pressure to the low-
pressure side of the tube.

The tone test is conducted by placing an

ultrasonic transmitter inside (or on one side)
of a test item. A warble pulse signal floods the
test item and penetrates any existing leak site.
Even thin spots in certain metals will be
vibrated by the signal. A scan for sonic
penetration will pinpoint a leak. This standard
tone generator is versatile enough to perform
any leak inspection procedure, e.g. seals,
Figure 1. Heat exchanger.
gaskets, welds, tanks, heat exchangers, and
pipes. Should multiple heat exchangers of the same
type need to be inspected while online, a
The method of generalized leak detection is
contact method may be employed. Contact
simple. An inspector equipped with an
zones along the length of the external shell are
ultrasonic instrument scans an area listening
created. An operator touches each zone and
for a distinct rushing sound. With continued
compares them to similar zones on other heat
adjustments of a sensitivity/volume control,
exchangers at the same test point. Should a
the leak sound is followed until the loudest
leak be present, there will be a change in the
point is heard. Since ultrasound is a short
acoustic properties of one zone when
wave signal, the inspector is able to
compared to the acoustic properties in another
discriminate between irrelevant background
similar zone. This is often heard as a loud,
noises and the leak signal. Some instruments
popping or crackling sound.
include a rubber focusing probe that narrows
the area of reception to shield against Inspectors also can conduct tests when a heat
competing ultrasounds and to help pinpoint exchanger is off-line. In such cases, an
the location of small leaks. inspector uses ultrasonic transmitters (tone
generators), and places them so they produce a
© 2004 SKF Reliability Systems All Rights Reserved 3

uniform ultrasound around the tube bundle.
Operators scan both ends of the tube listening
for an increase in sound level, which will
indicate a leak or a tube that is thinning. The
preferred inspection method is pressure or
vacuum, but the tone generator technique is a
good backup for unique situations.
In one company where leaks in heat exchanger
tubes could short circuit the gas around
absorption towers and pollute the
environment, management now relies on
ultrasonic technology to comply with
mandatory state emissions limitations.
Some of the facility’s heat exchangers have as
many as 1100 tubes. Before ultrasonics, they
used to pressure-test each tube: put a plug in
each end and then pump air into each unit
holding the pressure to see if it bled off.
Testing a series of tubes in this manner was
labor intensive. Now the company uses
ultrasonics. With an ultrasonic generator,
technicians surround the tube bundle with
ultrasound and scan the tube sheets for the
tubes that carry the sound, indicating a leak.
Using ultrasonic technology translates into
savings, the product supervisor reports. In its
largest plant, they have six heat exchangers.
When they shut it down to pressure test 300-
400 tubes, it used to take 24-30 hours. Using
the ultrasonic instrument cuts downtime to
only four or five hours. That is a tremendous
savings in man-hours and operating time, and
in addition, the facility is complying with
environmental regulations.
Inspecting Internal Leaking
Valves
To determine the condition of a valve,
inspectors employ an “A, B, C, D, and
sometimes E” method. They touch the
instrument's contact probe at two equidistant
points upstream of the valve to create a
baseline reading and compare them to two
equidistant points downstream. If the
© 2004 SKF Reliability Systems All Rights Reserved
Ultrasonic Inspection
upstream points A and B are equal and the
first downstream test point C is louder than A
and B, one can assume there is a leak. There
may be situations in which structure-borne
ultrasounds emitted from a source just
downstream of the test valve could negatively
influence the test and produce a false positive
or incorrect diagnosis. To guard against this,
the D and E test points are used. If one
touches the second downstream test point D
and it is louder than C, this might indicate that
the valve is not leaking and the sound source
is originating further downstream. Testing the
fourth test point E further downstream will
confirm this. If E is louder, one can assume
that the sound is irrelevant to the valve and is
caused by a competing structure-borne
ultrasound.
Locating the Source of Pressure
and Vacuum Leaks
Ultrasound detection is also used to deal with
both pressure and vacuum leaks. The only
difference in detecting leaks in the systems is
that the greatest amount of turbulence will
occur externally in a pressure leak while in a
vacuum leak it will be produced internally.
Since leak scans are typically performed
externally, the intensity of the sound in a
vacuum leak under the same flow conditions
will be less than that of a pressurized leak.
Most often, an inspector uses a standard
scanning probe to locate a leak. The probe
contains a piezoelectric transducer that when
exposed to ultrasound pressure flexes and
produces an electrical charge. The airborne
leak sounds are converted from mechanical
energy to electrical energy and amplified and
translated into the audible range.
In some leak conditions, the signal may either
be difficult to reach or too subtle to detect
with standard scanning probes. Specialized
probes have been developed to help locate
leaks at a distance and to detect low-energy
4

