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RP 62-3

VALVE LEAK DETECTION USING


ACOUSTIC EMISSION
December 1999

Copyright © The British Petroleum Company p.l.c.


Copyright © The British Petroleum Company p.l.c.
All rights reserved. The information contained in this document is subject to
the terms and conditions of the agreement or contract under which the
document was supplied to the recipient's organisation. None of the
information contained in this document shall be disclosed outside the
recipient's own organisation without the prior written permission of
Manager, Standards, BP International Limited, unless the terms of such
agreement or contract expressly allow.
BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING

Issue Date December 1999


Doc. No. RP 62-3 Latest Draft No.
Document Title
VALVE LEAK DETECTION USING
ACOUSTIC EMISSION

APPLICABILITY All Businesses


Regional Applicability: International

SCOPE AND PURPOSE

This Recommended Practice describes the historical development and current status of non-intrusive acoustic
leak detection techniques as applied to valves. It is intended to promote the more widespread use of this
technique with the aim of minimising shut-downs and allowing monitoring of through valve leakage in
support of emission reduction initiatives and safety requirements.

AMENDMENTS
Amd Date Page(s) Description
___________________________________________________________________

CUSTODIAN (See Quarterly Status List for Contact)


Valves
Issued by:-
BP Amoco Upstream Technology Group,
Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM
Tel: +44 1932 76 3937 Fax: +44 1932 76 3864
CONTENTS

Section Page

FOREWORD................................................................................................................................................iii

1. INTRODUCTION.................................................................................................................................. 1

2. BACKGROUND .................................................................................................................................... 1

3. APPLICATION...................................................................................................................................... 2

4. EQUIPMENT......................................................................................................................................... 2
4.1 Guidance in Use of Instrument...................................................................................................... 2
4.2 Operation of Instrument ................................................................................................................ 3

5. SURVEY PROCEDURE....................................................................................................................... 4

6. QUANTIFICATION CORRELATIONS AND CONFIDENCE LIMITS ...................................... 4


6.1 Gas Leakage Correlation ............................................................................................................... 5
6.2 Liquid Leakage Correlation........................................................................................................... 5
6.3 Large Ball Valve Correlation 10" to 36" (Gas and Liquid)........................................................... 5
6.4 Confidence Limits of Predictive Equations................................................................................... 5
6.5 Calculation of Leakrates................................................................................................................ 6

7. GUIDANCE IN THE USE OF THE TECHNIQUE ........................................................................... 7


7.1 Background Noise......................................................................................................................... 7
7.2 Temperature .................................................................................................................................. 7
7.3 Effect of Downstream Pressure ..................................................................................................... 7
7.4 Calibration of Sensors ................................................................................................................... 7
7.5 Insulation....................................................................................................................................... 7
7.6 Gas Type ....................................................................................................................................... 7
7.7 Liquid Type................................................................................................................................... 8
7.8 Frequency of Survey ..................................................................................................................... 8

8. GUIDANCE IN APPLICATION OF TECHNIQUE .......................................................................... 8


8.1 Loss Control Surveys .................................................................................................................... 8
8.2 Relief Valve Condition Monitoring............................................................................................... 8
8.3 ESDV Leakage Measurement ....................................................................................................... 9

APPENDIX 1 ............................................................................................................................................... 11
LIST OF REFERENCED DOCUMENTS............................................................................................. 11

FIGURES..................................................................................................................................................... 12
FIGURE 1 (PART 1) VPAC LITERATURE ........................................................................................ 13
FIGURE 1 (PART 2) VPAC LITERATURE ........................................................................................ 14
FIGURE 2 (PART 1) LISTEN UP ........................................................................................................ 15
FIGURE 2 (PART 2) LISTEN UP ........................................................................................................ 16
FIGURE 3 SCHEMATIC OF FRONT PANEL OF LEAK DETECTOR ............................................. 17
FIGURE 4 RECOMMENDED MEASUREMENT POSITIONS ......................................................... 18
FIGURE 5 VALVE READINGS LOG SHEET .................................................................................... 19

