UE Systems Ultraprobe 100 User manual

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ULTRAPROBE®100
Instruction Manual

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SafetyAdvisory
Please read before using your instrument
WARNING
Improper use ofyour ultrasonic detectormay result in death orserious injury. Observe all
safety precautions. Do not attempt to make any repairs or adjustments while the equipment
is operating. Be sure toturn off and LOCK OUT all electrical and mechanical sources before
performing any corrective maintenance.Always refer to local guidelines for appropriate
lockout and maintenance procedures.
Safety precaution:
Although your ultrasonic instrument is intended to be used while equipment is operating, the
close proximity of hot piping, electrical equipment and rotating parts are all potentially
hazardous to the user. Be sure to use extreme caution when usingyour instrument around
energizedequipment. Avoid direct contact with hot pipes or parts, any moving parts or
electrical connections. Do not attempt to check findings by touching the equipment with your
hands or fingers. Be sure to use appropriate lockout procedures when attempting repairs.
Be careful with loose hanging parts such as the wrist strap or headphone cord when
inspecting near moving mechanical devices since they may get caught. Don't touchmoving
parts with the contact probe. This may not only damage the part, but cause personal injury
as well.
When inspecting electrical equipment, use caution. High voltage equipment can cause
death orsevere injury. Do not touchlive electrical equipment withyour instrument. Use the
rubber focusing probe with the scanning module. Consult with your safety director before
entering the area and follow all safety procedures. In high voltage areas,keep the
instrument close to your body by keeping your elbows bent. Use recommended protective
clothing. Do not getclose to equipment. Your detector will locate problems at a distance.
When working around high temperature piping, usecaution. Use protective clothing and do
not attemptto touch any piping or equipment while it is hot. Consult with your safety director
before entering the area.

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The Ultraprobe 100..................................................................................................5
Components ...........................................................................................................6
Metered pistol housing .........................................................................................6
Bargraph Display..................................................................................................6
Battery Level Light................................................................................................6
Sensitivity Selection Dial........................................................................................6
Head Set Jack.......................................................................................................6
Trigger Switch......................................................................................................6
Scanning module..................................................................................................7
Rubber focusing probe: .........................................................................................7
Contact Stethoscope module .................................................................................8
Headset..............................................................................................................8
Premium Kit ........................................................................................................8
WTG-1 warble tone generator (premium kit)............................................................8
To use the WARBLE TONE GENERATOR:...................................................................9
To charge the Warble Tone Generator:....................................................................9
Ultraprobe applications ..........................................................................................10
leak detection....................................................................................................10
How to locate leaks ............................................................................................11
To confirm a leak:...............................................................................................11
Overcoming difficulties .......................................................................................11
Shielding techniques ...........................................................................................12
Low level leaks...................................................................................................12
Tone test (Ultratone ) .........................................................................................13
Do not use the Tone test in a complete vacuum......................................................14
Electric arc, corona, tracking detection .....................................................................15
Detecting bearing wear.......................................................................................16
Detecting bearing failure.....................................................................................17
For comparative test...........................................................................................17
Slow speed bearings ...........................................................................................17
General mechanical trouble shooting ....................................................................18
Trouble shooting ................................................................................................18
Locating faulty steam traps..................................................................................18
General steam/condensate/flash steam confirmation .............................................19

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Inverted bucket traps..........................................................................................19
Float and thermostatic........................................................................................19
Thermodynamic.................................................................................................19
Thermostatic traps .............................................................................................20
Locating faulty valves..........................................................................................20
Procedure for valve check:...................................................................................21
Confirming valve leakage in noisy pipe systems ......................................................21
Ultrasound technology ...........................................................................................22
Ultraprobe®100 Specifications................................................................................23

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The Ultraprobe 100
provides easy, accurate leak detection and mechanical inspection through
advanced ultrasonic technology.
Before you begin testing, it isadvisable to familiarize yourselfwith the basic components of
your kit.

