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SKF CMIN400, Manual

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SKF CMIN400 Manual Download Page 44

Inspector 400 Applications 
Locating Faulty Steam Traps 

2 - 18 

Inspector 400 Ultrasonic Probe 

User Manual 

General Steam / Condensate / Flash 
Steam Confirmation  

In instances where it may be difficult to determine the 
sound of steam, flash steam or condensate: 

•

 

Touch at the immediate downstream side of the 
trap and reduce the sensitivity to get a midline 
reading on the meter (about 50%).  

•

 

Move 15.2 to 30.5 cm (6 to 12 in) downstream 
and listen.  Flashing steam will show a large 
drop off in intensity while leaking steam will 
show little drop off in intensity.  

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 
sound of the bucket clanging against the side of the 
trap.  
A Float and Thermostatic trap normally fails in the 
“closed” position.  A pinhole leak produced in the ball 
float causes the float to be weighted down, or water 
hammer collapses the ball float.  Since the trap is 
totally closed, no sound is 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 
indicates either steam or gas is blowing through the 
air vent.  This indicates that the vent failed in the open 
position and is wasting energy.  

Summary of Contents for CMIN400

Page 1: ... follow the instructions and safety precautions in this manual can result in serious injury Keep this manual in a safe location for future reference Copyright 2009 by SKF Reliability Systems All rights reserved 5271 Viewridge Court San Diego CA 92123 1841 USA Telephone 858 496 3400 Fax 858 496 3531 Customer Service 1 800 523 7514 ...

Page 2: ...ers SKF 2009 The contents of this publication are the copyright of the publisher and may not be reproduced even extracts unless prior written permission is granted Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct indirect or consequential arising out of the use of the information...

Page 3: ...port tracking your proof of ownership and staying informed about upgrades and special offers Please visit our website for more details on these benefits Tell us how we re doing It s important that you re satisfied with the quality of our product user manuals We appreciate your feedback if you have comments or suggestions for improvement please tell us how we re doing 062909jj ...

Page 4: ......

Page 5: ...deficiency in any Product sold by SKF even if such claim is based on tort including negligence or strict liability breach of contract or any other legal theory If the Product does not conform to this limited warranty Buyer must notify SKF or SKF s authorized service representative within thirty 30 days of discovery of the nonconformity provided however that SKF shall not be liable for any claim fo...

Page 6: ...U all Wireless Monitoring Systems V T all Vibration PenPlus all Machine Condition Advisors MCA all transmitters all SKF software all Monitor Interface Modules MIM all Machine Condition Transmitters MCT MicroVibe P and Custom Products with the prefix of CMCP with the exception of any consumable or expendable items TWO YEAR WARRANTY Products warranted for two 2 years by SKF are as follows all standa...

Page 7: ...ded by Buyer must meet the requirements stipulated by SKF Criteria 2 SKF or its authorized service representative has installed the On line System or has audited the installation and commissioned the On line System On line Systems are defined as systems consisting of Multilog Condition Monitoring Unit s CMU Multilog Local Monitoring Unit s LMU and any sensing or input devices the interconnect cabl...

Page 8: ... requested or authorized in writing by SKF Buyer shall forward to SKF any Product claimed by Buyer as being defective Buyer shall prepay all transportation charges to SKF s factory or authorized service center SKF will bear the cost of shipping any replacement Products to Buyer Buyer agrees to pay SKF s invoice for the then current price of any replacement Product furnished to Buyer by SKF if the ...

Page 9: ...WARRANTY REPRESENTATION OR INDEMNIFICATION EITHER EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NON INFRINGEMENT b IN NO EVENT SHALL SKF BE LIABLE OR OBLIGATED FOR SPECIAL EXEMPLARY PUNITIVE INCIDENTAL DIRECT INDIRECT GENERAL OR CONSEQUENTIAL DAMAGES INCLUDING BY WAY OF EXAMPLE ONLY LOST PROFITS OR SAVINGS LOSS OF BUSINE...

Page 10: ...essential purpose so long as SKF is willing and able to perform to the extent and in the manner prescribed in this limited warranty SKF MARLIN Microlog and Multilog are registered trademarks of the SKF Group CM F0001 Revision P 12 07 SKF Reliability Systems 5271 Viewridge Court San Diego California 92123 USA Telephone 1 858 496 3400 FAX 1 858 496 3531 Web www skf com reliability ...

Page 11: ... Housing 1 8 Scanning Module 1 9 Contact Stethoscope Module 1 11 Headset 1 13 Inspector 400 Applications 2 Leak Detection 2 1 Electric Arc Corona Tracking Detection 2 7 General Mechanical Inspection Detection 2 10 Detecting Bearing Failure 2 13 General Mechanical Trouble Shooting 2 15 Locating Faulty Steam Traps 2 16 Locating Faulty Valves 2 21 ...

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Page 13: ...Precaution Although your ultrasonic instrument is intended for use 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 using your instrument around energized equipment Avoid direct contact with hot pipes or parts any moving parts or electrical connections Do not attempt ...

