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Acoustic
Emission Testing
Staying competitive with smart inspection
In industrial systems where safety, uptime, and precision matter most, identifying damage before it escalates is critical. Regulations such as the German Ordinance on Industrial Safety and Health( BetrSichV) require proactive strategies to prevent hazardous situations. Acoustic Emission Testing offers an innovative, real-time solution for monitoring asset integrity, helping to streamline maintenance and extend inspection intervals. TÜV SÜD demonstrates how this advanced testing method can also lead to significant cost savings while supporting smooth production processes.
By Rainer Semmler, Head of Process Safety Management, Hermann Schubert, Head of Digital and Continuous Inspection, TÜV SÜD Industrie Service
Acoustic Emission Testing: Sensors on a process vessel.
As industries face increasing demands for modularity, adaptability, and continuous output, traditional inspection approaches are reaching their limits. These methods— often cyclical and invasive— cannot easily accommodate the fluctuating stress profiles modern systems endure. Acoustic Emission Testing( AT) presents a viable alternative. It is a sensor-based technique that captures acoustic signals emitted by structural changes in materials, such as crack propagation or corrosion onset. AT sensors detect transient elastic waves that originate from subtle vibrations or displacements in structural integrity, even if they are mounted externally on equipment surfaces. Normally, a piezoelectric measuring principle is used for these
A flat-bottom storage tank is inspected using Acoustic Emission Testing.
sensors. Once activated, they continuously monitor the system and feed data into specialised software. This allows for both high-resolution monitoring and pinpoint localisation of anomalies, all“ without” halting operations. By avoiding shutdowns, operators maintain throughput and eliminate many risks associated with opening systems. Additionally, components are not exposed to cleaning agents, humidity, or potential contaminants. Moreover, AT can be adapted to various component geometries and materials, making it ideal for stainless steel piping systems, pressurised equipment, and integrated machines such as pumps, mixers, and compressors.
Monitoring materials and mechanisms in demanding environments In industrial facilities that handle aggressive media, high pressures, or extreme temperatures, corrosionresistant alloys( CRAs)— such as austenitic stainless steels, duplex grades, and nickel-based alloys— are fundamental to ensuring long-term structural integrity. These materials are chosen for their ability to withstand harsh chemicals, mechanical stress, and thermal cycling. As a result, CRAs are widely used in pressurised equipment, piping systems, and rotating equipment across sectors like chemical processing, energy, and water treatment. www. heat-exchanger-world. com Heat Exchanger World October 2025
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