Best Practices for Condition Monitoring Using Ultrasound

Adrian Messer
Manager of US Operations
UE Systems, Inc.

Over the decade or so, it has been interesting to see the evolution of maintenance and
reliability. To some, the word maintenance brings a perception of general housekeeping duties
such as janitorial tasks, or changing light bulbs, but for most, maintenance has become almost
synonymous with reliability. I feel like the reliability field is in a transition phase, meaning more
people are becoming more proactive regarding maintenance, rather than being reactive once a
failure has happened. Additionally, the condition monitoring tools that are available today are
more advanced, and in some cases can give the user almost instantaneous information in order to
make a diagnosis on an asset. Mobile devices such as tablets and smart phones have been
integrated. For some applications, continuous/remote monitoring is almost a must. Now, with
the internet of things coming into play, more machines and assets will be coming online for
continuous monitoring and will be monitored for energy conservation purposes. So, continuous
monitoring of assets will be a must for years to come.
Airborne & structure-borne ultrasound has certainly become a major player in condition
monitoring. Once considered just a leak detector, more maintenance & reliability professionals
are realizing all of the benefits associated with using ultrasound for condition monitoring
applications. The I-P-F Curve with which we have all become familiar with reflects that trend.

Figure 1: The I-P-F Curve shows Ultrasound as being the first technology that detects a
failure that is mechanical in nature such as early stage bearing wear, or subsurface bearing
fatigue

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 Not only should we be concerned about the P-F interval once a failure has been detected,
but just as important is the I-P interval. The I-P interval is where precision maintenance is used
to ensure that the equipment is being installed properly using precision balancing and alignment
and installing the bearings properly. Precision maintenance is achieved when ultrasound is used
to prevent over and under lubrication of bearings, thus helping to extend the I to P interval.
Studies have shown that at least 60% of premature bearing failures can be attributed to
lubrication. Whether it’s over lubricated, under lubricated, using the wrong grease for the wrong
application, or contaminated lubricant, the majority of premature bearing failures are lubrication
related. Ultrasound instruments can be used to prevent over and under lubricated bearings. The
source of the ultrasonic noise is friction. When a bearing is in need of grease, there is an
increase in friction, and consequently an increase in noise or decibel level. When listening to a
bearing that is in need of lubrication and watching the decibel level on the display of an
ultrasonic instrument, as grease is applied, the inspector will notice a gradual drop in the decibel
level. Eventually back down to a more normal level. When grease enters the bearing housing,
there is less friction and less noise, which explains the drop in the decibel level. If the bearing is
already over lubricated, or is already sufficiently lubricated, as soon as grease is applied, the
inspector will notice a gradual increase in the decibel level, letting them know that the bearing
already had enough grease. When ultrasound is used for condition based lubrication, thus
preventing over and under lubrication of bearings, a large majority of premature bearing failures
can be prevented, there is less potential for unplanned downtime, and more problems can be
found since the lubricators are listening to the bearings rather than just applying grease with only
a grease gun.

How Do I Get Started?

There are two common questions that many first time users of ultrasound technology for
condition monitoring have. The first is, “how do I set baselines?” The second is, “how do I
know if what I’m listening to is good or bad?” They are very valid questions since there is no
previous ultrasound data on the equipment to be tested, and the users are simply unfamiliar with
using ultrasound for this application.
We will expand on three different condition monitoring with ultrasound techniques for
this article. For setting baselines, we will discuss two methods, the comparison method and the
historical method. We will also discuss making use of recorded ultrasounds to make a better
diagnosis as to what’s good and what’s bad. When a recorded ultrasound is played back in
spectral analysis software, we can view both the FFT and the Time Wave Form of that sound.
This helps to “paint a picture” of what it is that we are hearing. Some ultrasound instruments
have the capability of viewing the FFT and Time Wave Form view in real time while data is
collected. A concept sometimes referred to as ultrasound imaging.

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The Comparison Method
One way to get a quick idea as to what is good and what is bad is by using the
comparison approach. With this method, the inspector simply compares the decibel level
readings at identical points on identical machines. Using this method, the inspector also begins
to “train” his or her ear as to what rotating equipment sounds like, and it will become obvious
that a bearing with a particular fault such as an inner race, or outer race defect, will sound much
different than a bearing that is in a “good” condition.
The baseline can then be set based off an average of decibel levels at the compared
points. The software may even default to the first reading taken and downloaded is what is used
for the baseline. The baseline can then be changed in the software as more readings are
collected.