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Components
Metered pistol housing
The main component of the Ultraprobe is its' pistol housing. From back to front, let's examine each
part.
Bargraph Display
The displayconsists of a ten segment LED bargraph that will indicate ultrasonic signal strength. A low
number of LEDs indicate a low level of ultrasound, conversely more intense ultrasonic signals will
display more LEDs.
Battery Level Light
This red light turns on only when the batteries needto be replaced.
NOTE: When the trigger on/off switch is pulled to the on position theBattery Level Light will flicker
on and then stay off. This is normal and has no relation to battery condition.
Sensitivity Selection Dial
There are eight (8)sensitivity levels which read out in related decibels of"0" to "70". As the dial is
turned to the right, to "0", the sensitivity ofthe instrument increases. As the dial is turned to the left,
to "70", the sensitivity decreases. A low level ultrasound emission produces low amplitude. For this
reason, the instrument should be in a high sensitivity position. 0 is the high sensitivity position. 0 is a
dB indication of threshold detection for the instrument. For higher amplitude signals, move the
sensitivity to the left towards "70". The dial dB indications, along withthe LED indications in the bar
graph may be usedto establishdB levels. To do this, just add 3 dB for each LED bargraph indication
to the dB level set in the sensitivity dial. EX: 0 dB on thesensitivity dial, plus 3 LED bargrah levels =
9dB (0+9). 40 dB on the sensitivity dial plus 4 bar graphs= 52 dB (40+12)
Head Set Jack
This is whereyou plug inthe headset. Besureto plug it in firmly until itclicks. Shouldatape recorder
be utilized, this is where thecord for the tape recorder is inserted. (Use a miniphone plug).
Trigger Switch
This is locatedon the underside ofthe Ultraprobe 100. The Ultraprobe is always "off" until thetrigger
switch is pressed. To operate, simply press the trigger; to turn the instrument off, release the trigger.

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Scanning module
This module is utilized to receive air-borne ultrasound such as the ultrasounds emitted by
pressure leaks and electrical discharges.
To use, make sure it is plugged in to the front end of the metered pistol housing by aligning the plug
with the receptical and inserting it firmly.
Scanning
Module
To use the Scanning Module:
1. Plug in to front end.
2. Start with the sensitivity selection dial at maximum (8).
3. Start to scan the test area.
The method of air borne detection is to go from the "gross to the fine". If there is too much ultrasound
in the area, reduce the sensitivity, place the RUBBER FOCUSING PROBE (described below) over the
scanning module and proceed to follow the test sound to its' loudest point. If it is difficult to locate the
sound due to a high intensity signal, keep reducing thesensitivity and following themeterto the
loudest point.
Rubber focusing probe:
The Rubber Focusing Probe is a circularshaped rubber shield. It is used to block out stray
ultrasound and to assist in narrowing the field of reception of the Scanning Module. It also
increases the sensitivity. To use,simply slip it over the front of the scanning module or the
contact module.
NOTE:To prevent damage to the module plug, always remove the module BEFORE
attaching and removing the Rubber Focusing Probe.

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Contact Stethoscope module
Contact Module
This is the module with the metal rod. This rod is utilized as a "wave-guide" that is sensitive to
ultrasound generated internally such as within a pipe, bearing housing, steam trap or wall. Once
stimulated by ultrasound, it transfers thesignal to a piezoelectric transducer located directly inthe
module housing.
To use the Stethoscope Module:
1. Align the pin located at the rear of the module with the jack in the front end ofthe Metered
Pistol Housing and plug in firmly.
2. Touch test area.
3. As with thescanning module, go from the "gross" to the "fine". Start a maximum sensitivity on
the Sensitivity Selection Dial and proceed to reduce the sensitivity until a satisfactorysound
and meter level is achieved.
Headset
Premium Kit
This heavy duty headset is designed to block out intense sounds often found in industrial
environments so that the user may easily hear thesounds received by the ULTRAPROBE. To use,
simply plugthe headset cord into the headset jack on the metered pistol housing, and place the
headphones over your ears. If a hard hat is to be worn, it is recommended to use UE Systems' model
UE-DHC-2HH Hard Hat Headphones which are specifically designed for hard hat use.
For those situations in which it is not possible or difficult to wear the standard headphones described
above, UE Systems has two options available:
1. the DHC 1991 Earpiece which loops around the ear, and
2. the SA-2000 Speaker Amplifier which is a loud speaker that is compatible with the
Ultraprobe headphone output jack.
WTG-1 warble tone generator (premium kit)
The WTG-1 Tone Generator is an ultrasonic transmitter designed to flood an area with ultrasound. It is
used for aspecial type of leak test. When placed inside an empty container or on one side of a test
item, it will flood that area with an intense ultrasound that will not penetrate any solid but will flow
through any existing fault or void. By scanning with theScanning Module, empty containerssuch as
pipes, tanks, windows, doors, bulkheads or hatchescan be instantly checkedfor leakage. This Tone
Generator is a WARBLE TONE GENERATOR. This internationally patented transmitter sweeps
through a number of ultrasonic frequencies in a fraction of a second to produce a strong, recognizable
"Warble" signal. The warble tone prevents a standing wave condition which can produce false
readings and provides for a consistency oftesting in practically any material.