leaks. For those leaks that are out of range,
(high up or far away), parabolic dishes are
used. These probes are designed to collect far
off sounds in the "parabola" and focus them
into an array of transducers where the sound
source is amplified. Depending on the size and
shape of the parabola, the focal range can be
as tight as five degrees, allowing a user to
pinpoint the location of a leak at distances
greater than hundred feet.
Low-level leaks, such as a vacuum leak in a
distillation column or leaks in pipe/flange
fittings, may be difficult to locate with
conventional scanning modules. A scanning
probe with an internal “horn” shape (referred
to as a close-focus module) may be used to
scan the leak site closely. The leak sound is
amplified and carried via the funnel-shaped
collecting cone to the sensing transducer
enabling users to identify the leak site.
For low-level pressure or vacuum leaks where
turbulent flow is low or non-existent, a unique
method that combines a liquid "bubble test"
with ultrasound can be used. A bubble
solution that has a low-surface tension is
applied to the suspect leak site. In the presence
of a leak, bubbles form quickly and burst
producing a detectable ultrasound. For
pressure leaks, an inspector uses the scanning
probe. Vacuum leaks can be located similarly.
Occasionally, there will be instances where
scanning a vacuum system will not work due
to poor sound conductivity from the vacuum
side to the scan side. For those situations,
using a contact probe with a liquid can be
extremely effective in locating the leak. This
contact probe has a metal rod that acts as a
wave-guide. By touching the test surface with
this probe and applying the liquid to the
surface, a leak sound will be heard when the
liquid is “sucked in” and sputters against the
internal walls. For vacuum systems, any liquid
that is compatible with the vacuum side can be
incorporated.
© 2004 SKF Reliability Systems All Rights Reserved
Ultrasonic Inspection
To pinpoint the source of a leak, inspectors
begin by scanning an area listening for a leak
sound. By adjusting the sensitivity/volume
control, they follow the sound to the loudest
point until they are right on top of the leak. In
certain cases, when employing the scanning
probe, inspectors may use a rubber focusing
probe with a narrow opening that allows them
to pinpoint an exact location.
Chemical sniffers may be affected by any
number of gasses present. But a key advantage
of ultrasound is that it is not gas specific and
may be used to locate a number of different
types of leaks in any kind of environment
even if there is a saturation of gasses.
Testing for Faulty Steam Traps
To perform an accurate test, it is important to
understand the way different traps function.
Acoustically, there are two types of traps:
continuous flow and intermittent flow. Poorly
operating trap conditions can range from a
complete blow-through to leaking to plugged.
Plugged traps will be cool and quiet while
operating traps and leaking traps will be hot
and produce sound. To be sure a trap is hot or
cold, before testing, it is recommended that
the temperature of the trap be taken with a
non-contact infrared thermometer.
Figure 2. Steam trap manifold.
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 Ultrasonic Inspection

Before beginning a survey, take a trap map For example, one facility reported that their
along with you to plan your route and make ultrasonic-based steam and maintenance
sure the traps are tagged/ identified accurately. program in one location of its plant saved
If an inspector does not have an accurate map $250,799 in the first year of the program
of the traps either he should make one or take alone. This translates into 37 million pounds
photos (with a digital camera) of the trap of steam saved when compared to the previous
locations and label them. Then he should year. Another area saved $141,670, or 25
create a method of identifying all traps with million pounds of steam a year.
tags so that any problem found can be easily
referenced and located for follow up action. Monitoring Bearing Wear and
Always note the type of trap you are testing. Lubrication Issues
Using the ultrasonic instrument, touch the trap Ultrasound inspection can provide an early
on the downstream side with the instrument’s warning of bearing failure, lack of lubrication,
contact probe and adjust the sensitivity to over-lubrication, for high-speed as well as
better hear flow conditions. Listen to the trap low-speed bearings. There are two methods -
operation and observe the meter. The "overall amplitude level" and "spectrum
downstream side is used to determine leakage. analysis" - that are commonly used to monitor
First touch directly upstream of the trap and bearings.
adjust the sensitivity to a midpoint level where
flow conditions can be observed without
overloading the display. Then touch
downstream listening for the trap operation.
An intermittent trap should have an
intermittent sound; a continuous flow trap will
have a modulating “continuous” flow. If one
is not sure of the type of trap being tested,
refer to the manufacturer’s guide or check
with your local trap supplier. Some ultrasound
equipment manufacturers and steam trap
manufacturers have sound samples available.

Inspectors should note the tag number of all

faulty traps and produce a non-compliance
report or a work order for repair. Test the traps
after they have been repaired or replaced Figure 3. Diagnosing bearing.
because sometimes a new problem can be
created inadvertently. In most cases, the inspection approach is
simple and straightforward. The first step is to
Few maintenance departments these days have establish a baseline reading by comparing
the time or staff to conduct daily inspections similar bearings for potential differences in
of traps. However, if process components of amplitude and sound quality. To do this, mark
equipment as well as main steam traps are a reference point on a bearing housing and
checked routinely (for example, quarterly), the touch this reference point with the contact
savings can be substantial. (stethoscope) probe of an ultrasonic
instrument. Next, adjust the sensitivity to hear
the bearing sounds more clearly and to bring
the intensity levels on the meter/display panel
© 2004 SKF Reliability Systems All Rights Reserved 6

