Ultrasound Technology and Compressed Air Audits

Brief Overview of Ultrasound

Ultrasonic frequencies are high frequency signals that are above range of human hearing.  Human hearing range is 20 Hz to 20 kHz  Ultrasound instruments sense 20 kHz to 100 kHz  High frequencies have characteristics that work differently than low frequencies in the audible range.


Low Frequency Sound Waves Range in Size from 3/4 of an inch to 56 feet (assuming the average hearing is 16.5 kHz)

High Frequency (Ultrasound) Sound Waves Range In Size from 1/8 of an inch to 5/8 of an inch (assuming ultrasound range from 20 kHz-100kHz) kHz-100kHz)

Ultrasonic Characteristics
Characteristics of short wave sounds:
  

 

They are directional/detectable They are localized to the source of emission They will reflect and not penetrate solid objects making them easy to block/shield They can be sensed in loud, noisy environments Subtle changes can be noted to provide early warning of failure

SOUND PENETRATION


Low Frequency Wave

Vibrate Solid Surfaces Large Objects Appear Transparent

High Frequency Wave

Short Weak Can not Penetrate Solid MPEG Objects SUPERSONIC FLYBY OF AN F14
SHOWING THE SOUND WAVE WITH A VAPOR CLOUD

How Do We Detect Ultrasound?

Using a digital ultrasonic translator which provides:  Display Screens with test data including Decibel and Frequency read outs.  Software for data management  Sound recording ability and sound analysis software

TYPICAL ULTRASONIC TRANSLATOR

How Do these Ultrasonic Translators Work?



The Ultrasound is detected and these sounds are then translated down into lower frequencies within the range of human hearing They are heard through headphones And observed as intensity increments on a meter or display panel.

Interchangeable Modules


Leaks Are Detected By:

Scanning Module Stethoscope Module Tone method Specialized Methods May Be Considered: Long Range Module
Non Accessible Leaks

Liquid Leak Amplifier

Laminar or TINY Leaks

Sound Recording
The translated ultrasound samples can be recorded for further analysis.


Use the heterodyned output: the headphone jack and connect to a suitable recording device. The captured sound can be analyzed using Spectral Analysis Software.

Where Do Air Leaks Occur?

     

Mechanical Seals Threaded Fittings Sealant Problems Gaskets Corrosion/Erosion Structure Penetrations

Considerations in Leak Detection

       

Turbulence Orifice Shape Fluid Characteristics: Viscosity & Molecular Wt. Pressure Differentials Distance From Leak Competing Ultrasounds Accessibility to Leak Atmospheric Conditions

Turbulence

Turbulent Leaks Emit Ultrasound Based on Their Shape, Pressure At the Leak, and other Factors

ORIFICE

Shape of the Orifice is the Determining Factor in How Much Detectable Ultrasound is Present

How An Air Leak Generates Ultrasound

Relating Sound Levels to CFM

dB vs. CFM
Digital Reading 10 dB 20 dB 30 dB 40 dB 50 dB 60 dB 70 dB 80 dB 90 dB 100 dB 150 PSIG 0.73 1.13 1.79 2.70 3.86 5.27 6.93 8.84 11.00 13.41 125 PSIG 0.69 0.95 1.48 2.28 3.35 4.70 6.32 8.21 10.37 12.81 100 PSIG 0.51 0.77 1.24 1.94 2.85 3.98 5.33 6.90 8.69 10.69 75 PSIG 0.38 0.58 0.99 1.62 2.47 3.54 4.82 6.31 8.03 9.96 50 PSIG 0.36 0.38 0.64 1.15 1.90 2.89 4.13 5.62 7.35 9.32 25 PSIG 0.03 0.22 0.58 1.10 1.79 2.65 3.68 4.87 6.23 7.75 10 PSIG 0.01 0.15 0.48 0.93 1.49 2.18 2.99 3.92 4.97 6.14

Note: All Readings are Compensated for Atmospheric Pressure

Conducting a Compressed Air Survey



Gather Data
Compressor Info PSIG Operating data Hours of Operation

   

Begin Survey at Compressor Follow Air Lines to all Pieces of Equipment Record dB Readings of Leaks Take Photographs of Leaks

How do we do this?
     

Create a route Set up the instrument Gather relevant data Test, listen, record Data log Generate Report

Create A Route
Plan carefully  With plant personnel, determine the optimal route for inspection and ease of follow up for repair.  Create a method of equipment identification (if none exists)

Set Up Instrument


Verify the sensitivity: it should be working the same from one inspection to the next. What frequency to use: record this for consistency What test module to use?

Gather Relevant Data

Date and Time  Compressor Data  Operating Pressures  Hours Operation  Any Special or Hazardous Conditions


Test, Listen, Record

Data Log
 

Data log all readings Take Photographs of all leaks

Generate a Cost Report



Place Recorded dB Readings in Analysis Software Generate Report of dB Sound Level of Each Leak Converted to CFM with Associated kW Usage and Annual Cost of Leak

Leak # dB Distance 1 2 3 4 5 6 7 8 9 10 63 60 71 33 44 44 37 36 61 51 0 0 0 0 0 0 0 10 0 0

Location/Equip Top of receiver DH annealer Gardner Denver Compressor DM3 EH1 Supply EH4 Annealer EH3 Supply Above EH3 Supply EH2 Annealer EV1 Supply

Leakage Annual kW use Rate CFM Cost 4.0 0.80 $349 3.6 0.72 $316 5.1 1.02 $446 1.2 0.24 $107 2.0 0.40 $174 2.0 0.40 $174 1.5 0.29 $128 0.6 0.13 $56 3.7 0.75 $327 2.6 0.52 $230

Place Pictures with Report



Place Photos of Each Leak Location that Numerically Matches the Cost Report

AIR LEAKS COST !!!!!!

LEAK DIA AIR-LOSS AIRCFM LOSS/DAY LOSS/DAY LOSS/YR. CU.FT/DAY $ $

--------------------------------------------------------------------------------------------------1/64 .40 576 0.14 50.40 1/32 1.60 2,304 0.58 211.00 3/64 3.66 5,270 1.32 481.00 1/16 6.45 9,288 2.32 846.00 3/32 14.50 20,880 5.22 1,904.00 1/8 25.80 37,152 9.29 3,389.00 3/16 58.30 83,952 21.00 7,661.00 1/4 103.00 148,320 37.08 13,526.00 5/16 162.00 233,280 58.32 21,275.00 3/8 234.00 336,960 84.24 30,731.00 --------------------------------------------------------------------------------------NOTE: Based on 100 PSI, $0.25 /mcf, 8760 hours / year

Questions on Leak Detection?

Other Uses for Ultrasonic Inspection



Electrical
Corona Tracking Arcing

Detecting Interference  Lubrication  Motor Testing  Complements Infrared



ELECTRIC INSPECTION


CORONA

TRACKING

ARCING

WHAT ULTRASOUND FOUND AND INFRARED MISSED

Here We See A 138KV Line In A Substation That Had a Wire That Was Corroded Due To Corona. It Broke Loose And Welded Itself Back To Another Point Due To The High Current Load. This Was NOT Detected By The System Monitors!!

OVER LUBRICATION


AN EXAMPLE OF:
OVER LUBRICATION BARE WIRE

Good

Bad Being Lubricated

Conclusion
 ULTRASOUND:

Versatile Simple to use Provides definitive data of air leaks Supports other technologies


QUESTIONS???

THANK YOU