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To use the WARBLE TONE GENERATOR:
1. Turn Tone Generator on by selecting either"LOW" for a lowamplitudesignal (usually
recommendedfor smallcontainers) or"HIGH" for high amplitude. In high, theWarble Tone
Generator will cover up to 113m³ (4,000cubic feet ) of unobstructed space. When the Tone
Generator is on, a red light (located below the recharge jack in the front) flickers.
2. Place the Warble Tone Generator within the test item/containerand seal or close it. Then scan
the suspect areas with the Scanning Module in the Ultraprobe and listen for where the"warble"
ultrasound penetrates. As an example, if the item to be tested is the seal around a window,
place theWarble Tone Generator on one side of the window, close it and proceed toscan on
the opposite side.
To test thecondition oftheWarble Tone Generator battery, set to the LOW INTENSITY position and
listen to the sound through the Ultraprobe headphones. Asmooth continuous warbling sound should
be heard. If a "beeping" is heard instead, then a full recharge of theWarble Tone Generator is
indicated.
To charge the Warble Tone Generator:
1. Use the recharger.
2. Plug the recharger cord into the recharge jack located on top of the front panel.
3. Plug the recharger into the local current supply
4. A completecharge will take 7hours.
5. Since there is no memory problem, the Tone Generator may be charged after short intervals
of use.
wtg1 warble tone generator (optional)

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Ultraprobe applications
leak detection
This section willcover airborne leak detection of pressure and vacuum systems. (Forinformation
concerned with internal leaks such as in Valves and Steam Traps, refer to the appropriate sections).
What produces ultrasoundin aleak?When a gas passes through a restricted orifice under pressure, it
is going from a pressurized laminar flow to low pressure turbulent flow. (Fig. 1). The turbulence
generates a broad spectrum ofsoundcalled "white noise". There are ultrasonic components in this
white noise. Since the ultrasound will be loudest by the leak site, the detection of thesesignals is
usually quite simple.
Figure 1: Pressure Leak
Figure 2: Vacuum Leak
A leakcan be in a pressurized system or in a vacuum system. In both instances, the ultrasound will
be produced in themanner described above. The only difference between the two is that a vacuum
leak will usually generate less ultrasonic amplitude than a pressure leak of the same flow rate. The
reason for this is that the turbulence produced by a vacuum leak is occurring within the vacuum
chamber while the turbulence of a pressure leak is generatedin the atmosphere. (Fig.2).
What type of gas leak will be detected ultrasonically? Generally any gas, including air, will produce a
turbulence when it escapes through a restrictedorifice. Unlike gasspecific sensors, the Ultraprobe is
sound specific.A gas specific sensor is limited to the particular gas it was designed to sense (e.g.,
helium). The Ultraprobe can sense any type of gas leak since it detects the ultrasound produced by
the turbulence of a leak.
Because of its versatility, the Ultraprobe may be utilized in a wide variety ofleak detection.
Pneumatic systems may bechecked, pressurizedcables, such as those utilized by telephone
companies, may be tested. Air brake systems on railroad cars, trucks, and buses may be checked.
Tanks, pipes, housings, casings andtubes are easilytested forleakage by pressurizing them.
Vacuum systems, turbine exhausts, vacuumchambers, material handlingsystems, condensers,
oxygen systems can all easily be tested for leakage by listening for the turbulence ofthe leak.