Page 14: ...to your body by keeping your elbows bent Use recommended protective clothing Do not get close to equipment Your detector will locate problems at a distance When working around high temperature piping use caution Use protective clothing and do not attempt to touch any piping or equipment while it is hot Consult with your safety director before entering the area Overview Ultrasound technology is con...

Page 15: ...erally referred to as airborne ultrasound Airborne ultrasound is concerned with the transmission and reception of ultrasound through the atmosphere without the need of sound conductive interface gels It can and does incorporate methods of receiving signals generated through one or more media via wave guides There are ultrasonic components in practically all forms of friction For example if you rub...

Page 16: ...ross The subtleties of change within the ultrasonic range will not be perceived and therefore omitted When a bearing is perceived as being bad in the audio range it is in need of immediate replacement Ultrasound offers a predictable diagnostic capacity When changes begin to occur in the ultrasonic range there is still time to plan appropriate maintenance In the area of leak detection ultrasound of...

Page 17: ...e test area a user may quickly spot a leak Electrical discharges such as arcing tracking and corona have strong ultrasonic components that may be readily detected As with generic leak detection these potential problems can be detected in noisy plant environments with the Inspector 400 ...

Page 18: ...esponse 20 to 100 kHz centered at 38 to 42 kHz Indicator 10 segment LED bargraph red Sensitivity Selection 8 position precision attenuation Power 9 volt alkaline battery non rechargeable Low Battery Voltage Indicator LED Headset Double headset wired monophonic Impedence 16 ohms Over 23 dB noise attenuation Response time 300 m sec Ambient Operating Temperature Range 0 to 50 C 32 to 120 F Relative H...

Page 19: ...oz 310 gms Probes Scanning Module SCM 1 Stainless Steel unisonic single transducer piezo electric crystal type Stethoscope contact Module Stainless Steel plug in type with 5 5 Stainless Steel waveguide Rubber Focusing Probe Circular shaped shields stray ultrasound signals focuses detected signals Carrying Case Cordura Nylon with die cut foam Warranty one year parts labor ...

Page 20: ...is advisable to familiarize yourself with the basic components of your kit Figure 2 Inspector 400 Kit Contents Pistol Housing The main component of the Inspector 400 is the pistol housing Let s define each part Bargraph Display The display consists of a ten segment LED bargraph that indicates ultrasonic signal strength A low number of LEDs indicate a low level of ultrasound more intense ultrasonic...

Page 21: ...lowest When it is necessary to detect a low level ultrasound start with the sensitivity at 8 If the ultrasound level to be sensed is too great adjust the sensitivity level down Head Set Jack This is where you plug in the headset Be sure to plug it in firmly until it clicks Should a tape recorder be utilized this is where the cord for the tape recorder is inserted Use a miniphone plug Trigger Switc...

Page 22: ...sure 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 sound to the loudest point If it is difficult to locate the sound due to a high intensity signal keep reducing the sensitivity and follow the meter to the loudest point Rubber Focusing Probe The Rubber ...

Page 23: ...emove the scanning or contact module before attaching and removing the Rubber Focusing Probe Contact Stethoscope Module The module with the metal rod The 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 the signal to a piezoelectric transducer located directly in ...

Page 24: ...Module Align the pin located at the rear of the module with the jack in the front end of the Pistol Housing and plug in firmly Touch the test area As with the scanning module go from the gross to the fine Start at sensitivity on the Sensitivity Selection Dial and proceed to reduce the sensitivity until a satisfactory sound and meter level is achieved ...

Page 25: ...00 To use simply plug the headset cord into the headset jack on the pistol housing and place the headphones over your ears A deluxe noise isolating type headphone CMAC8600 2 is available as an option and if a hard hat is to be worn it is recommended to use the optional SKF model CMAC 8600 3 Hard Hat Headphones which are specifically designed for hard hat use ...

Page 26: ......

Page 27: ...it is going from a pressurized laminar flow to low pressure turbulent flow Figure5 The turbulence generates a broad spectrum of sound called white noise There are ultrasonic components in this white noise Since the ultrasound is loudest by the leak site the detection of these signals is usually quite simple Figure 5 Figure 6 A leak can be in a pressurized system or in a vacuum system In both insta...

Page 28: ...limited to the particular gas it was designed to sense for example helium The Inspector 400 can sense any type of gas leak since it detects the ultrasound produced by the turbulence of a leak Because of its versatility the Inspector 400 may be utilized in a wide variety of leak detection Pneumatic systems may be checked pressurized cables such as those utilized by telephone companies may be tested...

Page 29: ...re is too much ultrasound in the area reduce the sensitivity setting and continue to scan If it is difficult to isolate the leak due to competing ultrasound place the Rubber Focusing Probe over the scanning module and proceed to scan the test area Listen for a rushing sound while observing the meter Follow the sound to the loudest point The meter will show a higher reading as the leak is approache...

Page 30: ...irections If the leak is at this location the sound increases and decreases in intensity as you sweep 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 surrounding sounds If it is the leak the rushing sound continues if it is not the leak site the sound drops off Overcoming Difficulties Competing Ultrasoun...

