How Acuren Uses Echo Z+ for Challenging Corrosion Inspections

At Echo Ultrasonics, we develop every couplant with one goal in mind—to perform where other couplants fail. Some of our best product insights come directly from the field, where real technicians put Echo formulas to the test in the harshest environments.

One of those stories comes from Bruce Hanson, a long-time ultrasonic inspection professional at Acuren in Cincinnati. His work inspecting power plant boiler tubes is as demanding as it gets—and Echo Z+ has become an essential part of his process.

Acuren performs ultrasonic thickness testing on boiler tubes affected by liquid ash corrosion, a condition their team refers to as “alligator skin” due to its rough, flaky surface texture. These inspections require precision—and a couplant that can perform under demanding conditions

Technicians use a ¼ delay line 25 MHz transducer to measure both the wall thickness of the tube and the scale layer formed by corrosion. The work is typically performed outdoors, often in confined or elevated spaces, where every tool and material needs to be practical and reliable.

“The technician has the gauge around their neck and the probe in one hand,” Bruce explained. “Getting the couplant out of a tube in those conditions just isn’t convenient.”

To make the process even easier, Bruce began transferring the Echo Z+ into small open-top jars. “With a jar, the techs can dip a finger in and apply the couplant right where they need it,” he said. “It’s thick enough that it won’t spill, and small enough to fit in the front pocket of our coveralls.”

Bruce’s team found that Echo Z+ is the only couplant that consistently delivers reliable readings on this difficult surface. The high-viscosity formula stays in place, even when applied to rough, flaky corrosion, allowing for consistent coupling and accurate thickness data.

Why Echo Z+ Works

What sets Z+ apart is its higher acoustic impedance compared to typical water-based couplants. This property allows ultrasonic energy to transmit more efficiently from the transducer into the metal surface—even when that surface is heavily corroded or uneven. While other couplants can trap tiny air gaps or lose contact on a rough scale, Z+ maintains a stable acoustic path, resulting in cleaner, stronger signals and more repeatable thickness readings.

This type of hands-on feedback is what aides Echo Ultrasonics’ product development. From viscosity adjustments to packaging options, insights from professionals like Bruce ensure Echo couplants perform in the toughest conditions.

The Takeaway

For Acuren, Echo Z+ isn’t just a reliable couplant—it’s a critical tool that keeps inspections running smoothly in harsh industrial environments. And for Echo Ultrasonics, it’s another example of how listening to the field shapes innovation.

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