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FIGURE 6 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION.............................. 20
FIGURE 7 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION.............................. 21
FIGURE 8 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION.............................. 22
FIGURE 9 LEAK CALCULATION FOR 5131 &D9203IS ................................................................. 23

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FOREWORD

Introduction to BP Group Recommended Practice and Specifications for Engineering

The Introductory volume contains a series of documents that provide an introduction to the BP Group
Recommended Practices and Specifications for Engineering (RPSEs). In particular, the 'General Foreword' sets
out the philosophy of the RPSEs. Other documents in the Introductory volume provide general guidance on
using the RPSEs and background information to Engineering Standards in BP. There are also recommendations
for specific definitions and requirements.

Value of this Recommended Practice

This Recommended Practice provides advice and recommendations on the application of non intrusive accoustic
detection techniques to the measurement of valve through seat leakage. Implementation of these techniques will
contribute to reduced operating costs and to eliminating shut-downs. The Recommended Practice supports
condition monitoring, planned maintenance, emission reduction and risk based inspection initiatives.

Feedback and Further Information

Users are invited to feed back any comments and to detail experiences in the application of BP RPSE's, to assist
in the process of their continuous improvement.

For feedback and further information, please contact the Custodian. See Quarterly Status List for contacts.

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1. INTRODUCTION

This Recommended Practice contains guidance for the use of Acoustic Emission (AE) techniques to
detect and estimate through valve leak rates.

AE valve leak detection is a non intrusive technique to detect and estimate the magnitude of fluid
leakage through valves. It relies on detecting and measuring the amplitude of high frequency
(100KHz to 600KHz) acoustic emission noise generated by the fluid leaking through the valve.
Measurement is made by holding a small sensor on the valve body using an acoustic couplant e.g.
grease and recording the signal level. Based on the signal level and valve type, size, differential
pressure and fluid the leak rate can be estimated. The accuracy of leakage quantification is not high
(typically within a factor of 3). In most applications however this level of accuracy is adequate for
trending valve performance, indicating that leakage is below a required threshold level or enabling
management decisions, for example to change out a valve, to be taken. Equipment is battery operated,
completely portable and intrinsically safe.

This recommended Practice relates specifically to the use of the PAC Model 5131 intrinsically safe
portable leak detector and associated VPAC technology package to enable estimation of valve leakage
rates. This proprietary technology is available from the Physical Acoustics Corporation (PAC). Their
publicity sheet giving useful general information about the technology is shown in Figure 1.

2. BACKGROUND

Acoustic techniques to detect valve leakage -essentially ‘listening for leakage’ through valves have
been available for many years. During the 1980’s BP using proprietary equipment developed a
methodology to quantify gas leakage through valves by relating acoustic signal level to valve leak
rate. This methodology was primarily used to detect and quantify leakage of gas to flare through
Pressure Relief Valves (PRVs) and Pressure Control Valves (PCVs) to reduce refinery losses. The
technique was extended during the 1990’s to cover liquid leakage through valves. Specifically the
technique was further extended in the late 1990’s to estimate gas and liquid leakage through large ball
valves on emergency shutdown applications, in order to assure the leakage integrity of these valves.
For a review of this work refer to Valve Leak Detection Using Acoustic Emission – Close out Report
D Harrison November 1999 (Ref 1).

An intrinsically safe version of the equipment was developed in partnership with Physical Acoustics
Ltd (PAL) and the technology was in 1993 licensed by BP to PAL. Under this agreement BP have
essentially royalty free rights to the technology. It should be recognised that this technology package
(Ref 2) is proprietary information and should not be disclosed to third parties.

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3. APPLICATION

Identification and quantification of leakage from valves on plant can yield benefits and cost savings in
the following areas.

Reduced losses to flare through leaking relief valves.

Reduces losses to atmosphere through vents

Maintenance planning - identification of leaking valves prior to shutdown

Monitoring and assurance of the leakage integrity of emergency shutdown valves

Assurance of the leak tightness of isolation valves prior to starting equipment maintenance

Troubleshooting - identification of leaking valves on systems.

