UP100 Ultrasonic Trap Tester

UP100 Ultrasonic Trap Tester
0876250/2
IM-P087-36
MI Issue 2
UP100 Ultrasonic Trap Tester
Operators Instructions
Introduction
The UP100 is a portable battery powered
instrument which gives visible and audible
indication of ultrasonic frequencies. It is
intended for use as a diagnostic tool in the
analysis of steam trap operation and can also
Printed
in the MI
UKIssue 2
IM-P087-36
be used to detect leaks in steam and
compressed air systems. Some experience,
together with a working knowledge of steam
trap operation, is required to correctly interpret
the signals.
© Copyright 19981
Technical details
The UP100 consists of 4 components:
1. The pistol housing.
2. The stethoscope probe module with
extension rods.
3. The headset with extension cable.
4. The flexible carrying case.
UP100 pistol housing
A. The UP100 pistol housing (A) requires a
9 volt battery located in a compartment at
the base of the handle. When the instrument
is not used for an extended period of time,
the battery should be removed.
Note: Battery not supplied
B. The bargraph display (B) consists of a ten
segment red LED bargraph that will
indicate ultrasonic signal strength.
C. The sensitivity selection knob (C) is
located on the back of the pistol next to the
bargraph display (B). Sensitivity level is
increased or decreased by turning the knob.
As the knob is turned up, the sensitivity of
the instrument increases, as the knob is
turned down, the sensitivity decreases.
Therefore, 8 is the highest sensitivity level
and 1 is the lowest. It is advisable to start
with the sensitivity at a low setting and
increase it slowly by adjusting the knob until
the required volume is achieved.
D. The low battery indicator light (D) is located
on the back of the pistol and above the
sensitivity selection knob (C). This red light
illuminates when the battery needs to be
replaced.
Note: When the trigger on/off switch is
pressed to the on position, the low battery
indicator light (D) will flicker on and then
stay off. This is normal.
E. The trigger switch (E) is located on the
underside of the UP100. The UP100 is
always "off" until the trigger switch is
pressed. To operate, simply press the
trigger; to turn the instrument off, release
the trigger.
F. The headset socket (F) is located next to
the sensitivity selection knob. This is where
the headphones are plugged in.
Stethoscope probe module
The stethoscope probe module enables a user
to hear internally generated ultrasounds. By
touching the probe to various points on steam
traps, machinery, valves, pipes, etc. the UP100
indicates the amount of ultrasound emitted.
Used as a stethoscope, bearings, compression
noises, steam traps, valves, even internal
arcing of circuit breaker switches can be
monitored. Extension rods to 780 mm are supplied.
Headset with extension cable
The headset supplied is a lightweight unit ideal
for extended periods of use.
Flexible carrying case
A soft reinforced nylon carrying case complete
with belt is supplied. This is large enough to
carry the pistol housing, stethoscopic probe
module, extension probes and headset.
The UP100 conforms to EN 50082-1
(electromagnetic compatability).
Note: The performance of the product may be
affected when used near strong sources of
electromagnetic interference such as found in
some industrial environments.
D
B
F
C
E
A
2
IM-P087-36 MI Issue 2
Operation ... testing steam traps
Before testing any steam trap, the following
information should be determined so readings
from the unit can be properly interpreted:
A. Type of steam trap ( thermodynamic,
inverted bucket, thermostatic, etc.) See
below.
B. Working steam pressure (1,2,10 bar, etc.)
C. Trap application and expected condensate
load. ( tracer, process, etc.)
Knowing the above, it is possible to predict the
type and sound level that should be heard and
will help set sensitivity level.
Condensate flow produces less ultrasound than
does steam leaking through a trap orifice.
Crackling or sputtering flow is associated with
condensate flashing in the low pressure area
downstream of the orifice. Leaking steam
generates a constant amount of ultrasound but
there will always be some condensate mixed in.
By using the UP100 on known good or leaking
traps, experience will be gained that will be
invaluable in carrying out steam trap checking.
Steam trap types
Note: All traps should be checked with the
probe firmly touching the trap outlet area or
adjacent pipe. Readings must not be taken
while the probe is moving.
A. Thermodynamic traps
This has a blast discharge and cycles on
and off. The UP100 will give a 0, then 100%
reading on this trap so low sensitivity
setting is normally recommended. A
properly sized trap in good working order
will discharge between 0-5 cycles/minute.
A trap which operates 10 or more cycles/
minute should be inspected for dirt or wear.
A continuous discharge means the trap is
either severely worn, is subject to high back
pressure, or dirt is preventing the disc from
closing off.
B. Inverted bucket traps
The discharge pattern is usually
semi-cyclical. On medium to heavy loads,
the trap will have a definite on/off cycle. The
ultrasonic tester reading will be a sweeping
motion, back and forth. Light loads will
change the discharge pattern to a modulating
low flow and the UP100 will give a low
continuous reading. When the trap is
malfunctioning, the readout will be a full
100% reading for steam leaks and an
erratic on/off type operation for lost water seal.
C. Float and thermostatic traps
The discharge pattern of this trap is a
continuously modulating flow. First,
determine the type of application; process
or light load condition. If the condensate
load is light, such as found on main drips and
tracers, sound levels will normally be low
IM-P087-36 MI Issue 2
and give a low level continuous readout. A
high level readout means that some part of
the trap has failed. When testing, be aware
that this type of trap has two orifices, the
main orifice located below the normal
condensate level, and the thermostatic air
vent at the top in the steam space.