Figure 2: The image above shows where readings were taken at 6 identical motors. The decibel level
on the 6 motor outboard points were all within three dB of each other except for Motor B. The Motor
B outboard point was 12 dB higher than the other 5 motors, thus indicating a need for further
inspection or action.

The Historical Method

The historical method is the preferred method for establishing baselines and alarm levels
in a bearing condition monitoring program. Using this method, the inspector first establishes a
route or database in the ultrasound software, which is subsequently loaded into the ultrasonic
instrument. Data is then collected at the various points along the route. When the initial round
of baseline data is collected, it may be necessary to collect data more frequently than needed in
order to build the history, and get an idea if the decibel readings are remaining similar in the

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initial historical readings. Once the baseline has been set, as long as the readings are remaining
consistent, the frequency that the readings are collected on can be adjusted. For example, when
collecting the initial data for setting the baselines, the readings may need to be taken once per
week for 4-5 weeks. Once the baseline is set, the readings can be taken only once per month, or
every other month depending on asset criticality and equipment runtime. With the initial data
history established, the inspector can select the reading that they wish to set as the baseline.

Figure 3: The above image shows a screen shot from a typical ultrasound route where data
has been collected on three pumps. The DriveA point has been expanded to show 6 historical
readings. The reading on March 20th is in bold which represents the baseline. Two alarm
levels have been reached. A low alarm on May 20th, and a higher alarm warning on July 20th

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 Figure 4: The above image is from the previous data discussed on the DriveA point. The bottom chart
shows a plot of the 6 historical readings. The readings are plotted against a low alarm and high alarm.
The plot at the top of the chart is a plot of the temperature readings to show the changes in
temperature over the 6 month period.

Setting Alarm Levels

Once a baseline has been established through either the comparison method, or the
historical method, alarm levels can be set. A low alarm is set to show a lack of lubrication, and a
high alarm is set to show a more critical failure stage for the bearing such as an inner race, outer
race, cage, or ball pass fault. Through years of studies and analysis of actual ultrasound data
from ultrasound users, it has been determined that an 8dB increase above a baseline represents a
lack of lubrication. A 16dB increase above a baseline represents a more severe failure for the
bearing. At the high alarm level, the bearing is in a failure mode that is beyond a lack of
lubrication. These alarm levels may need to be adjusted when testing slow speed bearings.
Slower speed bearings (generally below 100rpm) alarm levels may need to be half of what the
normal alarm levels are set, but it really depends on what the decibel level trend of the initial
historical readings indicate.

Ultrasound Imaging
Through advancements in airborne and structure-borne ultrasound instruments and
software, the user can obtain an “image” of the sound that is being heard to analyze, diagnose,
and confirm mechanical fault conditions in rotating equipment. The concept of ultrasound
imaging is to record ultrasounds heard via the ultrasound instrument, and then play back those
recorded sounds in a spectrum analysis software. This will provide the inspector with the
audible sound heard in the field during the inspection and a visual “image” or spectrum of the
recorded ultrasound in both the FFT and Time Wave Form view. This method will help to

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reduce the subjectivity of only relying in changes in the decibel level and changes in the sound
tone or quality heard by the inspector.

Examples of Ultrasound Imaging

The first example below is from a motor and pump combination where there were a total
of eight of these all running the same and performing the same function. The 60hp motor was
powering a pump that was pumping water. The image below was taken while the data was
collected. The comparison below is between two of the eight total motor and pumps.

While collecting data, both decibel readings and sound files were recorded. The below screen
shots from the spectral analysis software that was used show a comparison between the points
“PUMP 3 MTROB 007” and the “PUMP 4 MTROB 010.” The images are FFT images from the
spectrum analysis software that were captured after the recorded ultrasound had been played
back. A spectrum analysis software is usually available for instruments that have onboard sound
recording. The instruments used to collect this data also had onboard spectrum analysis which
shows the FFT and Time Wave Form views on the display in real time while the data is
collected.

