I have been tasked to develope a recommended practice for the PdM programs at 5 power plants on the application of ultrasound. Are there any good references out there that include types of machines to survey and frequency of monitoring. I've developed some program elements that work for me but I'm reluctent to make what I do the model because of the differences in experience and work load at other plants. Any help would be appreciated.
rgf

Do you have contact with the operators at the 5 power plants, they will be able to tell you what gear they are using and what is causing them grief. I would suggest you talk to them and try and design it around thier problems, then blossom out into the rest of the plant things. In my expierence if you can help them with some of the things that give them problems then they will help promote and expand your program with you not even trying.

A few big ticket items within Power industry can be as follows:
Steam traps, Valves, Air systems and electrical surveys ar all good places to start.

Cheers,

Hooch

Hooch, Do you test steam traps with a ultrasound at all???

Airborne Ultrasound in a power plant is "imperative". As you know depending upon whose instrument you are using will result in the success that you have. For instance one major manufacturers unit cannot be used for condenser water box leak detection anothers can. However, for pdm the three major manufacturers SDT, UE and CSI, all would prove to be sufficient for your needs.
Applications would include and not limited to: (sense we always finding new uses or applications)

Leak Detection

• compressed air (pressure or vacuum/in-leakage)
  
• heat exchanger on-line/off-line
  
• Condenser water box
  
• expansion joints
  
• steam leaks
  
• in-leakage around turbine (yes it can)
  
• scanning weld seams of water inlet pipes, in-leakage (where applicable)
  Mechanical
  
• bearings
  
• acoustic lubrication
  
• gearbox
  
• conveyors
  
• fans/blowers
  Steam Trap Troubleshooting
  Electrical Scanning
  
• Switchgear
  
• Substations
  
• Distribution
  
• Radio / TV Interference
  
• ELECTRICAL SAFETY / ARC FLASH PROTECTION
  

Many of the plants that I have spoke to are still greatly undermanned, just yesterday I was in a plant that had only 2 men reading vibration reports of a plant operating 24/7. I imagine you have a vibration analysis programs and I hope you do not have manpower issues. But when a plant is undermanned, not having the level of certified professionals on hand such as a vibration tech, you have to allow other technologies such as ultrasound to assist your pdm program. There are many plants out there currently using airborne ultrasound having the technicians take readings of all the motors that vibration cannot get to, as they see the decibel range increasing overtime appropriate action can be taken. Wether that is to lubricate, remove and replace, or as many do send a vibration tech to confirm. Trending overtime is a must for bearings, compartive methods (comparing bearings of the same duty, rpm, manuf) is second best when trending, snapshot "listening" to a bearing is not a good idea. Like have you heard any good bearings lately? Just listening to a bearing is not good enough.
Work your ultrasound into your pdm programs and certify your technicians in the many applications. Seek a training class that is not specific to your instrument (who needs another sales presentation?). Please do not forget integrating your ultrasound with your IR Program...it is a must.

I am a consultant for a fairly large firm in Australia mainly work in the underground coal mines myself, but we have several other consultants which cover power plant operations.
I do not go to any sites with steam traps at the moment but they have been tested in the past. We have just picked up some work at some local power plants and there is talk already of starting a program for them.

Jim has highlighted some very good points in his reply. The key to these technolgies is to intergrate results with all other forms of testing, then you can get a clearer picture of what is truely happening.

I hope this helps

Hooch