into range if the received sound amplitudes are
either too high or too low. If frequency tuning
is used, tune the instrument to 30 kHz.
Compare similar bearings under the same load
and RPM conditions. Most of the bearings
should be within the same range with the same
sound quality (usually a rushing noise similar
to an air leak). The bearing with the lowest
reading can be used as the baseline reading.
Another method is to take an average of the
readings and use that as the baseline.
A few rough guidelines on amplitude increase
are as follows. An 8 dB gain over baseline
with no change in sound quality could indicate
pre-failure, or lack of lubrication. A 12 dB
increase could show the very beginning of the
failure mode and may sound rough. A 16 dB
gain could indicate advanced failure
condition, while a 35-50 dB gain warns of
catastrophic failure. Once a series of bearings
have been tested and a baseline set, data is
recorded and then compared to future readings
for historical trending and analysis.
Spectral analysis is another important feature
for ultrasound mechanical and bearing
condition analysis. It enhances vibration
analysis programs and can be used when no
vibration program exists. This can be achieved
by either connecting the ultrasound instrument
to a vibration analyzer with a cable from the
headphone (heterodyned output) to the
vibration analyzer, or to incorporate spectral
analysis software, which some suppliers of
instruments offer. If spectral analysis software
is used, the sounds must be recorded with a
tape recorder or minidisk and played back
through the software. If the software is loaded
on a laptop computer, the sounds may also be
recorded directly to the software. Some
ultrasound instruments have on-board sound
recording capability and can download the
sound samples directly to a computer. Once
recorded, the sound samples may be analyzed
in either a spectral screen or a time series to
determine the condition of the equipment.
© 2004 SKF Reliability Systems All Rights Reserved
Ultrasonic Inspection
This approach can be used to test and analyze
low as well as medium and high-speed
bearings, gears, pumps, and compressor
valves.
Figure 4. Compressor.
Determining when to lubricate bearings and
how much lubricant to apply are two of the
issues facing technicians responsible for
maintaining bearings. Under-lubrication can
wear out a bearing before its time; applying
too much lubrication often can lead to
catastrophic results to the bearing or long term
damage to motor coils and windings.
Traditionally, lubrication scheduling has been
“time-based.” Equipment suppliers often
recommend lubrication schedules based on
hours of operation. In addition, they
frequently provide instructions as to the
amount of lubricant to be applied during these
scheduled maintenance procedures. It is not
uncommon to hear of instructions where
customers have been told to lubricate at short-
time intervals and to suggest adding what
appeared to be excessive amounts of grease.
The concept of lubrication intervals is based
on a simple premise: to keep equipment
running optimally by preventing a bearing
from running dry and causing catastrophic
damage. It is a solid “preventive” concept.
However, there is a balance that must be
struck between preventing lubrication
7

starvation and the extreme of over lubrication.
Also, one has to take into account secondary
functions of the lubricant such as keeping-out
contamination, and to absorb wear debris,
leading to shorter (re)lubrication intervals. In
any case, to accomplish the goal of lubrication
optimization, one should know when (not) to
(re)lubricate and how much lubricant to add.
This may be accomplished with a condition-
based lubrication strategy. Simply put, the
condition of the bearing determines when to
lubricate. If a bearing is working properly and
does not demonstrate any changes that warrant
lubrication, such as increased decibel levels
(over a baseline), temperature, or
contamination level, the bearing should be left
alone. Should such conditions change and a
bearing demonstrates a need for lubrication,
then a lubricant should be (re)applied.
Monitoring the lubricant as it is applied can
also help to determine how much to add and
when to stop the application.
At one facility, a maintenance supervisor
became suspicious when a pump manufacturer
recommended that he lubricate the bearings on
pumps every two weeks and send them in for
overhaul in two years. The manufacturer
recommended 42 pumps of grease (a full
ounce). The supervisor decided to use his
ultrasonic instrument to monitor the bearings
in action. He set up an inspection route and
found that all it took was six or seven pumps
of lubrication once every six months! He
reported that it saved his company manpower
and time and extended the life of the
equipment. When he sent the pumps in, as
prescribed by the manufacturer, the repair
shop informed him that the next rebuild cycle
could be extended an additional six months
because the pumps were in better shape than
they had expected.
Conclusions
In this article, we have discussed ultrasonic
leak detection and mechanical inspection
© 2004 SKF Reliability Systems All Rights Reserved
Ultrasonic Inspection
methods in general. Of course, every
hydrocarbon processing plant is unique, and
inspection methodologies should be tailored to
the specific needs of a facility. The best advice
is to research the variety of preventive /
predictive instruments and accessories
available, and then talk with manufacturers
and service providers regarding what best
suits the needs. Ultrasonic instruments have
also proven effective for the detection of valve
blow-by, cavitations in pumps, corona in
switchgear, and the inspection of and the
integrity of seals and gaskets in tanks.
Figure 5. Switchgear.
About UE Systems
For more information, contact UE Systems,
Inc. at: ue@uesystems.com
UE Systems manufactures and distributes
hand held portable ultrasonic instruments for
leak detection, mechanical and electrical
inspection. Customers can select products
ranging from simple analog to sophisticated
digital instruments and software to meet
specific inspection needs. Established in 1973,
it is the recognized worldwide leader in the
technology of airborne/structure borne
ultrasound. A network of trained specialists as
well as comprehensive training material and
courses supports the products.
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