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Ultrasonic Inspection: Compressors

Ultrasonic Testing

Statistics show that the average air system wastes between 25% and 35% of its air due to leaks. A 1000 CFM compressed air system with a 30% leak rate costs an additional $45,000 per year to operate.¹ The best way to maximize the cost of operation of running a compressor is to use ultrasound to minimize the number of air leaks in the system. Ultrasound can also be used to monitor the opening and closing of valves and pistons as well as determining the condition of the motor bearings.

When monitoring the opening and closing of valves or pistons of a compressor, it is necessary to use the UL101 in conjunction with the solid probes. Additionally, SoundCTRL can be used to record the ultrasonic output and zoom in on the waveform to see the individual cycles, providing better detail about its operation. Clogged or worn valves will have a distinct muffled sound compared to the crisp sounding impact of a new, clean valve.

The use of the UL101 and the Concentrators or Acoustic Extension Probes is best suited for finding air leaks. It is best to start at the compressor and work out, along the air lines. In some instances, it is difficult to survey within 50 feet of the air line. Therefore, it is recommended that the PowerBeam 300 be used. The parabolic attachment can detect ultrasound from up to 300 feet away and pinpoint the source within one degree from center.

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1. Federal Energy Maintenace Program, Operations and Maintenance.