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How to locate leaks
1. Use the SCANNING MODULE.
2. Start off with the sensitivity selection at 0 (Maximum).
3. Begin to scan by pointing themodule towards the test area. The procedure is to go from the
"gross" to the "fine" - more andmore subtle adjustments will be made as the leak is
approached.
4. If there is too much ultrasound in the area, reduce thesensitivity setting and continue to
scan.
5. If it is difficult to isolate the leak due tocompeting ultrasound, place the RUBBER FOCUSING
PROBE over the scanning module and proceed to scan the test area.
6. Listen for a "rushing" sound while observing the meter.
7. Followthe soundto the loudest point. The meter will showa higher reading as the leak is
approached.
8. In order to focus in onthe leak, keep reducing thesensitivity settingand move the instrument
closer to the suspected leak site until you are ableto confirm a leak.
To confirm a leak:
Position the Scanning Module, or the rubber focusing probe (if it is on thescanning module) closeto
thesuspect leak site andmove it, slightly, back and forth, in all directions. If theleak is at this location,
the sound will increase and decrease in intensity as yousweep over it. In some instances, it is useful
to position the rubber focusing probe directly over the suspect leak site and push down to "seal" it from
surroundingsounds. If it is the leak, the rushing sound will continue. If it is not theleak site, thesound
will drop off.
Overcoming difficulties
Competing Ultrasounds
If competing ultrasounds make it difficult to isolate a leak, there are two approaches to be taken:
a) Manipulate the environment. This procedure is fairly straight forward. When possible, turn off
the equipment that is producing the competing ultrasound or isolate the area by closing a door
or window.
b) Manipulate the instrument and use shielding techniques. If environmental manipulation is not
possible, try to get as close to thetest site as possible, and manipulate the instrument so that
it is pointing away from the competing ultrasound. Isolate the leak area by reducing the
sensitivity ofthe unit and by pushing the tip ofthe rubber focusing probe upto the test area,
checking asmall section at a time.

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Shielding techniques
Since ultrasound is a high frequency, short wave signal, it can usually be blocked or "shielded".
NOTE:When using any method, be sure to follow your plant's or company's safety guidelines. Some
common techniques are:
1. Body: place your body between the test area and thecompetingsounds to act as a barrier.
2. Clip Board: Position theclip board close to the leak area and angle it so that it acts as a
barrier between the test area and the competingsounds
3. Gloved Hand: (USE CAUTION) usinga gloved hand, wrap thehand around the rubber
focusing probe tipso that the index finger and the thumb are close to the very end and place
the rest of the hand on the test site so that there is a complete barrier ofthe hand between the
test area and the background noise. Move the hand and instrument together over the various
test zones.
4. Wipe rag: This is the same method as the "gloved hand" method, only, in addition to the
glove, use a wipe rag to wrap around the rubber focusing probe tip. Hold the rag in the
gloved hand sothat it acts as a "curtain", i.e., there is enough material tocover the test site
focusing probe. This is ususally themost effective method since it uses three barriers: the
rubber focusing probe, the gloved hand and the rag.
5. Barrier:When covering a large area, it issometimes helpful to use some reflective material,
such as a welders curtain or a drop cloth, to act as a barrier. Place the materialso that it acts
as a "wall" between the test area andthe competingsounds. Sometimes the barrier is draped
from ceilingto floor, at othertimes, it is hung over railings.
Low level leaks
In ultrasonic inspection ofleakage, the amplitude ofthe sound often depends upon the amount of
turbulence generated at the leak site. The greater the turbulence, the louder the signal, the less the
turbulence, the lower the intensity ofthe signal. When a leak rate is so low that it produces little, if any
turbulence that is "detectable", it is considered "below threshold". If a leak appears to be ofthis
nature:
1. Build up the pressure (ifpossible) to create greater turbulence.
2. Utilize LIQUID LEAK AMPLIFIER. This patented method incorporates a UE Systems product
called LIQUID LEAK AMPLIFIER, orLLA for short. LLA is a uniquely formulated liquid
substance that has special chemical properties. Used as an ultrasonic "bubble test, a small
amount of LLA is poured over a suspected leaksite. It produces a thin film through which the
escaping gas will pass. When itcomes in contact with a low flow of gas, it quickly forms a large
number ofsmall "soda-like" bubblesthat burst as soon as they form. This bursting effect
produces an ultrasonic shock wave that is heard as a cracklingsound in the headphones. In
many instances thebubbles will not beseen, but they will be heard. This method is capable of
obtainingsuccessful leak checks insystems with leaks as low
as 1x10-6 ml/sec.
NOTE: The lowsurface tension ofthe LLA is the reasonsmall bubbles form. This can benegatively
changed bycontamination of the leak site with another leak fluid which can block LLA or cause large
bubbles to form. If contaminated, clean the leak site with water, solvent or alcohol (check with plant
regulations before selecting a decontaminatingcleaning agent).

