It’s a fact, all machines fail. The thing is, how do you go about predicting machinery failure, so that you can deal with unplanned stoppages on your terms?
You need a solution that helps predict those failures early on. A condition monitoring device with the functionality to go about plannned and off plan routines and which provides you with an early warning alarm, so that you can schedule maintenance tasks to fit in with production loads. SDT helps you take control of your assets.
The SDT270 ultrasound detector provides greater insight into the health of your assets. Whether it’s in the form of equipment failures, unplanned production downtime or costly, last-minute repairs, the SDT270 helps you maximise uptime, minimise costs and maintain control of your assets.
Our products have flexible features that enable us to tailor a package to suit your budget & specific needs.
Downtime is a constant threat to any business. The SDT270 Ultrasound Detector identifies reliability problems and assists in the reduction of your energy costs. Whether it’s in the form of equipment failure, unplanned production downtime or costly, last-minute repairs, you need a device that helps you maximise uptime, reduce costs and maintain control of your assets.
Preserve the health of your assets with the SDT270 ultrasound detector. Hear air leaks, trend and monitor the condition of your bearings, safely inspect electrical panels and schedule repairs on your own terms, long before they shut you down – all with ultrasound technology.
Industry runs on machinery. Bearings, pumps, electric motors, compressors, presses, gearboxes and much more. All of which can break unexpectedly, causing plants to stop. When production stops your business loses money.
Few bearings make it to the end of their engineered lifecycle. This is can be due to poor workmanship, bad lubrication practices or neglect. Problems can even arise right after installation due to poor installation of the machine.
No two machines are the same. Across industry, machines operate under different loads, climates and conditions, making their maintenance requirements unpredictable. Many machines are still maintained on calendar based PM’s, while others are run-to-fail. Both strategies are wasteful. There has to be a better way.
Poorly Maintained Equipment leads to Catastrophic Failures. Without regular inspections and condition monitoring, there’s no way of knowing the exact condition of your assets. Unexpected machine breakdowns sneak up on you, threatening your bottom line, the environment and worst of all, workers’ safety.
Downtime is expensive, and that cost is amplified when it is unplanned. With a condition monitoring program, asset health is trended and analysed to anticipate and plan for future failures.
Few bearings make it to the end of their engineered lifecycle. This is due to poor workmanship, bad lubrication practices and neglect. Problems can even arise, right after commissioning because of poor installation.
No two machines are the same. Across industry, machines operate under different loads, climates and conditions, making their maintenance requirements different. Many machines are still maintained on calendar based PM’s, while others unbelievably still use run-to-fail methods. Both strategies are wasteful. There has to be a better way.
Bearing Condition Monitoring
Why you should use Ultrasound for Mechanical Inspection? Ultrasound detects friction, impacting and turbulence, earlier than any other condition monitoring technology.
Bearing defects cause friction and impacting. Lubrication issues, whether it’s under or over lubrication, cause increased bearing friction and eventually impacting. These faults are detected early on in the failure mode through ultrasound waveforms, well before the bearing reaches the point of no return. This means that corrective maintenance can be planned, to restore the bearing and plant health status, in a timely and orderly fashion.
Ultrasonic detection is now recognised to be a decisive strategic priority. It avoids numerous unexpected incidents which are usually very costly and contributes to the improvement of the quality of your production as well as output.
Compressed air is one of the three highest cost utilities in use at a plant. It is also one of the least maintained in terms of system leaks. Leaks are expensive and wasteful, but most often ignored. Finding and fixing leaks is an easy way to reduce energy costs but finding them is not easy because of background noise. A good quality ultrasonic detector can hear leak turbulence despite the ambient noise of the factory floor. The high frequency component of a leak is directional making it easy to locate its source.
Like compressed air leaks, vacuum leaks can cause grief for manufacturers who rely on negative pressure for their processes. Vacuum leaks represent energy waste but they also affect product quality. Methods for finding vacuum leaks are similar to those used for positive pressure leaks. Since the turbulent flow produced by the leak is drawn inward, finding these leaks requires the inspector to be much closer to the leak source. In many instances vacuum leaks are found using the RS1 Needle Contact Probe.
Any gas under pressure will produce turbulent flow at the leak site making it detectable with airborne ultrasound inspection. To help start, maintain, or regenerate your leak detection program we’ve posted resources that you can read online or download.
Ultrasound is best for Monitoring Steam Traps
Steam is a gas and as it flows through piping and steam traps there is turbulent flow, or lack thereof. Ultrasound technologies ability to detect turbulence, even through thick piping makes it an essential tool when looking for faulty, failed steam traps.
How to Detect a Failed Steam Trap
Ultrasound technology is the perfect tool for detecting failed steam traps as faults can be found while the system is online. With an ultrasound detector you can hear:-
Your maintenance teams goals in regards to the steam system should include:-
Detect Valve Leaks and Blockages, Maintain Flow, Prevent Waste.
Valves play a crucial role in the transportation of gas, oil and water throughout your plant. They start and stop flow while also preventing backflow and regulating flow and pressure.
Internal & External valve leaks are a threat to your process, find them with SDT270.
They can be found in the hundreds and even thousands at large facilities. Steel, pulp, food and pharmaceutical as well as other industrial facilities installed on their pipes. When valves fail or leak it will result in the loss of energy, product quality and can also lead to potential downtime.