In order to identify if a valve is leaking that valve must be in the closed position and there must be a
pressure differential across the valve seat. The leakage of fluid through the valve generates an
acoustic signal. From the amplitude of the noise signal as measured and input of valve operating
parameters the leak rate through the valve can be determined. For measurements on valves on liquid
service a differential pressure of 1bar or greater is required to give adequate detection sensitivity. See
section 8.3.2 for further details.

A publicity sheet ‘Listen Up’ gives a brief review of application areas see Figure 2.

4 EQUIPMENT

The equipment for site use comprises:

PAC Model 5131 intrinsically safe portable leak detector, in field carrying case.

D92031S High temperature (125 °C) intrinsically safe sensor.

A suitable acoustic couplant (as used in ultrasonic testing) is also required, high temperature (high
viscosity) grease is ideal, together with a scraper for cleaning rusty surfaces for good sensor coupling.

4.1 Guidance in Use of Instrument

The instrument used is a Physical Acoustics 5131 portable monitor and D9203IS sensor. The
instrument and sensor are intrinsically safe to: Cenelec Ex ia IIC T4, Factory Mutual C1.1 Div 1,
Groups A,B,C,D, haz, T4.

The instrument is a self contained, fully portable, computer controlled single channel acoustic
emission monitor. It measures the RMS value in decibels (dB) of the acoustic emission noise between
the frequencies of 100 KHz and 600KHz. This frequency range eliminates all audible and
mechanically generated noise which is usually of a much lower frequency. The instrument output is
displayed on a liquid crystal display and four keys provide for simple operation of the unit. The
instrument has a 300 register memory for storage of data points, which can be downloaded to a PC via
a RS-232 interface if required.

The instrument contains five AA size nickel-cadmium batteries. Battery life is typically eight hours
on a single six hour charge. Do not overcharge, it is acceptable to charge overnight, but no longer.
The batteries do have a memory and will reduce in capacity if recharged after partial use. The unit
must only be recharged in a safe area.

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4.2 Operation of Instrument

Four keys control all the instrument functions. A schematic of the front panel is shown in Figure 3.
The main functions available are described below:

Switch on instrument Press Enter Key


Switch off Instrument Press Menu Key for 2 seconds
(Instrument will switch off after 2
minutes if not used)
Change Register Use cursor keys
Save Data Point Press Enter Key

When the instrument is switched on it automatically self checks and enters the data acquisition mode
which allows readings to be taken. Measurement of the acoustic level is automatic. The right hand
display shows the current average signal level (ASL) detected in dB. When in this mode, with the
sensor not contacting any surface, the instrument should read 12-13 dB. Any other reading would
indicate a fault, generally with a loose connection or damaged sensor cable. The average signal level
(ASL) is taken over 10 seconds, the activity bar chart below the main display indicates the
instantaneous level. The left hand display figure shows the register number (1 to 300) and the centre
figure the current value stored in that register.

Other modes available for configuration purposes are:

Memory Clear
Send to PC
System Self Test
System set-up

These are accessed via the Menu key, however they are not normally required during surveys.

The most common error message will be ‘Batteries Weak’ which indicates that the batteries require
recharging. Other error messages ‘ROM Error’, ‘RAM Error’ and ‘Backup Failure’ require the
instrument to be sent for servicing.

Refer to supplier’s instrument instruction manual for detailed guidance on instrument operation.

5 SURVEY PROCEDURE

5.1 Prepare a list of valves to survey. Note valve type, inlet size, duty and differential pressure.

This information may conveniently be loaded onto the spreadsheet supplied with the user package.

5.2 Advise the installation’s Operations Group of survey plans and operator support requirements and
obtain necessary permits.

5.3 Ensure the instrument has been charged correctly from previous use. Connect the sensor to the input,
power up and confirm that the instrument carries out its self test function.

5.4 Identify valve, ensure the valve is closed and that there is a differential pressure across the valve.

5.5 Record the upstream and downstream pressure across the valve.

5.6 Select measuring position. The best position is a smooth flat surface on the valve reasonably close to
the expected source of the leak.