Figure 4a: Pump 3 MTR OB (Good) Figure 4b: Pump 4 MTR OB (Bad)

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In Figure 4a and Figure 4b, notice the difference between the two points. Both motors are
operating under the same conditions, but the Pump 4 MTR OB point has a much different
spectrum. If you were listening through the headset of the ultrasound instrument, it would also
have a much different sound. Another image of the Pump 4 MTROB point, captured from
onboard the ultrasound instrument, can be seen below.

Figure 5: Pump 4 MTR OB from ultrasound

instrument. Notice the distinct 175.8Hz harmonics
detected.

The spectrum analysis software used has a built-in bearing fault frequency calculator. By
entering in the speed (rpm) and the number of balls (bearings), an outer race, inner race, ball
pass, and cage frequency are calculated. For this particular motor, the speed was 1750rpm and
the type and number of bearings was confirmed to be 10. The fault frequency calculated by the
spectrum analysis software confirmed an inner race fault at 175Hz. This is the same fault
harmonic detected on the ultrasound instrument. Another interesting point was the fact that the
vibration analysis data was collected two days later, and did confirm an inner race fault on the
Pump 4 motor outboard point.

Ultrasound technology has also proven to be very effective at monitoring slow speed
bearings. If you have the right data collector, software, training, and time it can be accomplished
with vibration analysis; however, it’s easily done with ultrasound. Even at speeds of 1rpm,
ultrasound can be used to listen to slow speed bearings. In extreme slow speed applications, if
the bearing is a good condition, there will be little to no ultrasonic noise simply because there is
no fault condition that would produce the ultrasonic noise. As a fault begins though, this will be
heard via the headset when inspecting the equipment, and it shows up very nicely on the time
wave form view when the sound has been recorded.

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 Figure 6: The time wave form view above is from a recorded ultrasound of a slow
speed bearing on a furnace that is turning approximately 1rpm. It shows very clearly that the
bearing is failing.

Conclusion

Implementing ultrasound for condition monitoring applications is easier than you think.
With a short learning curve, ease of collecting data, and remote monitoring solutions, ultrasound
can become another valuable tool to use for your condition monitoring efforts. When setting up
your ultrasound database, consider starting out with routes that are manageable and will create
value to your overall reliability program, taking into account factors such as an asset criticality
ranking, inspecting assets with failure modes that ultrasound will detect, or using ultrasound on
equipment that has high failure rates to get a better idea as to what might be causing the failures.
When collecting baseline data, consider recording the sound of what you’re hearing. This
provides additional information for historical purposes such as comparing baseline sounds (FFT
or Time Wave Form) to when the same point reaches an alarm level. Once the baseline and
alarm levels have been set, the only other time a sound file should be recorded is when the point
reaches an alarm level. As long as the decibel readings are below the alarm levels, only the
decibel level is stored. Also, when the initial data is taken, take before lubrication and after
lubrication readings. If the decibel level drops after lubrication, then that is the reading that
should be used for the baseline since that point was in need of lubrication to begin with.

If these critical steps are followed when establishing ultrasound as a condition monitoring
tool, then more problems will be found, premature bearing failures can be greatly reduced, and
condition monitoring data collection becomes more effective. Lubrication PM’s can also

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become more effective because ultrasound trends will show which bearings need to be
lubricated. Therefore, instead of greasing everything on a time based lube route, only the points
that are currently in the lubrication alarm from ultrasound trends are greased until the decibel
level drops back down to the baseline dB. Therefore, if you’re only using ultrasound as a leak
detector, I would encourage you to take a more in depth look into condition monitoring with
ultrasound.

Keywords:

Ultrasound
Equipment Reliability
Condition Monitoring
Preventive Maintenance
Lubrication
Reliability Centered Lubrication
Bearings
Asset Reliability

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 Equipment Reliability, Track 3

Improving Equipment Reliability with

Ultrasound

Adrian Messer, CMRP

UE Systems, Inc.
 UE Systems, Inc.

• Founded in 1973
• Considered one of the pioneers in airborne &
structure-borne ultrasound technology
• Globally supported ultrasound instruments for
use in various equipment reliability applications
• All instruments are made in the USA
• Sustaining Corporate Sponsor of SMRP

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 What We’ll Be Covering:

• Two common questions asked by first time users

of ultrasound for condition monitoring:
– How do I know if what I’m listening to is good or bad?
– How do I set my baselines and alarm levels?