Page 31: ...und Isolate the leak area by reducing the sensitivity of the unit and by pushing the tip of the rubber focusing probe up to the test area checking a small section at a time Shielding Techniques Since ultrasound is a high frequency short wave signal it can usually be blocked or shielded When using any method be sure to follow your plant s or company s safety guidelines Some common techniques are Fi...

Page 32: ...akage the amplitude of the 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 of the 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 of this nature Build up the pressure if ...

Page 33: ...ension is the reason small bubbles form This can be negatively changed by contamination 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 decontaminating cleaning agent Electric Arc Corona Tracking Detection There are three basic electrical pro...

Page 34: ...ost often this sound is perceived as a crackling or frying sound in other situations it is heard as a buzzing sound Typical applications include insulators cable switchgear buss bars relays contactors and 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 switc...

Page 35: ...ce may be located with a gross detector such as a transistor radio or a wide band interference locator Once the general area has been located the scanning module of the Inspector 400 is utilized with a general scan of the area The sensitivity is reduced if the signal is too strong to follow When this occurs reduce the sensitivity to get a midline reading on the meter and continue following the sou...

Page 36: ... etc for arcing tracking and corona Figure 9 General Mechanical Inspection Detection Ultrasonic inspection and monitoring of the mechanical condition of a machine is another method for detecting incipient the onset of bearing failure The ultrasonic warning generally appears prior to a rise in temperature or an increase in low frequency vibration levels ...

Page 37: ...d 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 while monitoring bearings at frequencies ranging from 24 through 50 kHz they found that the changes in amplitude indicate incipient bearing failure before any other indicators including heat and vibration changes A...

Page 38: ...reatly assist a user in determining bearing problems When listening it is recommended that a user become familiar with the sounds 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 certain cases a damaged ball can be heard as a clicking sound whereas a high intensity uniform rough sound may indicate a damaged...

Page 39: ... reading Therefore be sure the contact probe is actually touching the bearing housing If this is difficult touch a grease fitting or touch as close to the bearing as possible Approach the bearings at the same angle touching the same area on the bearing housing Reduce sensitivity if unsure of this procedure refer to Sensitivity Selection Dial Listen to bearing sound through headphones to hear the q...

Page 40: ...ergy These normal microscopic disuniformities begin to produce wear and the possibilities of small fissures may develop which contributes to the Pre Failure condition Therefore aside from normal wear the fatigue or service life of a bearing is strongly influenced by the relative film thickness provided by an appropriate lubricant Slow Speed Bearings Monitoring slow speed bearings is possible with ...

Page 41: ...nt unplanned down time And just as important if equipment should begin to fail in the field the Inspector 400 can be extremely useful in trouble shooting problems To trouble shoot Use the contact stethoscope module Touch test area s Listen through headphones and observe the meter Adjust sensitivity until mechanical operation of the equipment is heard clearly Probe equipment by touching various sus...

Page 42: ...ckground noises A user can 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 Determine what type of trap is on the line Be familiar with the operation of the trap Is it intermittent or continuous drain Try to check whether the trap is in operation is it hot or co...

Page 43: ...es this may be longer than 30 seconds Bear in mind that the greater the load that comes to it the longer period of time it will stay open When checking a trap ultrasonically a continuous rushing sound is often the key indicator of live steam passing through There are subtleties for each type of trap that can be noted Use the sensitivity levels of the Sensitivity Selection Dial to assist your test ...

Page 44: ...oses 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 sound of the bucket clanging against the side of the trap A Float and Thermostatic trap normally fails in the closed position A pinhole leak produced in the ball float causes the float to be we...

Page 45: ...ly fails in the open position allowing continuous blow through of steam Thermostatic Traps bellows and bimetallic operate on a difference in temperature between condensate and steam They build up condensate so the temperature of condensate drops to a certain level below saturation temperature in order for the trap to open By backing up condensate the trap tends to modulate open or closed depending...

Page 46: ...re 11 Normal Steam Trap Operation Inverted Bucket With bimetallic traps as the bimetallic plates set due to heat they sense and the cooling effect on the plates they may not set properly which prevents the plates from closing completely allowing steam to pass through This is heard as a constant rushing sound ...

Page 47: ...on the low pressure or down stream side This produces white noise The ultrasonic component of this white noise is much stronger than the audible component If a valve is leaking internally the ultrasonic emissions generated at the orifice site are heard and noted on the meter The sounds of a leaking valve seat varies depending upon the density of the liquid or gas In some instances it is heard as a...

Page 48: ...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 the valve at the valve seat and just downstream of the valve Valve Check Procedure Use the stethoscope module Touch downstream side of valve and listen through headset When necessary if there ...

Page 49: ... false leak signals To determine if the loud signal on the down stream side is coming from a valve leak or from some other source Move close to the suspected source for example the conduit or the other valve Touch at the up stream side of the suspected source Reduce sensitivity until the meter displays a midline 50 reading Touch at short intervals such as every 15 to 30 5 cm 6 to 12 in and note th...

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