Figure 4 indicates some good measurement positions for different types of valve. For PRVs the best
measurement point is generally the valve inlet flange. For ball, gate, globe and plug valves flats on

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the base or side of the valve body can provide the best measurement position though the valve flanges
are often more accessible for steady positioning of the transducer and thus give more consistent
readings.

For large valves (10” diameter and above) care should be taken to identify the position on the valve
body giving the highest noise reading and this value recorded and position recorded. The position of
highest noise may be determined by moving the transducer methodically over the valve body.
Alternatively the valve may be divided into sections adjacent to the upstream and downstream seats
and at the upstream and downstream flanges. At each section divide the section into approximately
300 mm arcs and take readings along each section. Typically for 10” to 18” valves there will be four
points in each section, for larger valves use 8 points. Results may be recorded on a log sheet an
example of which is shown in Figure 5.

5.7 Remove loose rust and paint with a scraper or wire brush from the measuring position and position
transducer on valve with a thin layer of acoustic couplant e.g. grease between the sensor and valve
surface.

Hold the sensor securely in position, without moving it, and watch the ASL reading (right hand
display value).

When the reading is stable (± 1 dB) and the activity bar chart is stable note the value or enter it into
the monitor’s memory. Repeat for other measuring positions if necessary.

5.8 If no change in signal level is obtained ( i.e. a reading of 13/14 dB) the valve may be classified as leak
tight. An indication of readily detectable threshold leak rates on gas is given in Figures 6, 7 and 8 for
different inlet pressures.

5.9 Where a change in signal level is noted it is necessary to measure and record signal levels in the
vicinity of the valve to ensure that the source of the noise is leakage from the valve rather than noise
transmitted through the pipework.

Readings should be taken as a minimum:

1. On the valve body


2. On the valve inlet side pipe flange
3. On the valve outlet side pipe flange

Additionally readings should be taken on the upstream and downstream pipework and flanges to
confirm that noise levels are falling as you move away from the valve.

5.10 If high background readings are recorded (20 dB or greater) attempt to locate source of background
noise. The most likely causes are adjacent leaking or throttling valves. If possible arrange for these
valves to be isolated and repeat readings. If background noise cannot be eliminated or reduced record
its value.

5.11 On completion of the valve noise measurement if any changes have been made to valve positions
request that valves are returned to their original positions.

6 QUANTIFICATION CORRELATIONS AND CONFIDENCE LIMITS

Four quantification correlations have been developed. The correlations consist of a base equation
relating AE signal level to valve leakage together with correction factors for valve size, valve type and
operating pressure.
It is useful to appreciate the origins of these correlations as their origins restrict appropriate
application.

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The equations are normally applied through spreadsheets supplied with the technology package.
Details of the correlation equations may be found in (Ref 1) and (Ref 2). As these correlation
equations are confidential and commercially sensitive they are not included in this RP.

6.1 Gas Leakage Correlation

This correlation has been developed from extensive laboratory and workshop tests on leaking valves.
Valve types included ball, gate, plug and relief valves. Valve size range was 1” to 6” though the
correlation is useable beyond this size range.

This correlation has been used extensively for BP loss control surveys and independent validations
have been carried out by other operators.

6.2 Liquid Leakage Correlation

This correlation was developed from workshop tests on 2”, 4” and 6” ball and wedge gate using water
as the test liquid.

6.3 Large Ball Valve Correlations 10” to 36” (Gas and Liquid)

These correlations were developed as part of a joint test programme with Shell primarily to assure the
leakage integrity of large ball valves. Workshop leakage measurements were carried out on gas and
liquid on 10”, 20” and 36” ball valves and validated against field measurements from valves in this
size range.

6.4 Confidence Limits of Predictive Equation

6.4.1 Gas Leakage Correlation

The predictive equation has been developed by curve fitting to a large set of experimental data

Defining the measure of error as

E% (measure of error) = (Predicted Leak Rate x 100 )/ Measured Leak Rate

The general equation which is based on 492 data points gives the following percentages of predictions
within the following error ranges.