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 What We’ll Be Covering:

• Reporting & documentation

– Reporting & documentation has become
critical for M&R professionals
– Advancements in instruments & software
allow for better reporting

4
 What We’ll Be Covering:

• Ultrasound Assisted Lubrication

– Premature bearing failures are attributed to
lubrication
– Ultrasound helps to prevent over & under
lubrication of bearings

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 What Does A World Class Ultrasound
Program Look Like?

Do you have an
People
ultrasound instrument, Educated
or an ultrasound
program?
Trained
Motivated
Supported
Culture

Processes
Tools
Asset Criticality
Understanding FMEA’s
Proactive vs.
Reactive Versatile
Planning & Easy to use
Scheduling Documentation
PM Optimization
 Why Ultrasound?

• The need for increased data collection has

grown
• Documentation and reporting has become
critical for maintenance & reliability professionals
• M&R professionals need easy to use tools with
the ability to be used for multiple applications
• Reliability technology and software in general
continues to advance
– Internet of things, remote monitoring, tablets, etc.
 Why Ultrasound?

• Ultrasound has evolved into a must have technology for

equipment reliability & condition monitoring
• Ultrasound is a versatile and easy to use technology with
multiple applications
• Increased use for both mechanical and electrical
applications
 I-P-F Curve

Infrared
Failure Begins P Ultrasound
Oil Analysis

I Vibration Audible Noise

P P1 P2 Hot To The touch

P3
P4
P5

Predictive Fault P6
Proactive
Domain Domain Domain

F
Max time for planning
 What is Ultrasound?

• Very simply, ultrasound instruments are listening

devices
• Listen for high frequency sound that is not heard
in the audible range (human hearing)
• Instruments listen for & translate the high
frequency sound into audible sound heard
through the headset
 What is Ultrasound?

• Ultrasonic range is 20kHz to 100kHz

• Normal human hearing is around 16kHz to
17kHz (upper range)
• Unit of measurement is a decibel (dB)
• Advantages:
– Very directional
– Easy to locate sources of ultrasound
– We can hear ultrasounds above normal plant
background noise
 What is Ultrasound?

• Leak Detection
– Compressed air/gas leaks Energy
– Steam traps Conservation ($$$)

– Valves

• Electrical Inspection
– Corona, Tracking, Arcing

• Equipment Reliability/Condition Monitoring

– Bearings
– Rotating Equipment
– Condition based lubrication
 Equipment Reliability with
Ultrasound

• To forecast failure
• To show trends
• To be used as a sorting tool
• To reduce waste
• Condition based lubrication
 Equipment Reliability with
Ultrasound

• Provides early warning of failure

• Isolates the sound source
• Quality of the bearing can be heard
• Helps prevent lubrication related failures
• Large number of points can be tested in a
shorter amount of time
• Identify previously unknown conditions
• Very effective on slow speed bearings
 Prepare to be Successful

• Perform a walk-through to determine most

efficient way to create database and collect data
• Take detailed careful notes while performing
walk trough to ensure accurate database
creation
• Review schematics of work flow
• Ensure smooth, easy, and safe walking route for
data collection
 Prepare to be Successful

• Prioritize your equipment based on criticality list

• Some equipment needs more frequent testing
than others
• Set up schedules based on your “criticality
index”: likelihood of breakdown, consequences if
it fails, safety, cost to repair, etc.
• If vibration routes are already in use, model your
ultrasound routes after your vibration routes
 Consistency = Repeatability

When Inspecting Bearings…

• Try to make it as repeatable as
possible
• Touch test points at same
angle
• Compare similar bearings
• Maintain frequency when
Comparing
• Confirm diagnosis
• Be Consistent!
 How Do I Set My Baselines?

• The Comparison Method

– This is the fastest way to get an idea
of what condition your equipment is
in when you first start your program,
or as a way to train yourself as to
what things should and shouldn’t
sound like
– Compare dB and recorded
ultrasound sound files on identical
points on identical machines
– Set baseline based off of an average
of the dB readings

Of the 6 motors tested, all were

within 3 dB of each other except
one which was 12 dB
 How Do I Set My Baselines?

• The Historical Method

– Create the route in the ultrasound software
– Upload the route from the software into an ultrasound
instrument
– Acquire the data
– Record both dB and sound files
– Download data back into the ultrasound software
 How Do I Set My Baselines?

