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SoundCTRL
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Client List and Testimonials The SoundScan Equipment was developed For Sonatest by CTRL Systems. It is based on their successful UL101 system.
Here is a list of some of their clients, Some references, and a selection of reference letters:
Abbreviated Testimonials
INA Schaeffler KG
Since we have been working with the UL 101, the number of air leaks which have been found in the production area has increased by 50%. Before, we only found obvious leaks. We have also found hard-to-find leaks in concealed locations and are now saving, thanks to early detection and elimination, between 15,000 and 25,000 Euros ($19,500 and $32,500) per year reports Siegfried Glotz, technical factory maintenance manager for INA Schaeffler KG in Höchstadt an der Aisch (near Nuremberg), where the company makes mostly roller bearings for the car industry. Glotz
has been using the UL 101 for this for two years. Previously* we could only find leaks by ear or if we could see them. That meant that the maintenance staff had to work in the production areas when no production was going on, and then tried to find the leaks acoustically, or with a leak spray, which produced bubbles and so showed where a leak was. The big problem with both methods was that they could only be used when there was no production. *The reduction in costs mentioned above reflects savings over and above the savings previously generated through an alternative leak detection program.
International Paper
Our continuous improvement group advocates the use of the UL101 as a maintenance best practice at all plants to help detect and correct equipment problems before downtime occurs. For a small investment, we have begun to see
significant improvements in equipment reliability. Several of our container plants are already using this technology, and they number among them, some of our most productive facilities. These plants estimate that they save eight hours of downtime per month through the use of the UL101 during regular PM rounds.
Brad Trahan, Divisional Maintenance Manager, International Paper
United Airlines
We've had great success with this tool.
United Airlines Maintenance Centre
Fellows Manufacturing
The CTRL UL101 ultrasonic detection device is an extremely useful preventive maintenance tool in the early detection of irregular sound signatures, which will reveal a problem before failure of equipment occurs. This will prevent costly down time and major damage to manufacturing equipment, such as motors, gearboxes, shafts, and conveyors, all of which contain bearings along with other moving parts.
Ford Motor Company
The Ford Chicago Assembly Plant has been using the detectors for approximately 4 years now, and are very happy with its capabilities The instrument is mainly used at this location to locate air leaks. With the extensive use
of air in the production process, compressed air has become more and more expensive. Though, to a lesser extent, our detectors are also used to detect steam leaks, vacuum leaks, and internal hydraulic leaks. Also, at times when the situation warrants, we have used ultrasound to look for possible bad bearings.
G.W. Butler, PM Planner
Chicago Assembly Plant
Adria Machine
I tried every ultrasonic sensor on the market. Only the UL101 provided me with the sensitivity and design necessary to use in my mounted leak detection system. And now, I have more than thirty systems in use throughout the United States
for detection of leaks in refurbished steel drums and totes. CTRL technology helped meto establish what is now being considered a new industry standard.
Tony Ivankovic, Adria Machine
Sclhumberger
Since we have begun to utilize CTRL's turnkey ultrasonic inspection program, we've seen quite a few significant benefits from the employment of the the technology, states Ron Stover, Operations Manager of Schlumberger Oilfield Services.
Johnson Controls
The UL101 allows fast identification of the scope of problems to be corrected. Cuts trouble shooting labour by 50% to 75% compared to conventional methods
Brehob Corporation
We have been using the UL101 for more than 3 years now to find air and gas leaks for our customers. We are extremely happy with its capabilities to find even the smallest leaks.
Praxair
We are happy to inform you that the detector is helping us in identification of leaks very effectively, particularly the valve internal seat leaks. These leaks, if unidentified, would lead to increased loading of centrifugal compressors and wastage of power. We have included a preventive maintenance job to our CMMS and through this we use this detector for monitoring the performance of all critical valves in the plant.
MVS Ramakrishna
Chief Manager-Reliability Centre
DKIN
Rolf B. Neurath, mechanical engineer and president of the DKIN (German Maintenance Committee, an association dedicated to the spread of best practice in industrial maintenance), considers the device an economical way of diagnosing. Before, there was actually no middle way. Either one relied on the screwdriver in the ear
and one's hearing ability, which left small leaks and damage in an early stage of development undetected, or one had to invest five-figure sums in complicated thermography or vibration analysis, for which employees had to be given special
training. With the UL101 there is available for the first time a usable instrument at a reasonable price. An advantage of the UL101 is that with very little technical effort equipment in the areas of electrics, electronics, mechanics, hydraulics, compressed air and gas can be reliably checked for defects, said the DKIN president. Especially in inaccessible
locations such as underground piping or equipment high over-ground the UL101 has proved a great help.
