Ultrasound Inspection for Predictive Maintenance: The 8 Pillars

Что такое ультразвуковая инспекция?

Ультразвуковая инспекция (Ultrasound Testing) — это неразрушающий метод контроля, который использует high-frequency sound (20-100 kHz) для:

• Обнаружения утечек сжатого воздуха и газов
• Механической диагностики (подшипники, насосы)
• Электрической инспекции (коронные разряды, дуги)
• Проверки оборудования (клапаны, паровые ловушки)

Как это работает?

Принцип действия

1. Turbulence и friction создают ultrasound
2. Ультразвуковой sensor "hears" эти sounds
3. Signal преобразуется в audible range
4. Operator interprets sound и intensity

Частотный диапазон

Тип звука	Частота	Обнаружение
Аудио	20 Hz - 20 kHz	Human hearing
Ультразвук	20 - 100 kHz	Ultrasound testing

Ультразвук выше, чем normal background noise, что позволяет pinpoint проблемы.

8 Столпов ультразвукового тестирования

SDT выделяет 8 основных применений:

1. Механический мониторинг {: style="max-height: 40px; width: auto;"}

Обнаруживает: Подшипники, шестерни, насосы, вентиляторы

Методика:

• Contact sensor на housing
• Listen для changes в sound
• Compare с baseline или etalon

Indicators:

• Smooth humming = Normal
• Grinding/rattling = Defect
• Increased intensity = Worsening

2. Смазка подшипников {: style="max-height: 40px; width: auto;"}

Проблема: Over-lubrication так же вредна, как under-lubrication

Решение: LUBExpert или manual method

Метод:

1. Measure before lubrication
2. Lubricate while listening
3. Stop при optimal level
4. Verify после

3. Утечки сжатого воздуха {: style="max-height: 40px; width: auto;"}

Типы утечек:

• Connection leaks
• Valve leaks
• Seal leaks
• Hose ruptures

Методика:

• Scan area с airborne sensor
• Follow sound to source
• Tag и document
• Calculate loss

4. Электрические дефекты {: style="max-height: 40px; width: auto;"}

Обнаруживает:

Тип	Ultrasound Signature
Corona	Steady, continuous buzzing
Tracking	Intermittent cracking
Arcing	Loud, irregular pops

Safety: Scan с safe distance!

5. Паровые ловушки {: style="max-height: 40px; width: auto;"}

Условия:

Condition	Sound	Temperature Δ
Working	Intermittent click	Hot inlet, warm outlet
Failed Open	Continuous steam	Same temp both sides
Failed Closed	Silence	Cold outlet

6. Гидравлические системы {: style="max-height: 40px; width: auto;"}

Обнаруживает:

• Fluid leaks в valves и cylinders
• Internal bypass
• Cavitation

Equipment: Same detectors как для air leaks

7. Клапаны {: style="max-height: 40px; width: auto;"}

Types проверяемых valves:

• Control valves
• Safety relief valves
• Check valves
• Solenoid valves

Method:

• Upstream/downstream comparison
• Listen для internal leakage
• Verify proper operation

8. Герметичность {: style="max-height: 40px; width: auto;"}

Применения:

• Ship hatch covers
• Bulk storage tanks
• Clean rooms
• Pharmaceutical isolators

Method: Ultrasound transmitter + receiver

Оборудование

Entry Level: SDT200

Features:

• Basic ultrasound detection
• Headphones для listening
• Analog output
• Simple, intuitive

Best for:

• Leak surveys
• Basic inspections
• Training

Mid Level: SDT270

Features:

• Digital recording
• FFT spectrum
• Data logging
• SD card expansion
• UAS3 compatible

Best for:

• Data collection
• Trend analysis
• Documentation

Advanced: SDT340

Features:

• Multiple sensors (US + vibration)
• Built-in IR thermometer
• Tachometer
• Bluetooth HD headphones
• focUS Mode (up to 256 kHz)

Best for:

• Comprehensive PdM program
• Complex diagnostics
• Multi-parameter monitoring

Методика инспекции

Pre-Inspection

1. Plan route — know what to inspect
2. Charge equipment — ensure batteries ready
3. Check settings — verify sensitivity
4. Review history — check previous findings

During Inspection

1. Scan systematically — follow your route
2. Listen carefully — train your ear
3. Document findings — note all issues
4. Tag problems — mark for follow-up

Post-Inspection

1. Download data — transfer to software
2. Analyze trends — compare с previous
3. Generate reports — communicate findings
4. Plan actions — schedule repairs

Interpretation Sounds

Common Sounds

Sound	Indication
Smooth rushing	Normal turbulence
Intermittent clicks	Working steam trap
Continuous hissing	Leak
Buzzing	Electrical corona
Cracking	Electrical tracking
Grinding	Mechanical wear
Rattling	Loose component

Training Tips

1. Start simple — learn obvious leaks first
2. Build a library — record reference sounds
3. Compare similar — compare like machines
4. Use spectrum — FFT helps visualize
5. Get certified — formal training helps

Building a Program

Phase 1: Assessment (Month 1)

• Baseline survey
• Identify critical equipment
• Set priorities
• Calculate potential savings

Phase 2: Pilot (Months 2-3)

• Select pilot area
• Train team
• Implement routine inspections
• Document results

Phase 3: Rollout (Months 4-12)

• Expand to other areas
• Integrate с CMMS
• Standardize procedures
• Continuous improvement

Phase 4: Optimization (Year 2+)

• Add permanent monitoring
• Advanced diagnostics
• Predictive analytics
• Industry best practices

ROI Calculator

Typical Savings

Application	Avg. Savings	Payback
Leak Detection	$15,000/100 traps	<3 months
Bearing Lubrication	50% grease reduction	<6 months
Steam Traps	$2,000/trap/year	<2 months
Mechanical	Prevent 1 failure/year	Immediate

Investment Range

• SDT200: $3,000-5,000
• SDT270: $8,000-12,000
• SDT340: $15,000-20,000
• LUBExpert: $10,000-15,000
• Software: $2,000-5,000

Typical ROI: 3-12 months

Resources

Training

• SDT Level 1 Certification
• SDT Level 2 Certification
• Online courses
• On-site training

Software

• UAS3 — data management
• LEAKReporter — leak surveys
• SHERLOGReporter — hatch testing

Standards

• ISO 17359 — Condition monitoring
• ISO 18436-8 — Ultrasound testing

Conclusion

Ультразвуковая инспекция — versatile, cost-effective tool для predictive maintenance. Starting simple (SDT200) и progressing (SDT270/340) позволяет build comprehensive program.

Key success factors:

1. Proper training
2. Consistent methodology
3. Data documentation
4. Management support
5. Continuous improvement

Ready to start? Contact us для consultation!