Machinery Fault Detection Through Ultrasound Technology

Abstract

Ultrasound is a versatile advanced technology that is utilized in the oil and gas industry for various mechanical and electrical applications such as bearing's faults detection, pump's cavitation, valve's leakage, steam traps, electrical faults, gearbox's issues, compressed air and gas leak's detection..etc. The technology allows the end-user to measure dynamic data using contact (Structure borne) and non-contact (air borne) sensors and converts the ultrasound waves to an audible range for humans to associate sounds with the measured signal. As a result, the sound of the machine can be heard and recorded as voice clip as well as time wave form, which in turn can be translated into frequency spectrum for analysis. The technology has recently evolved in the industry as an important condition monitoring tool, to increase the reliability of rotating equipment. Moreover, it used as a complementary tool to vibration analysis. As well, it can be used as a tool for troubleshooting and preventive maintenance inspection. Ultrasound is sound waves with frequencies that are higher than the upper audible limit of human hearing. The human hearing limit varies from person to another, and it is approximated to be around 20Hz to 20 kHz. This is in contrary to the ultrasound range, which is above 20,000 Hz, and hence, it is in audible to human. This range is used widely in various industrial processes, including: cleaning, cutting, forming, testing of materials, and welding. It is characterized by its directional waves, unlike normal sound waves that travel in all directions. This directional characteristic makes ultrasound useful for many applications. Furthermore, ultrasound technology is used in different fields: medical, automotive, etc. and recently in the oil and gas industry as non-destructive-testing tool (NDT). Leak detection. Steam traps inspection. Bearing condition monitoring. Bearing lubrication monitoring. Electrical Inspection. Valve condition monitoring. Pump cavitation. Gearbox issues.