Ultrasound World IV (2008)

Ultrasound World IV Program Abstracts
The Ultrasound World IV program was full of exciting presentations packed with useful information. Here is a selected sampling of Presentations that were offered throughout the conference. 
 

Abstract:  We'll explain how we started our ultrasound program and the benefits we've experienced. Using visual and audible examples we will show how ultrasound technology is used in our plant to identify specific problem areas, repair those areas while avoiding catastrophic failure and how it has improved cost savings in plant downtime..

Ultrasound technology has become an integral part of the predictive maintenance program at the Armstrong in Pensacola Florida plant.  Implementing the technology required a "buy-in" from upper management and since then we now have 3 certified technicians.  The success of this program has influenced 5 other Armstrong plants to initiate an ultrasonic PdM program.

Abstract: Ultrasound is growing into an integral part of our maintenance activities.  I would like to share with you many case studies of how the technology has detected the onset of lubricant degradation, the onset of mechanical failure, and the workflow that integrates ultrasound with vibration, and Infrared.

Every plant environment is a little bit different, and it will take experimentation to understand the proper fit of ultrasound into your maintenance culture.   The strategy of implementing Ultrasound in our plant is reaping benefits in many ways.  We gained benefit from a dollars and cents standpoint, but also from improving teamwork and communication between the operations, maintenance, and engineering teams.

My goal is to share with you not only how the technology works, but also the power in sharing this diverse technology with a wide range of individuals to leverage the Return on Investment, (ROI).

Abstract: Ultrasound predictive maintenance is a cost effective approach to preventing unplanned downtime and improving equipment efficiencies.  For years Panama Ports had no organized predictive maintenance program.  This paper will describe how Panama Ports used ultrasound technology as part of a predictive maintenance program that has resulted in many thousands of dollars in savings on equipment, stocking of parts, improved efficiencies, extended life expectancy and asset availability.  Examples will demonstrate how we were able to improve bearing lubrication procedures, trend and analyze faulty bearings along with some unexpected side benefits that include parts stocking efficiencies and lubricant usage.

Abstract: We have a great number of technologies to choose from when it comes to nondestructive testing. Each of these technologies is fantastic on their own for troubleshooting; however, each and every one has its limitations.

While performing an electrical inspection there will be times that if you are using only one source to do the inspection, you very well could miss a dangerous potential problem.

Ultrasonic emissions from electrical apparatus have a very distinctive sound due to the unique characteristics of the electrically-induced ultrasonic emissions. An increased diagnostic capability results when ultrasonic detection is used together with infrared thermography.

In this session we will discuss using ultrasound and infrared thermography together in performing an electrical inspection survey. 

Presenter: Joseph D. Gierlach Jr., Vice President, Technical Training and Support, TEGG Corporation, Pittsburgh, PA. 
Presentation: What you can't hear, can hurt you!. All sound is not created equal and we must make distinctions  

Abstract: Ultrasonic testing has been around for many years throughout different disciplines and industries. With its unique ability to detect high frequency emissions well above the human range of hearing, it has allowed many to benchmark and identify problematic areas in many venues. Although no one system typically works without the other in most commercial and industrial facilities, there is a common component that is universally present and loss of it would result in EVERY system in a facility to cease. Electricity!

Without it, nothing works generally speaking. Despite beliefs that "there are no moving parts" in electrical systems, there are movements that occur 60 times every second! This creates "stresses" on components and can cause deterioration of conductors and insulators on low, medium, and high voltage items.

We will take a look at a few examples of where this technology has identified deficiencies in systems and prevented loss of electrical supply, as well as the necessary training to identify characteristic "footprints" of these deficiencies through spectral analysis.

Presenters:   Paul Payne  and  Kevin Whitehead, Senior Commercial & Industrial Technicians, Tennessee Valley Authority.
Presentation: "The Leaky Plant & How to Quantify What You Find"

Abstract:
· Typical Air System Components Within A Plant
· Why and How They Leak
· Reporting Leak Locations and Cost/Savings
· Recording and Quantifying Compressed Air Leaks So the Boss
  Can Understand It.