In normal operation on process equipment
such as heat exchangers and air handlers,
the flow will be continuous and at a high
sound level. For the ultrasonic test to be
accurate, the load must be removed or
lightened to allow the trap to shut or throttle
back considerably.
Readings should be compared at high and
low loads. To reduce the load, the air flow
on a coil should be shut off; on a heat
exchanger, the liquid flow turned off or a
blowdown valve before the trap opened to
reduce the load. In any case, the trap should
shut off or throttled back to a point where a
good test can be made. When load has
been reduced or cut off, the ultrasound
reading should be very low or at zero level
if the orifice is tightly closed.
D. Thermostatic/radiator trap
These traps are often on low pressure and
the usual discharge pattern is a dribbling
type action. The load on convectors and
radiators is normally low and should give a
very low or zero readout when the unit is on
and operating. Since thermostatic traps are
wide open when cold, the trap can be tested
for both opening and closing by turning off
the steam supply to the trap and allowing
the trap to cool. When trap is cool, open
steam valve while UP100 is contacting the
trap outlet. Trap discharge should start wide
open, then quickly shut. This test proves full
function of the trap and should be used if
normal test proves inconclusive.
E. Thermostatic/general purpose trap
Element design and filling contained will
vary, but generally this trap dribbles on light
load and modulates on heavy loads but can
also cycle on/off. Main drips and tracers
where loads are light should give a low
readout and cycle on/off. On most process
use, the trap will tend to modulate or some
times cycle. For testing, the same
procedure given above for process on float
and thermostatic traps should be used.
Closing the trap off and letting it cool will
open the valve fully. When turning the trap
back on, the trap will blast full open and then
shut down within a minute. The UP100 will
be able to indicate both full flow and shutoff
condition. This method should be used if
the reading that is normally given by the
trap is unclear as to whether it is good or
leaking steam.
3
F. Bimetallic trap
Bimetal traps do not respond to load change
as fast as other types and the discharge
pattern is normally modulating or dribbling.
Bimetal traps are usually found on drips,
tracers and light load applications, so
discharge would normally be continuous
with a low sound level. Draining
condensate ahead of the trap should shut it
off, and ultrasound levels should drop to
zero. Bimetal traps are wide open when
cold so when initially tumed on the trap will
blast full open until the bimetal expands and
closes.
Ultrasound readout should be high on
startup and should throttle near to zero or
zero when trap heats and closes. The "cool
down/startup" test should be run if normal
test methods are not conclusive. Care must
be taken as many bimetal traps will take
a "set" in operation. These traps can leak
steam if the valve stem is not readjusted
periodically to the operating conditions.
G. Oriflce drain devices
These are not automatic traps but are units
designed for continuous flow with some
steam loss on low load. The ultrasonic
tester can only tell that the unit is passing
either steam or condensate and is not
clogged shut. Excessive steam leakage will
be indicated only if the orifice is oversized
for the load.
Other uses for the UP100
A. Shutoff valves in closed piping (Ball,
gate, globe, etc.)
Shut valve; place probe on valve outlet.
Ultrasonic reading should be zero if valve is
tightly closed and not leaking. Replace valve
as necessary.
B. Control valves and temperature
regulators
Shut valve by diverting control signal to
valve, or turn temperature adjustment
below set temperature so valve shuts. Place
UP100 on valve discharge side. With valve
closed, ultrasound reading should be zero.
Be aware that some valves (e.g. cooling
controls) contain a constant bleed or
bypass flow.
C. Parallel pressure reducing valves
The ultrasound test can be used to check
which reducing valve is operating under
various load conditions. It can also be used
to aid in setting sequential operation of
parallel valves at set pressure + 0.2 bar
apart. Place probe on outlet of each valve to
check operation as the demand changes
the reduced pressure.
4
D. Troubleshooting pilot-operated pressure
reducing valves and temperature
controls
On a valve which is overshooting, the UP100
can be used to determine whether the pilot
or the main valve is leaking. To test, shut
pilot off by reducing the pressure or
temperature set point and place sonic probe
on bypass transmission tube. A zero
reading should be shown if pilot is closed
fully. If pilot is leaking, significant readings
should be picked up and pilot trim must be
changed. If pilot is working properly, main
valve leakage or transmission tube oriflce
blockage is occurring and must be repaired.
Maintenance
There are no user servicable parts in the UP100.
When the instrument is not used for an
extended period of time, the battery should be
removed.
Return of faulty equipment
Please provide the following information with
any equipment being returned:1. Your name, company name, address and
telephone number, order number and
invoice and return delivery address.
2. Description and serial number of
equipment being returned.
3. Description of the fault or repair required.
4. If the equipment is being returned under
warranty, please indicate:
(i) Date of purchase
(ii) Original order number
PLEASE RETURN ALL ITEMS TO:
Returns Investigation Department
Runnings Road
Kingsditch Trading Estate,
Cheltenham,
Glos, GL51 9NX.
United Kingdom
Alternatively, please return any items to your
local Spirax Sarco branch.
Please ensure all items are suitably packed for
transit (preferably in the original cartons).
IM-P087-36 MI Issue 2
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