Hydraulic System Leak Detection
Use Ultrasound to Detect Hydraulic System Leaks, Cavitation, and Bypassing.
Hydraulic systems operate under high pressure — and even small leaks can cause major problems. Energy loss, slipping actuators, fire hazards, and contamination are just a few of the risks.
Ultrasound gives you a fast, simple way to locate leaks and pinpoint faults in hydraulic circuits.
How Ultrasound Detects Hydraulic Leaks
When pressurized hydraulic fluid escapes through a crack, seal, or fitting, it creates turbulent flow. This turbulence produces high-frequency sound (ultrasound), which can be detected with a handheld sensor or acoustic imaging camera.
– Airborne sensors pick up the sound of external leaks — even pinhole sprays.
– Contact probes detect internal issues like valve bypass, cavitation, or worn seals.
Ultrasound can be used during normal operation. It’s fast, safe, and precise.
What Are Hydraulic Leaks Costing You?
Leaks in hydraulic lines, fittings, valves, or cylinders often go unnoticed — especially if they’re internal. But just because you can’t see them doesn’t mean they’re not there. Left unchecked, hydraulic leaks lead to:
Energy Loss
Escaping fluid reduces pressure and efficiency.
Component Damage
Pumps and actuators work harder to compensate.
Maintenance Overload
Leaks drain fluid and time, increasing labor and cost.
Reliable Ultrasound Method for Hydraulic System Inspection
Hydraulic system failures such as leaks, cavitation, and worn components can cause significant downtime and safety hazards. Our proven ultrasound inspection method provides an efficient and non-intrusive solution to detect these issues early.
The ultrasound inspection process involves scanning hydraulic components externally, quickly identifying problems through distinct ultrasonic signals caused by fluid leaks, cavitation bubbles, or friction in worn components.
Our experienced team has successfully trained maintenance personnel, assisted in integrating proactive hydraulic inspections, and provided direct inspection services. We ensure your hydraulic systems remain reliable, efficient, and safe, minimizing downtime and enhancing overall equipment longevity.
Recommended Tools
Our route-based data collection solutions combine airborne and contact ultrasound sensors with precision vibration analysis into versatile, multi-purpose reliability data collectors. Fully integrated with the world's most powerful predictive maintenance software, these intuitive tools streamline asset inspections, simplify workflows, and deliver superior reliability outcomes.
Learn MoreOur ultrasound and vibration permanent monitoring solutions offer industry-leading sensitivity for the earliest possible fault detection. Engineered for durability and ease-of-use, these solutions provide remote, automated diagnostics—reducing maintenance costs and delivering a comprehensive, facility-wide view of asset health.
Learn MoreImaging technologies enhance visibility into hidden problems—revealing heat, sound, and motion that the eye can’t see. From thermal and acoustic imaging to motion amplification, reliability teams can use these vision enhancing technologies to detect failures. Our imaging solutions are a powerful way to see more, understand faster, and act with confidence.
Learn MoreUltrasound-guided lubrication empowers maintenance teams to grease bearings with precision by monitoring friction in real time during greasing tasks. By comparing live decibel readings to historical baseline data, technicians can identify when lubrication is truly needed, and when enough has been applied; preventing both under- and over-lubrication.
Learn MoreHow to Inspect a Hydraulic System with Ultrasound
01
Listen Around Hoses and Fittings
Scan connections, joints, and lines for high-frequency hissing.
02
Inspect Valves and Cylinders
Use a contact sensor to detect bypassing or internal leakage.
03
Scan Pumps and Reservoirs
Check for cavitation, suction leaks, or mechanical friction.
04
Tag, Repair, and Reevaluate
Fix identified issues and confirm the repair with a follow-up scan.
Get Started in Three Simple Steps
Frequently Asked Questions
Ultrasound delivers fast returns by catching failures early — not just in hydraulics. Many facilities recover their investment in weeks through savings from air leak detection, steam trap failures, and valve issues. One tool solves multiple high-cost problems.
Ultrasound fits nearly any environment — from noisy mechanical rooms to high-voltage electrical panels. It’s used across industries to inspect rotating machinery, find leaks, diagnose electrical faults, and confirm lubrication. A single ultrasound tool covers a wide range of assets.
Yes. With a contact probe, you can hear valve bypass, seal leakage, and cavitation.
No. Most hydraulic inspections with ultrasound are performed live and under normal pressure.
Both external (sprays, mist) and internal (bypass, return line flow) — even if they’re silent to the human ear.
Yes. Ultrasound is passive and non-contact. It reduces the need for close inspection of high-pressure components.
In addition to hydraulics, ultrasound detects compressed air leaks, steam traps, valves, electrical discharges, and more.