© SDT North America 2003 All Rights Reserved Strategies for an effective ultrasound inspection program By: Allan Rienstra SDT North America 1-800-667-5325

© SDT North America 2003 © SDT North America 2003 All Rights ReservedAll Rights Reserved

Strategies for an effective Strategies for an effective ultrasound inspection programultrasound inspection program

By: Allan RienstraBy: Allan RienstraSDT North AmericaSDT North America1-800-667-53251-800-667-5325www.sdtnorthamerica.comwww.sdtnorthamerica.com


Why we need a strategyWhy we need a strategy

Ultrasonic Inspection ProgramUltrasonic Inspection Program Versatile Predictive Maintenance TechnologyVersatile Predictive Maintenance Technology Results Right Out of the BoxResults Right Out of the Box A Strategy Ensures Long-Term SuccessA Strategy Ensures Long-Term Success

Steam Traps Leak Detection Condenser Leaks Acoustic VibrationMonitor Bearings


Realize the potentialRealize the potentialWorld is full of great World is full of great ideasideasSome of the best are Some of the best are never implementednever implementedSome are, but full Some are, but full potential is never potential is never reachedreachedA sound strategy A sound strategy ensures potential is ensures potential is reachedreached


At home in any tool boxAt home in any tool boxApply the Technology forApply the Technology for

Energy ConservationEnergy Conservation Predictive MaintenancePredictive Maintenance ReliabilityReliability Lubrication Best PracticesLubrication Best Practices Quality ControlQuality Control Building EfficiencyBuilding Efficiency Building SafetyBuilding Safety General DiagnosticsGeneral Diagnostics Lean Mfg StrategiesLean Mfg Strategies Plant Noise ReductionPlant Noise Reduction Integrate with Vibration Integrate with Vibration

AnalysisAnalysis Integrate with InfraredIntegrate with Infrared

Industrial ApplicationsIndustrial Applications Leak DetectionLeak Detection Condition MonitoringCondition Monitoring Rolling Element BearingsRolling Element Bearings Lubrication ControlLubrication Control Electrical InspectionElectrical Inspection Steam Trap InspectionSteam Trap Inspection Valves and HydraulicsValves and Hydraulics Pump CavitationPump Cavitation Containment Wall InspectionContainment Wall Inspection Building Envelope IntegrityBuilding Envelope Integrity Underground Tank TestingUnderground Tank Testing Integrity of VehiclesIntegrity of Vehicles Coal PulverizationCoal Pulverization


A sound strategy is the keyA sound strategy is the key

Invest in good Invest in good technologytechnology

Implement a sound Implement a sound strategystrategy

Take the right stepsTake the right steps

Follow the planFollow the plan

Keep a positive flowKeep a positive flow


Step 1Step 1Assemble a Team or Task Assemble a Team or Task ForceForce

Get everyone onsideGet everyone onside Discuss as a part of regular Discuss as a part of regular

maintenance meetingsmaintenance meetings Borrow examples from other Borrow examples from other

successful programssuccessful programs Show how different Show how different

departments can all benefitdepartments can all benefit


Step 2Step 2Identify a need for US Testing Identify a need for US Testing programprogram

Too many leaks – compressors are Too many leaks – compressors are at capacityat capacity

Solve over greased bearing problemSolve over greased bearing problem Reduce number of failed steam Reduce number of failed steam

trapstraps Eliminate building envelope leaksEliminate building envelope leaks Faster more efficient leak detection Faster more efficient leak detection

in condensersin condensers Compliment vibration and infrared Compliment vibration and infrared

programprogram Put predictive maintenance into Put predictive maintenance into

hands of many instead of fewhands of many instead of few

Over-greased Bearings

Electrical Inspections


Step 3Step 3Justify the need by recognizing key areas where Justify the need by recognizing key areas where improvement can be benchmarkedimprovement can be benchmarked

Fix LeaksFix LeaksReduce demandReduce demandreduce energy costsreduce energy costslonger life for compressorslonger life for compressorsnoise reduction, noise reduction,

Over Greased BearingsOver Greased BearingsLonger bearing lifeLonger bearing lifelonger seal lifelonger seal lifeless contamination, less contamination,

Reduce number of failed steam trapsReduce number of failed steam trapsMore efficient delivery of steam More efficient delivery of steam reduce energy costsreduce energy costs


