COURSE OVERVIEW:

Ultrasound technology has emerged as a premier tool for early-stage fault detection, offering the ability to "hear" mechanical and pressurized system defects long before they are visible or audible to the human ear. This course explores the physics of high-frequency sound waves and their practical application in identifying friction, turbulence, and ionization in industrial environments. Participants will examine how ultrasonic sensors translate inaudible signals into decibel levels and sound files that reveal the health of critical plant assets.

The scope of this training focuses on the two primary pillars of industrial ultrasound: bearing health monitoring and leak detection. We will investigate the specific acoustic signatures of failing rolling element bearings, focusing on the detection of lubrication starvation and early-stage fatigue cracks. The curriculum covers the systematic approach to compressed air and vacuum leak surveys, emphasizing the quantification of energy losses and the significant cost savings associated with timely repair.

Coverage also includes the use of ultrasound for electrical inspection, such as detecting corona, tracking, and arcing in high-voltage cabinets. By focusing on the integration of digital ultrasound data with other condition-based maintenance (CBM) technologies, the course provides a comprehensive methodology for modernizing asset management. Through this detailed study, attendants will gain the expertise necessary to conduct precision audits, diagnose complex mechanical issues, and enhance the overall energy efficiency and reliability of their facility.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the fundamental principles of acoustic emission and ultrasound.
2. Operate various types of ultrasonic detectors and data loggers.
3. Differentiate between airborne and structure-borne ultrasonic signals.
4. Identify early-stage bearing failures through decibel trending.
5. Utilize ultrasound to prevent over-lubrication and under-lubrication.
6. Conduct comprehensive compressed air and steam leak surveys.
7. Quantify the financial impact of detected leaks based on flow rates.
8. Detect internal valve leakage and steam trap malfunctions using ultrasound.
9. Inspect electrical systems for corona, tracking, and arcing.
10. Utilize spectral analysis of recorded sound files for fault diagnosis.
11. Develop a standardized ultrasound inspection route for plant assets.
12. Establish baseline ultrasonic levels for new and refurbished equipment.
13. Integrate ultrasound findings into a multi-technology reliability report.

TARGET AUDIENCE:

This course is designed for Maintenance Technicians, Energy Auditors, Reliability Engineers, Lubrication Specialists, and Mechanical Inspectors.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.