Page 190 - CW E-Magazine (22-7-2025)

Special Report Special Report

ACOUSTIC EMISSION TESTING strain. To maintain safety, its reactors
and tanks operating under pressure and
Cut costs, cut downtime: Smarter maintenance variable temperatures – require regular
checks. This could mean, for example,
with sound an annual budget of roughly €1-mn
would be allocated for inspections.
s industrial systems grow more
complex and safety standards RAINER SEMMLER By shifting to AT with sensors
Abecome increasingly stringent, Head of Process Safety Management mounted on the hull of the vessels,
precise and effi cient maintenance must TÜV SÜD Industrie Service the facility could bypass water-based
be prioritised. One testing method, Email: rainer.semmler@tuvsud.com pressure testing, avoiding residual
Acoustic Emission Testing (AT), is moisture that can lead to corrosion.
a viable alternative to traditional HERMANN SCHUBERT This alone could trim 20% off the in-
approaches which can reveal structural Head of Digital and Continuous spection spending – about €200,000
shifts through sound-based diagnos- Inspection annually. More importantly, because
TÜV SÜD Industrie Service
tics. Instead of halting production, this Email: hermann.schubert@tuvsud.com the drying period in this scenario has Schubert_TÜV SÜD_3: Pressure gas containers for the transport and storage of hydrogen,
technique listens in on operating equip- been eliminated, two days of produc- for example, are also subjected to inspections using AT.
ment, helping detect emerging issues testing without dismantling compo- tion are preserved, recapturing an for several units, which could reduce assuming only 70% of projected bene-
before they escalate. TÜV SÜD informs nents reduces the likelihood of post-test estimated €160,000 in potential revenue. inspection costs considerably; saving fi ts are realised, a plant could still save
companies on how to employ AT to issues or those that may arise between in some cases around €100,000. With around €400,000 annually. More than
promote safe and economic operations. inspection intervals, such as moisture- Savings extend beyond the obvious fewer technicians needed and stream- just a cost-cutting measure, AT helps
induced corrosion or seal damage. Seals on large tanks typically need lined planning, such a bundling approach facilities increase operational uptime,
Acoustic Emission Testing (AT) This non-intrusive nature not only replacing every time the units are makes routine checks faster and more enhance safety, and reduce environ-
is an approved alternative for pres- safeguards the equipment but also the opened – a task both time-consuming manageable. mental impact by eliminating the
surised equipment inspections under surrounding processes that rely on it and costly. With AT, since sensors are disposal of testing fl uids.
Germany’s Industrial Safety Ordinance Schubert_TÜV SÜD_1: A fl at-bottom storage functioning without interruption. attached to the outside of equipment, The integration of AT into a site’s
(BetrSichV). The key advantage to this tank is inspected using AT. tanks remain closed during testing, broader inspection routine brings added From condition checks to predictive
approach is that it minimises disruption defects which can lead to signifi cant The savings potential resulting in fewer replacements and effi ciency. Follow-up checks are more strategy
by doing away with traditional hydro- consequences: safety risks, unexpected Any production site manufactur- lower labour requirements. That can focused, avoiding unnecessary repeti- Thanks to advances in sensor design
static or visual internal tests. Instead shutdowns, or expensive repairs. ing polymer resins faces frequent ins- translate to annual savings of approxi- tion. This optimisation could account and data analytics, AT has evolved into
of opening up equipment, or poten- Beyond savings in time and resources, pection-related downtime and budget mately €25,000. Moreover, this could for an additional €50,000 in annual more than a diagnostic tool – it now
tially draining, cleaning, and refi lling it substantially lower the chance of leaks savings – a result of better coordination plays a key role in predictive main-
with water – which adds downtime and caused by reassembly. and reduced resource waste. tenance strategies. Smart, networked
risk – sensors are fi xed on the outside sensors and AI-powered interpretation
of the component. Inspections are thus AT’s early detection capabilities Extending equipment lifespans tools support facilities in the transition
performed during pressure tests or as mean that previously unforeseen main- Because the approach used in AT from reactive to condition-based servi-
the system runs, dramatically reducing tenance – in some facilities costing does not require the start-stop cycles cing. This not only optimises equip-
turnaround and operational strain. up to €50,000 yearly – can be largely associated with other testing methods, ment health but also feeds into broader
avoided. Predictive planning allows the wear and tear from thermal or pressure goals like energy effi ciency and sus-
What makes AT a game-changer is engineers to address minor wear before fl uctuations is avoided. This reduces tainability.
the accuracy of data it provides. After it evolves into critical damage. A plant the need for frequent replacements and
the sensor has been put in place, it picks could save around €40,000 a year by extends the longevity of parts. Even a As a certifi ed method under
up acoustic signals in the form of tran- reducing emergency interventions alone. conservative 5% reduction in equip- BetrSichV and a growing component of
sient elastic waves released by mate- ment costs – or about €10,000 – could Industry 4.0 frameworks, AT is proving
rials under stress. By interpreting these Consolidated testing for added be directly attributed to this effect. its value not just in immediate savings
emissions, engineers gain an extensive effi ciency but in long-term resilience. With TÜV
view of component integrity and can One often overlooked benefi t of A cumulative impact SÜD, many facilities are discovering
identify internal changes that may not AT is its ability to evaluate multiple These individual savings could how to integrate acoustic insight into
be visible from the outside. systems at once. Instead of inspect- amount to roughly €500,000 each year – the heart of their operations – building
ing each vessel or machine separately, a signifi cant return that makes the smarter, more sustainable plants from
Using AT, it is possible to detect Schubert_TÜV SÜD_2: AT: Sensors on a process vessel. plant managers could combine testing adoption of AT a strategic win. Even the inside out.

190 Chemical Weekly July 22, 2025 Chemical Weekly July 22, 2025 191

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