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Tone test (Ultratone )
The Tone Test is an ultrasonic method for non-destructive testingwhichis used when it is difficult to
pressurize or draw a vacuum in a system. This ultrasonic test is applicable to a wide range of items,
including: CONTAINERS, TUBES, PIPES, HEAT EXCHANGERS, WELDS , GASKETS, SEALS, DOORS,
WINDOWS, OR HATCHES.
The test is conducted by placing an ultrasonic transmitter, called TONE GENERATOR, inside (or on
one side) ofthe test item. The warble pulse-signal from the TONE GENERATORwill instantly "flood"
the test item and penetrate any existing leak hole. Depending on configuration and material, even thin
spots in certain metals can be vibrated by the signal. By scanning for sonic penetration on the
exteriorsurface (oroppositeside) ofthe test item with the Ultraprobe,the leak will be detected. It will
be heard as a highpitched warble, similartobird chirping.
The Tone Test incorporatestwo basic components: a TONE GENERATOR (anultrasonic transmitter),
and the Scanning Module in the Ultraprobe. To conduct the test:
1. Makecertain the test item has no fluids or contaminants such as water, mud, sludge, etc.,
that can block the path of thetransmitted ultrasound.
2. Place the Tone Generator within the container, (if it is a room, door or window to be tested,
place the Tone Generator on one side pointing in the direction ofthe area to be tested) and
close, or sealso that the Tone Generatoris enclosed within.
NOTE: The size ofthe test area will determine the amplitude selection of the Tone Generator. If the
item to be tested is small, select the LOW position. For larger items, use the HIGH position.
3. Scan the test area with the Ultraprobe as outlined in LEAK DETECTION procedure. (i.e., start
with the sensitivity selection at 0 and proceed down). When positioning the Tone Generator,
place the transducer facing and close to the most crucial test area. If a general area is to be
checked, position the Tone Generator so that it willcover as wide an area as possible by
placing it inthe "middle" ofthe test item.
How far will thesound travel? The Tone Generatoris designedtocover approximately 113m³ (4000
cubic feet ) ofuninterrupted space. This is slightly larger than the size of a tractor trailer. Placement is
dependent upon such variables as the size of the leak to be tested, the thickness of the test wall and
thetype ofmaterial tested (i.e. is it sound absorbant orsound reflective?). Remember, youare dealing
with a high frequency, short wave signal. If the sound is expectedto travel through athick wall, place
the Tone Generator close to the test zone, if it is athin metallic wall, move it farther back and use
"low". For uneven surfaces it may be necessary to use two people. One person will move the Tone
Generator slowly close to and around the test areas while another person scans with the Ultraprobe
on the otherside.

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Do not use the Tone test in a complete vacuum.
Ultrasound will not travel in a vacuum.Sound waves need molecules to vibrate and conduct the
signal. There are no moveable molecules in a complete vacuum.
If a partial vacuum is to be drawn where there are still some air molecules to vibrate, then the Tone
Test may be implemented successfully. In a laboratory, a form of the Tone Test is utilized in seal
leaks of an electron beam microscope. The testchamberhas beenfitted with a specially designed
transducer to emit the desired tone and a partial vacuum is created. A userthen scans all seams for
sonic penetration. The Tone Test has also beeneffectively utilizedtotest tanks before they are put on
line, piping, refrigerator gaskets, caulking around doors and windows for air infiltration testing, heat
exchangers for leaking tubes, as a Q.C. test for automobile wind noise and water leaks, on aircraft to
test for problems associated with cabin pressure leaks and glove boxes for seal integrity defects.
Optional
Pipe Threaded
Tone Generator
UE-WTG2SP

