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© SDT North America 2003 All Rights Reserved Strategies for an effective ultrasound inspection program By: Allan Rienstra SDT North America www.sdtnorthamerica.com
© SDT North America 2003 All Rights Reserved Why we need a strategy Ultrasonic Inspection Program Versatile Predictive Maintenance Technology Versatile Predictive Maintenance Technology Results Right Out of the Box Results Right Out of the Box A Strategy Ensures Long-Term Success A Strategy Ensures Long-Term Success Steam TrapsLeak DetectionCondenser LeaksAcoustic VibrationMonitor Bearings
© SDT North America 2003 All Rights Reserved Realize the potential World is full of great ideas Some of the best are never implemented Some are, but full potential is never reached A sound strategy ensures potential is reached
© SDT North America 2003 All Rights Reserved At home in any tool box Apply the Technology for Energy Conservation Energy Conservation Predictive Maintenance Predictive Maintenance Reliability Reliability Lubrication Best Practices Lubrication Best Practices Quality Control Quality Control Building Efficiency Building Efficiency Building Safety Building Safety General Diagnostics General Diagnostics Lean Mfg Strategies Lean Mfg Strategies Plant Noise Reduction Plant Noise Reduction Integrate with Vibration Analysis Integrate with Vibration Analysis Integrate with Infrared Integrate with Infrared Industrial Applications Leak Detection Condition Monitoring Rolling Element Bearings Lubrication Control Electrical Inspection Steam Trap Inspection Valves and Hydraulics Pump Cavitation Containment Wall Inspection Building Envelope Integrity Underground Tank Testing Integrity of Vehicles Coal Pulverization
© SDT North America 2003 All Rights Reserved A sound strategy is the key Invest in good technology Implement a sound strategy Take the right steps Follow the plan Keep a positive flow
© SDT North America 2003 All Rights Reserved Step 1 Assemble a Team or Task Force Get everyone onside Get everyone onside Discuss as a part of regular maintenance meetings Discuss as a part of regular maintenance meetings Borrow examples from other successful programs Borrow examples from other successful programs Show how different departments can all benefit Show how different departments can all benefit
© SDT North America 2003 All Rights Reserved Step 2 Identify a need for US Testing program Too many leaks – compressors are at capacity Too many leaks – compressors are at capacity Solve over greased bearing problem Solve over greased bearing problem Reduce number of failed steam traps Reduce number of failed steam traps Eliminate building envelope leaks Eliminate building envelope leaks Faster more efficient leak detection in condensers Faster more efficient leak detection in condensers Compliment vibration and infrared program Compliment vibration and infrared program Put predictive maintenance into hands of many instead of few Put predictive maintenance into hands of many instead of few Over-greased Bearings Electrical Inspections
© SDT North America 2003 All Rights Reserved Step 3 Justify the need by recognizing key areas where improvement can be benchmarked Fix Leaks Fix Leaks Reduce demand reduce energy costs longer life for compressors noise reduction, Over Greased Bearings Over Greased Bearings Longer bearing life longer seal life less contamination, Reduce number of failed steam traps Reduce number of failed steam traps More efficient delivery of steam reduce energy costs
© SDT North America 2003 All Rights Reserved Step 4 Set Written Goals for the Program A goal is just a wish until you write it down A goal is just a wish until you write it down Goals must be adjustable Goals must be adjustable Don’t be afraid to aim too high Don’t be afraid to aim too high Goals should be long short, medium, and long term Goals should be long short, medium, and long term 3 month goal – research and purchase equipment 6 month goal – get certification training 9 month goal – compare benchmark data to Justification Re-visit your goal sheet often Re-visit your goal sheet often
© SDT North America 2003 All Rights Reserved Step 5 Establish How ROI Will be Measured What criteria will your group use to measure results? What criteria will your group use to measure results? Leaks – How can cost savings be quantified? Over lubrication – How can improved practices be measured? Condensers – was leak detection time significantly reduced to justify using US Testing? Establish methods and implement them Establish methods and implement them Review, Review, Review Review, Review, Review Increased Uptime Decreased Waste
© SDT North America 2003 All Rights Reserved Step 6 Purchase High Quality Ultrasound Inspection Tools Do your research Do your research Contact more than one vendor Contact more than one vendor Have an onsite demonstration Have an onsite demonstration Get feedback from other successful programs Get feedback from other successful programs Look for equipment that is upgradeable Look for equipment that is upgradeable Equipment must be accurate – benchmarked data Equipment must be accurate – benchmarked data
© SDT North America 2003 All Rights Reserved Step 7 Certification Training Invest in training at multiple levels Invest in training at multiple levels Operators AND Managers Course should be Course should beDynamicInteractivePractical Increase the confidence of the inspector Increase awareness of the benefits of airborne ultrasound inspection at the management level
© SDT North America 2003 All Rights Reserved Step 8 Choose a Leader to Champion the Program This person often emerges after training This person often emerges after training Have confidence Have confidence Have conviction Have conviction Honesty and Accountability Honesty and Accountability Want the Program to Succeed Want the Program to Succeed Be Mentally Invested in all Applications Be Mentally Invested in all Applications
© SDT North America 2003 All Rights Reserved Step 9 Reward Success Establish a system to reward success Establish a system to reward success Post results Post results As a Group, When a Goal is Achieved, Claim That Accomplishment As a Group, When a Goal is Achieved, Claim That Accomplishment
© SDT North America 2003 All Rights Reserved Step 10 Review, Review, Review Review, Review, Review Part of regular meetings Ensure everyone is 100% sold on the program Re-enforce the benefits for all departments Be 100% committed (mentally invested) to the success of the program
© SDT North America 2003 All Rights Reserved Summaries Use all or part of the strategy suggested Adopt this strategy to your own plan Realize full benefits of Ultrasonic Inspection Program for long term Airborne ultrasound inspection is an efficient solution if planned and implemented effectively
© SDT North America 2003 All Rights Reserved End Thank you, we appreciate your attention and interest! Click below to download a copy of our “Strategies for an Effective Airborne Ultrasound Program” white paper Request your own copy of this presentation on CD ROM. (Correct address and telephone required to courier CD) Contact: SDT North America
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