CTRL UL101 hand held device is a versatile instrument whose applications are limited only by the imagination of the maintenance user. Diagnosis with ULTRASOUND is perhaps the most sophisticated technology on the market today, and is very economical and easy to use. PERMAWELD has more than a DECADE of experience in application based usage of the CTRL Ultrasound technology, and offers to Indian industry regular “Predictive Maintenance and condition monitoring services”.

Our services are offered to companies that purchase the CTRL kit and also those who sign up for ANNUAL service contracts. We customize the product usage charts for specific applications and customer environment.

ULTRASOUND is noise which is NOT AUDIBLE to the human ear ( normal range of human hearing is 20Hz to 20,000 Hz). Ultrasound waves are emitted at 40,000 Hz and the instrument IGNORES ALL OTHER AMBIENT SOUND in the plant giving maintenance staff a “sixth sense”.

This sixth sense saves huge costs by “predicting through early warning diagnosis of potential failure and losses that remain “hidden” draining profits. Ultrasound is emitted in many areas within process plant and machinery wherever there is “friction, high and low speed vibration, impact, electrical arcing, corona discharge, locating and pin pointing LEAKS”. This will indicate the condition of internal parts by listening to NON ACOUSTICAL sounds such as vibration through housings wherein lie bearings and gears, internal leaks, vacuum leaks, hydraulic valve passing, and condition of mechanical components.

The following list include just some of the specific applications that you may consider when using the UL 101 for facility maintenance.

ANY leak to atmosphere creates an obvious “rushing sound” and can be traced to pin point accuracy to identify the nature of the sound and action prioritized and taken accordingly. ALL joints OUTWARDS from the compressor should be checked regularly to save on energy and gas loss. The filter/dryer can be tested using the UL101 and the Ultrasound transmitter UT2000 saving time and energy in place of pressure testing. This is done by opening the housing and removing the filter cores. Then insert the UT 2000 transmitter ( that is switched on to start emanating ultrasound) into the housing, close and bolt it down. Using the UL 101 on ALL BRAZED joints and shell casing to search for the loudest transmitter noise. The intensity of the noise increases when a leak is present. They can be repaired and tested again in this non invasive and convenient way!

Many structures and buildings have compressed air, oxygen and natural gas lines often with secondary systems. The UL 101 will find leaks in such lines WITHOUT closing down the system or inconveniencing the tenants. Pressure leaks to atmosphere can be easily detected 15 to 20 feet away! It will also identify “minute” leaks that soap suds will NOT detect and if used in conjunction then crackling or snapping sound will be created when minute soap bubbles break. This is useful when air movement or gas saturation makes a “sniffer” ineffective. Air conditioning refrigerant leaks as small as ½ ounce per year can be located with UL 101.

These use various operating controls such as thermostats and shutter stats with low pressure compressed air in the range of 15 PSI. If the pneumatic tubing or control devices in the system leak enough air to drop BELOW minimum operating pressure the CONTROLS will cease to function. This means that a thermostat will be unable to call for MORE heat or flow. Using the UL 101, each room, area that has such a control can be scanned from the doorway to detect a leaking thermostat, etc. A complete check can start at the Compressor ( checking internally for unloader valve leaks) an check each joint going outwards.

The UL 101 pays for itself in a very short time even if a leak of just 1/16 inch is located in a 100 PSI line. ONE such leak can cost over ONE LAC per annum in steam generation costs!!

Steam Traps block steam vapour and pass condensate out of the system. A steam trap regularly OPENS and CLOSES!! TWO types of malfunction can occur. A steam trap that is stuck OPEN creates LOSSES and is an expensive waste of steam. A steam trap stuck in CLOSED position keeps the heating element or power device from receiving steam and making it non functional. The UL101 is used to listen. If the sound is there ALL THE TIME then the trap is stuck OPEN, and if there is NO SOUND then it stuck CLOSED! There is a laser attachment called POWER BEAM 300 that can “pick up and bring back sounds that are far and inaccessible or at heights”. The instrument eliminates the mess and uncertainty of conventional testing methods such as listening with a screw driver or using hot melt crayons. The UL 101 can also be used to scan tube ends of STEAM CONDENSORS. The Water jackets need to be drained for access. The steam side of the condenser needs to be isolated and pressurized with air between 2 and 4 psi and then checked for integrity.

Vacuum leaks are almost impossible to locate, and air leaking into a large vacuum condenser in turbo generators dramatically increase costs. The UL 101 is able to “hear” and readily finds vacuum leaks, eliminating time consuming techniques used to detect them.

Using the UT 2000 Ultrasound transmitter the UL 101 device can be used to check the integrity of any “chamber” without or before final testing with air, water pressure etc to save time and cost. As a QC device in fabrication of vessels, tanks and even in car manufacturing it can replace conventional “shower testing” to check cab integrity and insure leak proof assembly.

Most buildings, power company substations and industry have power systems that have high voltages over 1000 volts. All high voltage systems are subject to “corona discharge”. Individual insulators leaking corona discharge to the ground can be easily detected. These waste expensive power and interfere with radio, TV and telecom equipment. The UL 101 can be used to rapidly, safely and easily locate the EXACT point of trouble. The UL 101 can also detect the arcing from motor slip rings and brushes.

The versatility of the UL 101 dramatically improves the speed and accuracy to detect leaks and assess the condition of a component. With the ability to PINPOINT the source of Ultrasound in few seconds or minutes the UL 101 device empowers your maintenance department to make PROACTIVE and CORRECTIVE decisions well in time BEFORE catastrophic failure occurs. It works even in very noisy environments, as it allows you isolate and differentiate current and potential defects MUCH BEFORE they become noticeable and heard by the human ear.


THE UL 101 saves huge unplanned costs, enhances safety and maintenance standards of your plant and machinery!!