Step 4Step 4Set Written Goals for the ProgramSet Written Goals for the Program

A goal is just a wish until you write it downA goal is just a wish until you write it down Goals must be adjustableGoals must be adjustable Don’t be afraid to aim too highDon’t be afraid to aim too high Goals should be long short, medium, and Goals should be long short, medium, and

long termlong term3 month goal – research and purchase 3 month goal – research and purchase equipmentequipment

6 month goal – get certification training6 month goal – get certification training

9 month goal – compare benchmark data to 9 month goal – compare benchmark data to JustificationJustification

Re-visit your goal sheet oftenRe-visit your goal sheet often


Step 5Step 5Establish How ROI Will be Establish How ROI Will be MeasuredMeasured

What criteria will your group What criteria will your group use to measure results?use to measure results?

Leaks – How can cost Leaks – How can cost savings be quantified?savings be quantified?Over lubrication – How can Over lubrication – How can improved practices be improved practices be measured?measured?Condensers – was leak Condensers – was leak detection time significantly detection time significantly reduced to justify using US reduced to justify using US Testing?Testing?

Establish methods and Establish methods and implement themimplement them

Review, Review, ReviewReview, Review, Review

Increased UptimeIncreased Uptime

Decreased WasteDecreased Waste


Step 6Step 6Purchase High Quality Purchase High Quality Ultrasound Inspection Ultrasound Inspection ToolsTools

Do your research Do your research Contact more than one Contact more than one

vendor vendor Have an onsite Have an onsite

demonstrationdemonstration Get feedback from other Get feedback from other

successful programssuccessful programs Look for equipment that is Look for equipment that is

upgradeableupgradeable Equipment must be Equipment must be

accurate – benchmarked accurate – benchmarked datadata


Step 7Step 7Certification TrainingCertification Training

Invest in training at multiple Invest in training at multiple levelslevels

Operators AND ManagersOperators AND Managers Course should beCourse should be

DynamicDynamicInteractiveInteractivePracticalPracticalIncrease the confidence of Increase the confidence of the inspectorthe inspectorIncrease awareness of the Increase awareness of the benefits of airborne benefits of airborne ultrasound inspection at ultrasound inspection at the management levelthe management level


Step 8Step 8Choose a Leader to Choose a Leader to Champion the ProgramChampion the Program

This person often emerges This person often emerges after trainingafter training

Have confidenceHave confidence Have convictionHave conviction Honesty and AccountabilityHonesty and Accountability Want the Program to SucceedWant the Program to Succeed Be Mentally Invested in all Be Mentally Invested in all

ApplicationsApplications


Step 9Step 9

Reward SuccessReward Success Establish a system to Establish a system to

reward successreward success Post resultsPost results As a Group, When a As a Group, When a

Goal is Achieved, Goal is Achieved, Claim That Claim That AccomplishmentAccomplishment


Step 10Step 10 Review, Review, Review, Review,

ReviewReviewPart of regular Part of regular meetingsmeetings

Ensure everyone is Ensure everyone is 100% sold on the 100% sold on the programprogram

Re-enforce the benefits Re-enforce the benefits for all departmentsfor all departments

Be 100% committed Be 100% committed (mentally invested) to (mentally invested) to the success of the the success of the programprogram


SummariesSummaries

Use all or part of the strategy suggestedUse all or part of the strategy suggested

Adopt this strategy to your own planAdopt this strategy to your own plan

Realize full benefits of Ultrasonic Realize full benefits of Ultrasonic Inspection Program for long termInspection Program for long term

Airborne ultrasound inspection is an Airborne ultrasound inspection is an efficient solution if planned and efficient solution if planned and implemented effectivelyimplemented effectively


EndEndThank you, we appreciate your attention and interest!Thank you, we appreciate your attention and interest!Click below to download a copy of our “Strategies for an Click below to download a copy of our “Strategies for an Effective Airborne Ultrasound Program” white paperEffective Airborne Ultrasound Program” white paperRequest your own copy of this presentation on CD ROM. Request your own copy of this presentation on CD ROM. (Correct address and telephone required to courier CD) (Correct address and telephone required to courier CD)

Contact:Contact:SDT North AmericaSDT North America1-800-667-53251-800-667-5325www.sdtnorthamerica.comwww.sdtnorthamerica.comfreecd@[email protected]

Documents

© SDT North America 2003 All Rights Reserved Strategies for an effective ultrasound inspection program By: Allan Rienstra SDT North America 1-800-667-5325