National Institute for Standards and Technology
If ever there was a maintenance tool which takes you into the 21st century and beyond, this is it.
USRO Supervisor, NIST
Jackson Memorial Hospital
The [CTRL UL101] leak detector is working great. We used it in a building that we knew had leaks but could not find. When we used the leak detector, we found five leaks inside of the drywall and repaired them. Now the air
compressors are cycling as they should.
Caterpillar Inc
The device [CTRL UL101] has saved us time and money in locating leaking fittings and devices without guessing as to where the problem lies.
PICO (Progressive Tool & Industries Company),
Automotive Test and Assembly Specialists, 21000 Telegraph Rd., Southfield, MI. 48034.
The type of test equipment that we use at our plant varies as follows:
1. Short Block Compression Testing:
This is when a Cylinder Block assembly equipped with pistons w/rings, crankshaft, and bearings is sealed up, air is pumped into the compression chamber, and the crankshaft is turned. The chambers are monitored and flow charts and information collected. Limits are placed on the leak rates. This test is able to detect missing rings on the pistons, missing or reversed bearings, and rear seal leaks.
2. Oil Cavity Air Testing:
This is a test that pressurizes the oil cavity of the engine. The intent is to detect any gaskets, sealants, rear crank seals, and intake manifold leaks. This test does also find porosity that may be in the tested areas. Again, flow rates are monitored, limits are set, and sealing of the oil cavity is the priority.
3. EGR Leak Testing:
This is a test to monitor the Exhaust Gas Recirculatory System of the engine (portions of the exhausted air from a vehicle is recirculated and re-burned) This includes the throttle body, exhaust manifolds, the EGR tubes and regulator, and dipstick tube are sealed off. The system is brought under pressure and monitored. Missing gaskets, missing components, and fasteners not
brought to final torque can be detected.
4. Cylinder Head Assembly:
The Assembly (cylinder head, valves, valve seals, retainers, keepers, and inserts) is sealed off at the Cylinder Head Assembly line prior to installation to the engine. Air pressure is applied, looking for leaks in the combustion chambers.
5. Engine Hot Test:
This is PICO's specialty. The fully assembled engine is started and monitored for: oil pressure, coolant pressure, computer diagnostics, and fuel injection etc. One cylinder is purposely not fired to monitor if it is firing in the first place. The station also checks idle stability.
6. Coolant Cavity Air Test:
Immediately after Hot Test, we check the coolant cavity system. The intent is to check for leaks between seals, etc. What we have come to find out is that once the aluminium engine is run at Hot Test and is HOT, porosity sometimes shows up. The porosity not only is apparent, but is in the Oil Cavity as well and this test picks it up too. Because Each test monitors many different locations of leaks throughout the engine, we need something to detect where it is. That is the reason for equipment such as yours. Our automatic stations indicate that we have or have not met our test parameters, but it does not pinpoint the leak failures. The Automation is set up to reject the engines to a repair bay. The mechanic will try to find the leak, and determine if it can be fixed. If it can, he will make the repair, and re-run it thru the automatic test station. If it cannot be fixed, the engine will be stripped back of its parts to the point where the defective component was originally installed, and re-entered into the assembly process with a new part, and then further processed.
February 25, 2002
Mr. Keith Davis, President
1004 Littlestown Pike, Suite H
Westminster MD, 21157
Subject: Ultrasound Diagnostic Tool For Maintenance Needs
Dear Mr. Davis:
We first became a customer of CTRL in 1991 when we installed VehicleCTRL
maintenance management software to keep track of our equipment and costs. Later in 1994, we purchased the CTRL UL101 ultrasonic sensor.
The CTRL UL101 proved itself in several areas within the first few months of use. Each week, our mechanics found a new way to use the UL101. For almost ten years, we have successfully used the UL101 to save time and manpower. This device enables us to pinpoint leaks in the air brakes within minutes during DOT inspections, so we can quickly make necessary repairs and get our trucks back on the road and in service.
We also use the UL101 for other applications such as testing of bearing condition and verification of welding on tanks. The UL101 plays a key role in helping us provide superior customer service, as it increases the availability of our equipment to service, keeping our trucks on the road where they are needed. When a device proves itself like the CTRL UL101, equipment managers should be quick to add it to their operations.
Sincerely,
John Mihm
Equipment Manager
RLO Contractors, INC.