Whether it’s internal or external leaks, or issues with flow regulation, valve leaks are a threat to your factory processes. A major component to a plants efficiency is valves operating properly. Ultrasonic inspection can quickly identify function and malfunctioning valves. So they can be tagged and repaired quickly to avoid, diminished production.
Industrial plants require a lot of power to operate and much like the machinery required for production, their electrical systems can also fail. When they do, the results pose tremendous threats to production and the safety of everyone within the facility.
Maintaining your Electrical Systems
The implications of total electrical system failures are far more severe than that of an ordinary mechanical failure. They have the potential to damage equipment, cut power flow and cause downtime for days, seriously injure workers in the immediate vicinity and even impact the surrounding area’s power grid.
Detecting electrical faults with equipment, especially arc flash is best done combining both infrared and ultrasound technology. Both technologies have their strengths when it comes to fault detection but ultrasound excels at detecting faults long before infrared would be able to.
Unlike electrical infrared thermography inspection, ultrasound devices can detect discharges in their earliest stages, long before they begin to generate heat.
Ultrasound Based Condition Monitoring
Ultrasound is a versatile technique that allows to detect problems and failures linked to friction, impact or turbulent flow.
With ultrasound, incipient failures can be identified at a very early stage and, well before other commonly used techniques, it can provide indications of deterioration or risk of upcoming failure.
As such, any well-balanced condition monitoring program should have ultrasound in the toolbox. The correct use of ultrasound allows for better planning of maintenance tasks but will also extend service life, avoid downtime and add reliability to a wide variety of shipboard equipment in an easy, quick and cost-effective manner.
Why using ultrasound on board ships?
The business model of shipping is to transport cargo from A to B and to deliver the cargo on time and in good condition.
In shipping, reliability of main engines and generators (and perhaps some critical equipment) is more and more being covered by a condition monitoring strategy.
The vast majority of “secondary” equipment, however, is generally not included in a condition monitoring program, whilst outage of this “secondary” equipment (e.g. hatch covers, mooring & cargo winches, cargo pumps, valves, cranes, heating and cooling equipment, safety equipment), may result in a commercial disaster through delays, cargo damage and consequent claims.
Ultrasound condition monitoring is easy, quick and simple. Data can be evaluated instantaneously, by the on-board team, and relayed to management allowing for very efficient and well-informed decision making.
Reveal leaks in underground storage tanks.
The ability to test for tightness with an ultrasound detector is extremely powerful and versatile. It is the only way to ensure that underground storage tanks are air tight.
But that isn’t all that ultrasonic tightness testing can be used on. There are many things that need to be air tight. Like the engine or cabin of a car, large shipping containers or the bearing housing in a paper production plant.
When something’s tightness integrity deteriorates, one or two things can happen. Media can leak out, or things can get in. And whenever possible, it is advantageous to avoid either one of these from happening.
Fuel leaking from underground storage tanks damage the environment and waste valuable resources. Overtime the tightness integrity of underground storage tanks or other air tight compartments can deteriorate, or, they were never air tight to begin with.
This is why tightness testing is an essential maintenance task to be carried out on underground storage tanks to prevent wasteful, harmful to the environment leaks.
Underground tanks can prove tricky to test for tightness integrity due to their inaccessibility. But this shouldn’t affect the frequency and the thoroughness they are inspected with. Leaking underground storage tanks result in contamination of the surrounding soil, groundwater and surface water. Not to mention, the loss of resources through the leak.
How SDT Tank Testing Method Works
SDT’s BiSonic Transmitter is at the heart of our tightness tests. The transmitter emits ultrasonic signals that fill the space that needs to be tested. If there are any flaws in the containers tightness these are detected immediately.
Scan seams & seals to verify tightness in vehicles, clean rooms & buildings.
Tightness integrity is an issue that plagues every industry. SDT270 is an ultrasound solution focused on pinpointing leaks in any volume. Cars, trains, airplanes, buildings, cleanrooms etc.
SDT270 is easy to use. Simply open the box, position the T-SONIC1, seal the volume and listen for leaks. SDT270 pinpoints even the smallest leaks.
Use SDT270 to pinpoint the exact location of leaks in vehicles, buildings, tanks and ships. Designed for use with SDT’s ergonomic Flexible sensor and compact T-Sonic1 transmitter, leak detection has never been easier.
Our products have flexible features that enable us to tailor a package to suit your budget & specific needs.
Fixturlaser UK offers full technical support and training on all of our products. Training can be arranged to be carried out at our premises or yours. Contact us for more details.
Fixturlaser Guide-U™ is our unique icon based user interface that guides the mechanic throughout the alignment process, zero text, no confusion. Press the icon of choice and follow the screen prompts. There are no text barriers or confusing tree sub-structures cluttering the mechanic’s path to ensuring precision shaft alignment each and every time.
With Fixturlaser True Position Sensing, no re-measurement or additional rotation of the machine train, in between adjustments, is necessary. You can see exactly how much your remedial actions are moving the machine, live. TPS™ is accurate & innovative, ensuring the quickest response time between machine failure & getting your machine back on-line.
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Phone: 01909 251001