1. Ultrasonic Leak Detection
Benefits, Usage and Evaluation
NP – 00E01561

2. Reginald Crowe
BSc Mechanical Engineering with Marine Engineering Option – University of Surrey, UK
35 years design and manufacture of industrial material handling equipment
Professional Engineer (MI) – 1980
RETAP Analyst for 3 years

3. Ultrasonic Technology
Offers many opportunities to dramatically cut energy consumption, improve bottom line, and improve “carbon footprint”
Four common areas are
Compressed air leaks
Steam leaks, .i.e. traps
Valves inspection
Motor/bearing wear
Electrical fault detection
Mechanical efficiencies
[NOTE: Electrical faults, motor/bearing wear and steam trap inspection works well in conjunction with infrared thermography]
Ultrasound detection is a cost effective, accurate and safe method for locating sources of energy waste and for preventing unplanned downtime

4. Ultrasonic Leak Detection
UE Systems Ultraprobe 3000SC (UP-3000SC) is a digital ultrasonic inspection, information, storage and retrieval system in a pistol-grip housing
UP-3000SC can quickly and accurately locate potential problems

5. UP-3000SC Features include: Wide, dynamic sensitivity range
“Spin and Click” operations to customize inspection modes, store and view data, and adjust instrument settings
Easy-to-read display panel with calibrated decibel readout
400 memory locations hold all of test data
Scanning and stethoscope plug-in modules for coarse to fine detection

6. Ultrasonic Leak Detection
What produces ultrasound in a leak
Gas passing through a restricted orifice (leak) moves from pressurized laminar flow to low pressure turbulent flow
Turbulence creates broad spectrum of sound called “white noise”
Some components of “white noise” are ultrasonic
Detection of these signals is usually simple to detect
UP-3000SC can sense any type of gas leak

7. Compressed Air: The Problem
Compressed air isn’t free
Compressed air accounts for 10% of all electricity used in U.S. manufacturing industries
Average facility loses an average of 30% of its compressed air to leaks
Much is undetectable by ear, to touch or sight
As of the end of 2007, the DOE reported that as many as 57% of facilities have taken little or no action to fix this problem

8. Leak Detection Survey
Walk through the plant – pay attention to obvious problems such as loud leaks you can spot and tag without the aid of an ultrasonic detector
Determine the best route for the inspection
Use the Ultraprobe to scan for leaks. Always wear the headphones during scanning.
Start at the compressor/supply side and work to the use side
Create a series of inspection “zones” to ensure all sections are covered
Tag all leaks

9. Leak Detection Survey (cont’d)
Be ready to fix as you go – a lot can be repaired on the spot
Test all leaks after they have been repaired
Calculate your savings
Report the results – let management know how much money you are saving
Maintain a program to reduce compressed air use and eliminate the use of unneeded compressors

10. Incorporating Ultrasonic Leak Detection into an Assessment
During the Onsite Assessment:
Assessment team determines if there are opportunities for locating and quantifying compressed air leaks. “Listen for Leaks”
Completes data collection checklist as needed, for example:
Air compressor system identifier
Compressed air system operating pressure
Operating hours per year
Data collection (see next page)

11. How to Locate an Air Leak
Use the UP-3000SC SCANNING MODULE, while wearing the headphones
Start off with sensitivity at Maximum (70)
Begin to scan by holding in the module “trigger”, pointing the module towards the test area
Adjust the sensitivity down if the ultrasound level is too high to tell the direction of the leak
Go from the “gross” (highest sensitivity) to the “fine “ (lowest sensitivity)
Move closer to the test area as you scan
Continue to make adjustments with the sensitivity to determine the direction of the leak sound
If necessary, place the RUBBER FOCUSING PROBE over the scanning module and get closer to the test area

12. Locating a Leak (cont’d)
Listen for a “rushing” sound while observing the meter dB display
Follow the sound to the loudest point. The meter will show a higher reading as the leak is approached
Adjust the sensitivity setting and move the instrument closer to the suspected leak site until you are able to confirm the leak
When loudest point has been determined position the module about 12 inches back and press down on the “sensitivity control/storage entry” dial to store the dB data. The screen will note that the “Record is Stored” and location number.
Repeat the process for other suspected leaks and store the reading in the UP-3000SC Storage Location for each leak found

13. Incorporating Ultrasonic Leak Detection into the RETAP Assessment
After the Onsite Assessment
Download data from UP-3000SC into the DMS software to calculate leak cost, size of leak and energy avoidance, such as – CO2, NO and SO2.
Note savings opportunities in the report

14. Example
Show how the dB readings are converted into quantified results (See the DSM software)

15. Based on 100 psig, $0.18/MCF, 8,760 Hours/Year
Air Leak Costs
Diameter OfLeak
Cubic Feet/Minute
CubicFeet/Day
Loss/DayDollars
Loss/MonthDollars
Loss/Year Dollars
1/64″
.45
576
$0.10
$3.15
$38.00
1/32″
1.60
2,304
$0.41
$12.60
$151.00
3/64″
3.66
5,270
$0.95
$28.85
$346.00
1/16″
6.45
9,288
$1.65
$50.50
$610.00
3/32″
14.50
20,880
$3.75
$114.30
$1,372.00
1/8″
25.80
37,152
$6.70
$203.40
$2,441.00
3/16″
58.30
83,952
$15.10
$459.60
$5,516.00
1/4″
103.00
148,320
$26.70
$812.00
$9,745.00
5/16″
162.00
233,280
$42.00
$1,277.00
$15,326.00
3/8″
234.00
336,960
$60.65
$1,844.85
$22,138.00
Based on 100 psig, $0.18/MCF, 8,760 Hours/Year

16. Useful Links Ultraprobe 3000
Plant Reliability & Ultrasound Technology Resources
NP – 00E01561