Mr. Keith Davis, President
1004 Littlestown Pike, Suite H
Westminster MD, 21157
Subject: Ultrasound Diagnostic Tool For Maintenance Needs
Dear Mr. Davis:
We purchased the CTRL UL101 ultrasonic sensor in 1994.
There are countless uses in our type of work. We use the tool whenever there is a noise we need to pinpoint. We have used it to diagnose injector problems in diesel engines, isolate bearing noises, pinpoint isolated air leaks in air brake systems, and to pinpoint various other engine and drive train problems. We have also been able to pinpoint bypass situations in a couple of our hydraulic crane systems. With the demands of maintaining a fleet of over 1,000 pieces of equipment, it is essential to use as much state-of-the-art technology as possible to utilize our mechanics time more efficiently. This tool has helped us in this quest.
Sincerely,
J. J. Mirabile
General Foreman - Maintenance
Bethlehem Steel Corporation
4780 West Harmon Ave
Las Vegas, NV 89103
May 10, 2002
Mr. Keith Davis, President
1004 Littlestown Pike, Suite H
Westminster, MD 21157
Dear Mr. Roche,
Subject: Ultrasound Diagnostic Tool For Maintenance Needs
We first purchased the CTRL UL101 ultrasonic sensor in 2002 to find a refrigerant leak. To our surprise, there were leaks in the pneumatic controls also, which were not aware of. The UL101 has been implemented as part of our routine service for the HVAC industry. I compared the UL101 with an older ultrasonic device, and the differences are like night and day. If a leak makes bubbles using soap and bubbles, the UL101 will pick it up. I can see many other applications for the use of this technology. I recommend that it be used for surveying high purity piping involved with integrated chip manufacturing and hospitals.
Thank you,
Larry Swanciger
Service Manager
York International
Mr. Keith Davis, President
1004 Littlestown Pike, Suite H
Westminster MD, 21157
Subject: Ultrasound Diagnostic Tool For Predictive Maintenance
Dear Mr. Davis:
We purchased the CTRL UL101 ultrasonic sensor in 2003 to find air leaks at our facility. I was very surprised how effective the UL101 was at finding and pinpointing the smallest of air leaks, leaks that would never have been found with my normal hearing. I was even able to locate a small amount of corona off a plc pack during an air survey. I do not
believe that infrared would have detected such a small arc in such early stages. The plc was replaced and the unit continues to work well.
Additionally, as a vibration analyst, my job requires much more than just finding air leaks. I have used the UL101 several times to verify bearings in good condition when vibration analysis suggested otherwise. This has saved numerous hours and money of unnecessary repairs. In one case, the UL101 was used to determine that the case of a bearing was not properly torque when installed, causing an extreme amount of vibration.
Vibration analysis only indicated a problem with the bearings. Proper diagnosis using the UL101 saved us from sending 12 people home for eight hours. I wanted to convey to others that this tool would make the difference between a good bearing and a bad bearing. I won’t do without it now. My biggest challenge is keeping others in the plant from stealing my UL101.
Sincerely,
Maurice Cousineau
Vibration Analyst
Nemak - Essex Aluminium Plant
Mr. Keith Davis, President
1004 Littlestown Pike, Suite H
Westminster MD, 21157
Subject: Ultrasound Diagnostic Tool For Troubleshooting Engine Problems
Dear Mr. Davis:
We purchased the CTRL UL101 ultrasonic sensor in 2002 to isolate noises on diesel engines as part of our commitment to improve service operation. We were impressed with the effectiveness of the UL101 at pinpointing sounds. Routine vehicle service and engine overhaul does not normally require the use of the UL101. However, there have been two or three occasions over the past year that has warranted a need for the device. On one occasion, we found an intake valve in a cylinder head that was in the process of wearing out. Without the UL101, we could not have been able to isolate it and would have spent a lot of time trying to diagnose the problem. On another occasion, we were doing routine service on a vehicle engine when we heard a strange noise. By using the
UL101, were able to pinpoint the noise. We pointed it out to the customer and asked them to keep an eye on it. After a short while, the customer brought the vehicle back for additional service because of the noise. Despite our limited use of the tool, the UL101 has proven itself very useful. Our estimate of cost savings from these events is __________. In other words it paid for itself in _____ months. The UL101 has proved its worth, saving us time in diagnosing, thereby reducing costs, while assisting us to provide the highest quality service.
Sincerely,
Gary Shields
Service Manager
Alban Engine Power Systems
CTRL Systems, Inc.