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Electric arc, corona, tracking detection
There are three basic electrical problems that are detected with the Ultraprobe 100:
Arcing: Anarc occurs when electricity flows throughspace. Lightningis a good example.
Corona: When voltage on an electrical conductor,such as an antenna or high voltage
transmission line exceeds the threshold value, the air around it begins to ionize to form a blue or
purple glow. Tracking: Often referred to as "baby arcing", followsthe path of damaged insulation.
Althoughtheoreticallythe Ultraprobe 100can beusedin low, medium and high voltage systems,
most ofthe applications tend to be inmedium and high voltage systems.
When electricity escapes in highvoltage lines or when it "jumps" across a gapin an electrical
connection, it disturbs the airmolecules around it and generates ultrasound. Most oftenthis sound
will be perceived as acrackling or "frying" sound, in other situations it will be heard as a buzzing
sound.
Typical applications include: insulators, cable, switchgear, buss bars, relays, contactors, junction
boxes. In substations, components such as insulators, transformers and bushings may be tested.
Ultrasonic testing is often used at voltages exceeding 2,000 volts, especially in enclosed switchgear.
Since ultrasound emissions canbe detectedby scanningaround doorseams and air vents, it is
possible to detect serious faults such as arcing, tracking andcorona without taking the switchgear off
line to perform an infrared scan. However, it is recommended that both tests be used with enclosed
switchgear.
NOTE: Whentesting electrical equipment, followall your plant orcompany safety procedures.
When in doubt, ask your supervisor. Never touch live electrical apparatus with the Ultraprobe.
The method for detecting electric arc and corona leakage is similar to the procedure outlined in leak
detection.
Instead of listening for a rushing sound, a user will listen for a crackling or buzzing sound. In some
instances, as in trying to locate thesource of radio/TV interference or insubstations, the general area
of disturbancemay be located with a gross detector such as atransistor radio or a wide-band
interference locator. Once the general area has been located, the scanning module of the Ultraprobe
is utilized with a generalscan of the area. The sensitivity is reduced if thesignal is too strong to
follow. When this occurs, reduce the sensitivity to get amid-line reading on the meter and continue
following the sound until the loudest point is located.
Determining whether a problem exists or not is relatively simple.Bycomparingsound quality and
sound levels among similar equipment, the problemsound will tend to be quite different.
On lower voltage systems, a quick scan of bus bars often will pick up a loose connection.
Checking junction boxes can reveal arcing. As with leak detection, the closer one gets to the
emission site, the louder thesignal.
Test switchgear, transformers, etc. for arcing, tracking & corona.

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Detecting bearing wear
Ultrasonic inspection and monitoring of bearings is by far the most reliable method for detecting
incipient bearing failure. The ultrasonic warning appears priorto a rise intemperature oran increase
in low frequency vibration levels. Ultrasonic inspection of bearings is useful in recognizing:
a. The beginning of fatigue failure.
b. Brinelling of bearing surfaces.
c. Flooding of or lack of lubricant.
In ball bearings, as the metal in the raceway, roller or ball bearing begins to fatigue, a subtle
deformation begins to occur. This deforming of the metal will produce an increase in the
emission of ultrasonic sound waves.
Changes in amplitude of from 12 to 50 times the original reading is indication of incipient bearing
failure. When a reading exceeds any previous reading by 12 db, it can be assumed that the bearing
has entered the beginning of the failure mode.
This information was originally discovered through experimentation performed by NASA on ball
bearings. In tests performed whilemonitoring bearings at frequencies ranging from 24 through 50
kHz, they found that the changes in amplitude indicate incipient (the onset of) bearing failure before
any otherindicators including heat and vibrationchanges. An ultrasonic system based on detection
and analysis ofmodulations of bearing resonance frequencies canprovide subtle detection capability;
whereas conventional methods are incapable of detecting very slight faults. As a ball passes over a
pit orfault in the racesurface, it produces an impact. A structural resonance of one ofthe bearing
components vibrates or"rings" by this repetitive impact. The sound producedis observed as an
increase in amplitude in the monitored ultrasonic frequencies of the bearing.
Brinelling of bearing surfaces will produce a similar increase in amplitude due tothe flattening
process as the balls get out of round. These flat spots also produce a repetitive ringingthat is
detected as an increase in amplitude of monitored frequencies.
The ultrasonic frequencies detected by the Ultraprobe are reproduced as audible sounds. This
"heterodyned" signalcan greatly assist auserin determiningbearing problems. When listening, it is
recommended that a user become familiar with thesounds of a good bearing. A good bearing is heard
as a rushing or hissing noise. Crackling or rough sounds indicate a bearing in the failure stage. In
certaincases a damaged ballcan be heard as a clickingsound whereas a high intensity, uniform
rough soundmay indicate adamaged race or uniform ball damage.
Loud rushing sounds similar tothe rushing sound of a good bearing only slightly rougher, can