Paul will give a "heads-up" as to some of the typical issues associated with the compressed air components that inspectors will encounter in practically every plant.  Using actual defective components retrieved from plants, as well as pictures taken at various facilities, Paul will explain their operation within the system, where and why some of these components leak, and the reasoning as to why the leaks need to be reported in a clear and concise manner. Paul will conclude by pointing out a few safety issues when shooting a plant. 

Building on Paul's presentation on leak components, Kevin will demonstrate how to use EPRI's, Compressed Air Survey software in conjunction with an Excel spreadsheet he developed for reporting and tracking compressed air leaks.  Using examples from Paul's talk, a "sample report" will be developed in 'real-time' to show the audience the importance of accurate and concise recording.  Hand-outs of the spreadsheet will be provided to the audience to follow along. 

Presenters:  Don & Darrel Adams, Northwestern, Inc.
Presentation: "Continuous Steam Trap Management Program."

Abstract: This presentation will review the results of a current evaluation of steam traps using ultrasound in a board drying application.  Current data compared to historical data can reveal valuable information that through analysis can help reduce energy cost and help management make proper decisions about frequency of testing to improve equipment performance.

Considering today's energy costs, every manager is on the lookout for ways to increase the efficiency of their steam system while reducing expenses and loss of energy.  Monitoring and evaluating steam traps using a systematic steam trap management program is the most productive way to maximize the potential of a facility's heating and processing systems while decreasing shutdowns and maintenance costs.  According to the U.S. Department of Energy, facilities that do not participate in an ongoing steam trap management program retain leakage in 20% of all traps in service; and, because many steam traps fail open, losses from failed traps can be significant. Software such as uCanKnow continuous steam trap management program can provide the solutions you need before these threatening problems become disruptive to productivity, causing loss in both time and money. 

Abstract: Ultrasonic air leak detection has been used successfully for many years to find and quantify leaks in reticulated gas systems, with the "Guess-timator" charts proving to be a useful guide in the estimation of overall leak rates. As the name implies this method has only ever been a gross approximation due to the many variables that determine the level of ultrasound generated by any given leak. To this end an improved leak rate estimation process has been developed to better account for the key variables affecting the leak rate and the corresponding ultrasonic sound level. Additional useful information will also be presented relating to loss rates based on real world case studies rather than the standard orifice data which in many cases overstates the actual leak rate encountered.

The application of the new leak estimation process and software tools to streamline leak surveys will also be presented in the form of case studies from both Australia and New Zealand.

Abstract: If used properly, ultrasound instruments can provide valuable information to plants in determining grease volumes for bearings and grease components. In an actual plant application the portable instrument provided the information to calculate the exact volume of grease to maintain a film for maximum bearing life. With this tool, as with all predictive tools, understanding how to effectively use them maximizes the cost benefit.

What is the most effective method for applying grease to a bearing? Most bearings generally need a constant film of lubricant in the range of 2-10 microns. The film of lubricant prevents the rotating elements from making metal-to-metal contact.  This presentation will discuss how our plant moved from scheduled lubrication (preventive scheduling) to condition-based lubrication using a specialized ultrasonic grease level instrument.  The method and results will be explained in detail. 

Abstract: To answer the question "why are we still having lubrication related failures?" maintenance and reliability professionals often times find themselves digging through RCFA' s, the CMMS, and other documentation in search of a predominant causal factor. Some of the most often overlooked modes of failure are incorrect lubricant applied, insufficient lubrication, or over lubrication. The fact is the very detailed nature of an effective and successful lubrication program necessitates the utilization of a detail oriented, highly skilled, conscientious resource. As important is the implementation of a color coding system that insures proper lubricant selection.

But what about the insufficient or over lubrication issue?

In the hands of a trained, conscientious craftsman an ultrasonic listening device is a valuable resource that enables the user to insure the " right" amount of lubricant is used when servicing the asset. Simply by listening to the assets ultrasonic frequencies as interpreted by the ultrasonic listening device, the user can take a proactive approach to eliminating the root causes of over or under lubrication in rotating assets, while also identifying defects in the early stages of failure, thereby allowing the maintenance department to plan and schedule the appropriate defect elimination strategy.

This presentation will provide details about the use of common sense practices for implementation of a successful lubrication program.