1004 Littlestown Pike, Suite H
Westminster, MD 21157
Dear CTRL Systems, Inc.:
We asked Adria Machine to build two test stands using your ultrasonic technology, one to test large plastic totes, the other to test 55-gallon plastic drums. We tested the stands. It was determined that the stands would find 100% of the leaks, which could be as small as a needle puncture. Our current and potential customers were invited to our facility in Baltimore, MD to see the technology. After consideration, several customers started purchasing one load of containers per month from Abbey. Within a few months, customers were purchasing several loads per week because none of the containers had leaks. We are pleased with the increase in business due to the successful implementation of ultrasonic technology.
Sincerely,
Abbey Drum Company
SOUTH DAKOTA AIR NATIONAL GUARD
HEADQUARTERS 114 FIGHTER WING (ANG)
SIOUX FALLS SD
To Whom It May Concern:
The U.S. Air Force has approved the use of an ultrasonic tester for Survival Equipment shops to use in the field to inspect a variety of flotation equipment, i.e. Life preservers, rafts and anti expose suits for purpose of locating air leaks. I have requisitioned and received the UL101 ultrasonic tester for this purpose. I have found that by using it, the UL101 is a time saving piece of equipment. It locates a leak very
quickly and easily, along with that, the UL101 requires no calibration and is stock listed, which enables anyone within the military to readily acquire one. This particular ultrasonic tester has met all my needs, and will advance the survival equipment shops to a new high tech level for the future.
Curt Sorenson, MSgt
CAF, Survival Equipment, WSTC
114th FW, Joe Foss Fld
Sioux Falls, SD, 57104
Atlas Copco
312 Summer Haven Circle
League City, TX 77573
Robert Roche
1004 Littlestown Pike Suite H
Westminster, MD 21157
Dear Bob Roche,
The CTRL UL101 is the best device on the market for leak detection. I have used numerous other devices and, quite frankly, have gotten tired of messing around with complex controls and lugging bulky equipment around. The ultrasonic sensor that you manufacture is simple to use, finds all the leaks, and its lightweight design contributes well to a full day’s work of leak detection. In addition, I do not have to worry about carrying extra batteries due to the UL101’s long battery life. I’m lucky if I change the 9-Volt battery once per month. If there were others who are considering making an investment for ultrasonic equipment
in order to save energy costs, I would gladly support their decision to purchase the CTRL UL101.
Sincerely,
Jeff Kaspic
Compressed Air System Auditor
Atlas Copco Compressors, Inc.
5720 Industrial Rd.
Fort Wayne, IN 46825
Keith Davis
1004 Littlestown Pike Suite H
Westminster, MD 21157
Dear Keith Davis,
You can add Brehob Corporation in Indianapolis, Indiana to your list of satisfied users of the UL101.
The unit works very well in our Compressed Air Leak Surveys and actually outperformed one of your competitor's units recently in a side-by-side comparison. We have been using the UL101 for more than 3 years now to find air and gas leaks for our customers. We are extremely happy with its capabilities to find even the smallest leaks. If I can be of further assistance, or if more information is needed, please feel free to contact me
Sincerely,
Robert Sanders
Air Audit Specialist
Brehob Corporation
CTRL Systems, Inc.
1004 Littlestown Pike, Suite H
Westminster, MD 21157
Dear Sir or Madam:
Our continuous improvement group advocates the use of the UL101 as a
maintenance best practice at all plants to help detect and correct
equipment problems before downtime occurs. For an investment of $6,700
per plant, we have begun to see significant improvements in equipment
reliability.
Ten container plants are already using this technology, and they number
among them, some of our most productive facilities. These plants
estimate that they save eight hours of downtime per month through the
use of the UL101 during regular PM rounds. Here are some of their
comments:
Comments on the value of the UL 101
The UL 101 makes detection much quicker than lifting out conveyor
rollers to check for air leaks, looking through electrical panels for
problems or checking bearings or gearboxes manually. Pinpoint accuracy
is key for detection, and what would have taken us a couple months to
find, now takes hours.
The UL 101 is very useful in detecting air leaks in our conveyor
systems while the plant is running
We use the UL 101 in conjunction with PM’s for proper lubrication and
to detect early signs of failure on bearings and gearboxes.
One maintenance technician used the tool to pinpoint a ceiling leak. A
lift was used previously but the leak was never found. By using the
UL101 and PB300 from the floor, the leak was found and fixed.
Brad Trahan
Divisional Maintenance Specialist
International Paper
6420 Poplar Ave.
Memphis, TN 38197
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