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indicate lack of lubrication.Short duration increases in the sound level with "rough" or "scratchy"
components indicate a rolling element hitting a flat" spot andsliding on the bearing surfaces
rather than rotating. Ifthis conditionis detected, more frequent examinationsshould be
scheduled.
Detecting bearing failure
COMPARATIVE TESTING. The comparative method involves testing two or more similar bearings
and "comparing" potential differences.
For comparative test
1. Use contact (stethoscope) module.
2. Select a "test spot" on thebearing housing. Touch that spot with thecontact module. In
ultrasonic sensing, the more mediums or materials ultrasound has to travel through, the less
accurate the reading will be. Therefore, be sure the contact probe is actually touching the
bearing housing. If this is difficult, touch a grease fittingortouch as close tothe bearing as
possible.
3. Approachthe bearings at thesame angle, touching thesame area on the bearing housing.
4. Reduce sensitivity (if unsure ofthis procedure, refer to SENSITIVITY SELECTION DIAL)
5. Listen to bearing sound through headphones to hear the "quality" of thesignal for proper
interpretation.
6. Select same type bearings undersimilar load conditions andsame rotational speed.
7. Compare differences of meter reading and sound quality.
It is important to consider two elements of potential failure. One is lack of lubrication while the other
is over lubrication.
Normal bearing loads causes an elastic deformation ofthe elements in thecontact area which give a
smooth elliptical stress distribution. But bearingsurfaces arenot perfectly smooth. Forthis reason, the
actual stress distribution in the contact area will be affected by a random surface roughness. In the
presence of a lubricant film on a bearing surface, there is a dampening effect on the stress distribution
and the acoustic energy produced will be low. Should lubrication be reduced to a point where the
stress distribution is no longer present, the normal roughspots will make contact with the race
surfaces and increase the acoustic energy. These normalmicroscopic disuniformities will begin to
produce wear and the possibilities ofsmall fissures may develop which contributes to the"Pre-Failure"
condition. Therefore, asidefrom normal wear, the fatigueorservice life ofa bearingis strongly
influenced by the relative film thickness provided by an appropriate lubricant.
Slow speed bearings
Monitoring slow speed bearings is possible with the Ultraprobe 100. Due to the sensitivity range, it is
quite possible to listen to the acoustic quality of bearings. In extremely slow bearings (less than 25
RPM), it is often necessary to disregard the meter and listen to the sound ofthe bearing. In these
extreme situations, the bearings are usually large (1"-2" and up) and greased with high viscosity
lubricant. Most often no sound will be heard as the grease will absorb most ofthe acoustic energy. If a
sound is heard, usually a crackling sound, there is some indication of deformity occurring.

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General mechanical trouble shooting
As operating equipment begins to fail due to component wear, breakage or misalignment , sonic and
more importantly, ultrasonicshifts occur. The accompanyingsound patternchanges cansave time
and guess work in diagnosing problems if they are adequately monitored. Therefore, an ultrasonic
history ofkeycomponents can prevent unplanneddown-time. And just as important, if equipment
should begin to fail in the field, the ULTRAPROBE can be extremely useful in troubleshooting
problems.
Trouble shooting
1. Use the contact (stethoscope) module.
2. Touch test area(s): listen through headphones and observe the meter.
3. Adjustsensitivity until mechanical operation ofthe equipment is heardclearly.
4. Probe equipment by touching various suspect areas.
5. To focus in on problem sounds, while probing, reducesensitivity graduallyto assist in locating
6. the problem sound at its' loudest point. (This procedure is similar to the method outlined in
LEAK LOCATION, i.e., follow thesound to its loudest point.)
Locating faulty steam traps
An ultrasonic test of steam traps is a positive test. The main advantage to ultrasonic testing is that it
isolates the area beingtested by eliminating confusing background noises. A usercan quickly adjust
to recognizing differences among various steam traps, of which there are three basic types:
mechanical, thermostatic and thermodynamic.
When testing steam traps ultrasonically:
1. Determine whattype oftrap is on the line.Be familiar with the operation ofthe trap. Is it
intermittent orcontinous drain?
2. Try to check whether the trap is in operation (is it hot or cold? Putyour hand near, but do not
touch the trap, or, better yet, use a non-contact infrared thermometer).
3. Use the contact (stethoscope) module.
4. Try to touch the contact probe towards the discharge side of the trap. Press the trigger and
listen.
5. Listen forthe intermittent orcontinuous flowoperation ofthe trap. Intermittent traps are usually
the inverted bucket, thermodynamic (disc) andthermostatic (under light loads). Continuous
flow: include the float, float and thermostatic and (usually) thermostatic traps. While testing
intermittent traps, listen long enoughto gauge the true cycle. In some cases, this may be longer
than 30seconds. Bear in mind that the greater the load that comes to it, the longer period of
time it will stay open.