• Once several readings have been taken (history) &

baselines have been set, set alarm levels using
standard delta values for failure modes
• Compare baseline sound files to alarm level sound files
• Trend & Report
• Review data from prior months/years
 Action Levels for Alarms

• 8 dB Lubrication
• 12 dB Minor Damage-Microscopic Faults
• 16 dB Damage-Visual Faults
• 35+ dB Severe Failure

Severe
Failure

Damage
(visual)
Microscopic
Damage
Lack of
Lubrication
The Historical Method
The Historical Method
Reporting & Documentation
 How Do I Set My Baselines?

• Things to consider:
– Initial ultrasound data should include both decibel readings
and sound files
– Once baselines have been established and alarm levels are
set, only decibel readings are stored
– Once the point reaches an alarm, record both decibel
readings and sound files for comparison & to potentially
diagnose any fault conditions
 How Do I Set My Baselines?

• Things to consider:
– Data may need to be acquired more frequently when
building the history
– Once the history, baselines, and alarm levels have been
established, the frequency of data collection can be
adjusted
– When setting baselines, it would be a good practice to
lubricate the bearing to see if there is a change in dB
– If the dB decreased after lubrication, that would be a
good reading to store and use as the baseline for that
point
 How Do I Set My Baselines?

• Things to consider:
– For slow speed applications, alarm levels may need to be
lowered
• Extreme slow speed bearings that are “good” produce very little ultrasonic
noise. As faults start to occur, this can be heard and viewed very nicely in
time wave form view of recorded ultrasounds
– For VFD applications, the alarm level increments should be
widened
• Since ultrasound is an early indicator, action doesn’t usually need to be
taken immediately. It allows for time to make a proper decision. If it is in
alarm the next reading, there should be cause for concern.
– An invalid baseline will present itself rather quickly once
historical data has been established
• A bearing that is already bad with a rising dB will continue to rise you just
don’t know where/when it began to rise
 How Do I Know If What I’m
Listening To Is Good Or Bad?

• Where ultrasound has evolved to as a

technology, is making use of recorded
ultrasound sound files
• “Paints A Picture” as to what it is that you’re
listening to
• Shows FFT & Time Wave Form
• Becomes more of a diagnostic tool

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 How Do I Know If What I’m
Listening To Is Good Or Bad?

• Analyze sounds for differences:

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How Do I Know If What I’m
Listening To Is Good or Bad?

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 How Do I Know If What I’m
Listening To Is Good Or Bad?
SKF 6316 Bearing at 1797rpm

Outer Race harmonic Outer Race harmonic

detected with Ultrasound detected with vibration

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How Do I Know If What I’m
Listening To Is Good Or Bad?
1rpm bearing on a furnace application

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 Lubrication Related Failures

• The majority of
premature bearing
failures are lubrication
related
– Under lubricated
– Over lubricated
– Wrong lubricant
– Lubricant contamination

Source: "Pump Users Handbook: Life

Extension” 2011 by Heinz Bloch
 Lubrication Related Failures

• The majority (~60%) of premature bearing failures are

lubrication related
• Traditional lubrication programs are time based
• How was the amount of grease applied determined?
• Using ultrasound we can determine when we have
applied enough grease & when we have began to over
lubricate
• Source of the ultrasound is friction
 Ultrasound Assisted Lubrication

• Using ultrasound while greasing will:

– Let the lubricator know when they have
applied enough grease
– When/If they have begun to over lubricate
– If there is anything else wrong with the
bearing
 Ultrasound Assisted Lubrication

• If bearing needs grease, dB will decrease as

lubricant is applied
• If bearing already has a sufficient amount of
grease, the dB will gradually start to increase
while applying lubricant
• If there is no change in the dB, further action
should be taken to see why there was no
change, or bearing is in a failure mode that
lubrication is not the solution
Ultrasound Assisted Lubrication

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Ultrasound Assisted Lubrication

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 In Conclusion

• Ultrasound is an effective, easy to use technology with

the benefit of being able to use it for multiple applications
• Ultrasound is more than a leak detector
• Relying on one technology runs the risk of not finding
failures early & the potential to miss certain failure
modes
• Ultrasound is a perfect complement to other
technologies in use
• A successful ultrasound program requires training &
support from the solution provider