Ultrasonic Inspection Services & Ultrasound Detection

Ultrasonic Condition Monitoring (UCM) is the process of using ultrasound technology to detect changes in the condition of machinery. Our ultrasonic inspection services use high-frequency sound waves to identify potential problems, such as cracks or other damage, before they cause major failures. These advanced sound-based techniques allow early intervention and support predictive maintenance strategies across industrial facilities.

Ultrasonic Condition Monitoring methods have revolutionized condition monitoring and mechanical inspection. Through advanced ultrasonic fault detection, it is possible to locate and determine the cause of many problems before they create safety risks or unplanned downtime. Our ultrasonic inspection services provide accurate trending data that maintenance teams can act on immediately.

Applications for ultrasound condition monitoring are found in a wide variety of industries including:

• Power Generation
• Petrochemical
• Mining
• Manufacturing
• Automotive

Ultrasound condition monitoring can be used to detect:

• Bearing Failures
• Lubrication Defects
• Mechanical Looseness
• Component Misalignment
• Cavitation in Pumps and Compressors
• Excessive Vibration
• Worn Gears
• Electrical Faults

Advantages of ultrasound condition monitoring:

• Enables predictive maintenance to be carried out before failures occur
• Reduces downtime and associated costs
• Improves safety by reducing the likelihood of accidents
• Increases equipment life
• Contributes to improved product quality

At Failure Prevention, we provide professional ultrasonic inspection services integrated with vibration analysis and condition monitoring programs. Our approach combines ultrasonic fault detection with actionable reporting so facilities can make maintenance decisions from a position of knowledge.

Our ultrasonic inspection services can locate air/gas leaks, vacuum leaks, and other defects even in noisy industrial environments. Because ultrasound operates at frequencies above human hearing, it cuts through background noise and allows precise localization of failure points.

Our ultrasonic inspection services follow industry best practices for compressed air/gas leaks, vacuum leaks, electrical faults (arcing, tracking & destructive corona), slow-speed bearings, and other applications requiring accurate ultrasonic fault detection. In rotating equipment, our ultrasonic bearing inspection techniques help identify lubrication needs and early friction changes before temperature or vibration increases.

We have extensive experience delivering ultrasonic inspection services using SDT ultrasound equipment and ultrasonic sensors. These tools allow consistent ultrasonic fault detection while supporting detailed documentation for maintenance planning and energy loss reduction.

Air/gas leaks are the most common areas addressed through ultrasonic inspection services. Leakage problems produce high-frequency ultrasound signatures that make ultrasonic fault detection extremely effective for identifying even small losses that waste energy and increase compressor run time.

The ultrasound emitted from a leak is proportional to the rate of the leak, which makes it easy to locate and quantify the problem. Our ultrasonic inspection services provide measurable data that helps maintenance teams prioritize repairs based on severity and cost impact.

We have extensive experience with ultrasound leak detection in a wide variety of industries and applications, from small compressed air systems to very large industrial plants. Our ultrasonic inspection services routinely uncover leaks responsible for significant energy loss, while also supporting ultrasonic bearing inspection programs for rotating equipment tied to compressed air systems.

Vacuum leaks can be more difficult to find than air/gas leaks because they often operate at lower pressure differentials. Our ultrasonic inspection services are designed to improve vacuum system reliability through accurate ultrasonic fault detection in hard-to-access areas.

By applying structured ultrasonic inspection services, we can identify vacuum inefficiencies quickly and recommend corrective actions that stabilize production and reduce energy waste.

Arcing and tracking are two of the most common electrical faults we encounter during ultrasonic inspection services. These issues often generate distinct high-frequency signatures that are easily detected using advanced ultrasonic fault detection methods.

Arcing can cause fires and equipment damage, while tracking can lead to slowly deteriorating insulation and eventually costly downtime. Our ultrasonic inspection services allow early identification of these hazards, improving plant safety and preventing unplanned outages.

Worn gears can cause decreased efficiency, increased vibration, and ultimately complete failure. Our ultrasonic inspection services enable early-stage ultrasonic fault detection of friction changes and surface wear before damage becomes extensive.

In integrated programs, we combine ultrasonic inspection services with ultrasonic bearing inspection to ensure complete rotating equipment health monitoring.

Cavitation is a common problem in pumps and compressors. It can cause damage to internal components and lead to increased downtime. Our ultrasonic inspection services detect cavitation signatures early through precise ultrasonic fault detection, allowing corrective action before mechanical damage escalates.

By incorporating ultrasonic inspection services into broader condition monitoring programs, facilities gain better control over equipment health and maintenance costs.
If you would like to learn more about our ultrasonic inspection services, please contact us today. We would be happy to discuss your specific needs and develop a customized solution tailored to your plant.

At Failure Prevention, we use ultrasound condition monitoring (UCM) as part of our predictive maintenance programs. Through structured ultrasonic inspection services and specialized ultrasonic bearing inspection, we locate and determine the cause of many problems before they result in failures.

The U.S. Department of Energy Compressed Air Challenge has found that 25% of compressed air is lost to leaks. Often plants find they are losing more than that. Our ultrasonic inspection services are specifically designed to uncover these losses through accurate ultrasonic fault detection.
FPA’s certified inspectors conduct compressed air leak detection programs as part of our ultrasonic inspection services to help you lower energy costs and improve system performance.

These programs are frequently paired with ultrasonic bearing inspection to ensure compressors and associated rotating equipment operate efficiently.

Fixing leaks provides immediate payback while increasing service life, increasing capacity for production surges, and stabilizing system pressure. Through professional ultrasonic inspection services, facilities reduce energy waste, extend equipment life, and improve overall maintenance effectiveness.