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In checking a trap ultrasonically, a continuous rushingsound will often be thekey indicator oflive
steam passing through. There are subtleties for eachtype oftrap that can be noted.
Use the sensitivity levels ofthe Sensitivity election Dial to assist your test. If a low pressure system is
to be checked, adjust the sensitivity UP toward 8; if a high pressuresystem (above 100 psi) is to be
checked, reduce thesensitivity level. (Some experimentationmay be necessary to arrive at the most
desirable level to be tested.) Check upstream and reduce thesensitivity so that the meter reads about
50% or lower, then touch the trap body downstream andcompare readings.
General steam/condensate/flash steam confirmation
In instances where it may be difficult to determine the sound of steam, flash steam or
condensate,
1. touch at the immediate downstream side of the trap and reduce the sensitivity to get a mid-line
reading on the meter (about 50%).
2. Move 15-30 cm downstream and listen. Flashing steam will show a large drop off in intensity
while leakingsteam will showlittle drop off in intensity.
Inverted bucket traps
INVERTED BUCKET TRAPS normally fail in the open position because the trap loses its prime. This
condition means a complete blow-through, not a partial loss. The trap will no longer operate
intermittently. Aside from a continuous rushing sound, another clue for steam blow-through is the
soundof thebucket clanging against theside ofthe trap.
bucket trap drawing
Float and thermostatic
A FLOAT AND THERMOSTATIC trap normally fails in the "closed" position. A pinhole leak produced
in theball float will causethe float to be weighted down orwaterhammer will collapsethe ball float.
Since the trap is totally closed - no sound will be heard. In addition,check the thermostatic element in
the float and thermostatic trap. If the trap is operating correctly, this element is usually quiet; if a
rushing sound is heard, this will indicate either steam or gas is blowing through the air vent. This
indicates that the vent has failed in the open position and is wasting energy.
Thermodynamic
THERMODYNAMIC (DISC) traps work on the difference in dynamic response to velocity change in
the flow ofcompressible and incompressible fluids. As steam enters,static pressure above thedisc
forces thedisc against the valve seat. The static pressure over a large area overcomes the high inlet
pressure ofthe steam. As the steam starts tocondense, the pressure against the disc lessens and
the trap cycles. A good disc trap should cycle (hold-discharge-hold) 4-10 times perminute.When it
fails, it usually fails in the open position, allowingcontinuous blow through of steam.

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Thermostatic traps
THERMOSTATIC TRAPS (bellows & bimetallic) operate on a difference in temperature between
condensate and steam. They build up condensateso that the temperature ofcondensate drops down
to a certain level belowsaturationtemperature in order for the trap to open. By backing up
condensate, the trap will tend tomodulate open or closed depending on load.
In a bellows trap, should the bellows becomecompressed by waterhammer, it will not function
properly. The occurrence of a leak will prevent the balanced pressure action of these traps. When
either condition occurs, the trap will fail in its natural position either opened or closed. If the trap fails
closed,condensate will back up and nosound will be heard. If the trap fails open, a continous rushing
of live steam will be heard with bimetallic traps, as the bimetallic plates set due to the heat theysense
and thecooling effect on the plates, they may not set properly which will prevent the plates from
closing completely and allowsteam to pass through. This will be heard as a constant rushing sound.
NOTE: A complimentary Steam Trap Trouble Shooting Guide is available. Visit our website
WWW.UESYSTEMS.EU
Locating faulty valves
Utilizing thecontact (stethoscope)module in the Ultraprobe, valves can easily be monitored to
determine if a valve is operating properly.As a liquid or gas flows through a pipe, there is little or no
turbulence generated except at bends or obstacles. In the case of a leaking valve, the escaping
liquid or gas will move from a high to a low pressure area, creating turbulence on the low pressure
or "downstream"side. This produces a white noise. The ultrasonic component ofthis "white noise" is
muchstronger than the audible component. If a valve is leaking internally, the ultrasonic emissions
generated at the orifice site will be heard and noted on the meter. The sounds of a leaking valve
seat will vary depending upon the density of the liquid or gas. In some instances it will be heard as a
subtle crackling sound, at other times as a loud rushing sound. Sound quality depends on fluid
viscosity andinternal pipe pressure differentials. As an example, waterflowing under low to mid
pressures may be easily recognized as water. However, waterunder high pressure rushing through
a partially open valve may sound very much like steam. To discriminate: reduce thesensitivity,
touch a steam line and listen to the sound quality, then touch a water line. Once you have become
familiar with the sound differences, continue yourinspection.
A properly seated valve will generate nosound. In some high pressure situations, the ultrasound
generated within thesystem will be so intense thatsurface waves will travel from other valves or parts
of the system and make it difficult to diagnose valve leakage. In this case it is still possible to diagnose
valve blow-through by comparing sonic intensity differences by reducing the sensitivity and touching
just upstream of thevalve, at the valve seat and just downstream of thevalve.