Ultrasonic Testing for Hydraulic Systems
Specialized Ultrasonic Testing programs for Industrial Hydraulic System Reliability & Maintenance.
Why it matters
Key Benefits
Leak Detection
Airborne ultrasonic detection identifies pressure and vacuum leaks in hydraulic systems systems that are inaudible to the human ear. Locating leaks quickly reduces energy waste and prevents process quality problems.
Bearing Lubrication Optimization
Ultrasonic monitoring of hydraulic systems bearings provides real-time feedback during grease application to prevent both under-lubrication and over-lubrication. Proper lubrication extends bearing life and reduces friction-related energy losses.
Early-Stage Fault Detection
Contact ultrasonic measurements on hydraulic systems detect high-frequency stress waves generated by metal-to-metal contact, friction, and impacts in the hydraulic pump, control valves, actuators, reservoir, filters, and accumulators. These signals appear weeks before vibration amplitude increases detectably.
Context
Challenge & Approach
The Reliability Challenge
Hydraulic valve internal leakage produces ultrasonic turbulence as fluid bypasses across spool lands or seats at system pressure, but detection sensitivity depends on leak rate, system pressure, and fluid viscosity. Relief valve bypass leakage at rates below the valve's rated flow capacity generates subtle ultrasonic signals. Check valve back-leakage produces ultrasonic emission only when reverse pressure is applied. External hydraulic oil leaks may not produce strong ultrasonic signals unless pressurized flow exits through small orifices. Pneumatic pre-charge systems in accumulators and overhead lines provide air-leak detection opportunities. Manifold-mounted valves have closely spaced potential leak sources that require precise directional sensing for localization.
Our Approach
We apply contact ultrasonic sensors to hydraulic valve bodies, relief valve outlets, and check valve housings to detect internal leakage through turbulent flow signatures. Spool valve bypass is assessed by comparing ultrasonic levels across identical valves in different positions. Relief valve bypass is measured during normal system operation and compared against expected levels at operating pressure. Airborne ultrasonic scanning covers all hose connections, tube fittings, manifold joints, and actuator seal areas for external leaks. Pneumatic system components (accumulators, overhead circuits, pilot air supplies) are scanned for air leaks. We quantify leak severity by dBu level and estimate energy waste from hydraulic pump loading to maintain leaking circuits. Reports include internal valve leakage assessment, external leak location mapping, pneumatic system leak inventory, energy waste calculations, and prioritized repair recommendations.
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Learn More →Ultrasonic testing detects bearing faults, lubrication deficiencies, internal leakage, and electrical discharge in hydraulic systems. Airborne ultrasonic detection locates pressure and vacuum leaks at joints, seals, and connections. Contact ultrasonic measurements identify early-stage metal fatigue and friction before vibration levels increase measurably.
Ultrasonic testing detects high-frequency stress waves that appear earlier in the fault progression than vibration amplitude increases in hydraulic systems. It is most sensitive to friction, impact, and turbulent flow, while vibration analysis excels at identifying specific fault types through frequency patterns. The two technologies are complementary rather than interchangeable for monitoring hydraulic systems.
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Find Every Leak in Your Hydraulic Circuits
Our ultrasonic testing identifies internal valve leakage and external fitting leaks across your hydraulic systems with quantified severity and repair prioritization.
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