% of predictions within error range


E= E= E= E=
50-200 33-300 20-500 10- 1000

69.0% 86.4% 94.7% 99.6%

It should be emphasised that the predictive equation does not offer a flow measurement but a
sufficiently accurate prediction of flow rate to enable economic or other decisions to be made

6.4.2 Liquid Leakage Correlation

The predictive equation was developed from 552 data points on ball and gate valves of sizes 2”, 4”
and 6”.

The table below shows the percentage of the 552 tests with predictions within certain fractions of the
true leak rate

<½ ½-2 >2 <1/3 1/3-3 >3


4 41 55 1 54 45

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The correlation is seen to over predict a significant proportion of readings. However in assessing the
leakage integrity of ESDVs critical readings are those where the equation under-predicts the actual
leakage. These under-predictions are a very small proportion of the readings.

6.4.3 Large Ball Valve Correlations

Gas Equation

Based on analysis of a population of 155 readings

% of predictions within error range


E= E=
50-200 33-300
54% 77%

Liquid Equation

Based on analysis of a population of 86 readings

% of predictions within error range


E= E=
50-200 33-300
79% 97%

6.5 Calculation of Leakrates

To facilitate calculation of leak rates a spreadsheet has been developed LEAKCALC1.xls this enables
leak rates to be readily calculated. The following equations are used for the following cases.

General valves on gas - GASCALC

General valves on liquid – LIQUIDCALC

Large Ball valves 10” - 36”on gas or liquid

Large Ball Valves – Gas Model


Large Ball Valves – Liquid Model

Operation of the spreadsheets is straightforward.

Select appropriate spreadsheet for valve type/fluid. As an example use of GASCALC will be shown

Input required data

Valve ID Optional
AE Signal Level (dB) 50
Pressure Difference (barg) 20
Inlet size (ins nominal bore) 2
Valve Type if gate or ball (y/n) n,n
3
Fluid Density (kg/m ) (optional) 1

The leak rate of 18.4 l/min and loss in tonnes/year (9.646) is calculated.

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The basic calculation is that of a volumetric leak rate and the loss in tonnes per year is only calculated
if data is inputted for fluid density.

A sample print out is attached Figure 9.

7 GUIDANCE IN THE USE OF THE TECHNIQUE

7.1 Background Noise

The acoustic transducer works at very high frequencies and generally background noise is not a
problem. The effect of background noise, when present, is to effectively desensitise the technique i.e.
the minimum leak rate that can be detected is reduced.

Generally to be valid a measured leak signal needs to be 5dB above background level. With for
example a background noise level of 20dB the threshold of detection is around 25dB. In calculating
leak rates the measured signal level should be used, i.e. the background level should not be subtracted.

7.2 Temperature

A maximum temperature limit of 125oC exists for the D92031S, above this temperature irreversible
change to the sensor may occur. Valves at temperatures significantly higher than 125oC may be tested
provided only short term contact is made with the valve.

An acoustic waveguide may be used on very high temperature plant but allowance should be made for
signal attenuation. Attenuation can be estimated by making a reading on a valve with and without the
waveguide. The attenuation dB due to the waveguide can then be determined.

7.3 Effect of Downstream Pressure

The correlation equations have been developed with a discharge pressure to atmosphere. Where the
downstream pressure is significantly higher than atmospheric, test work has shown that the correlation
equation remains reliable. The leak rate calculated from the correlation equation is that at STP.
Differential pressure across the valve should be used as the pressure input.

7.4 Calibration of Sensors

The sensors are reliable and generally work or do not work. One known mode of failure is breakage
of one wire in the sensor cable which has the effect of halving the output signal. The instrument is
supplied with two sensors and it is recommended that back to back readings should be taken
occasionally on a known leak to check that their output agrees. Additionally it is possible to carry out
workshop calibration against a reference leak.

7.5 Insulation

Readings of noise level cannot be made through insulation. Where valves and pipework are insulated
it is necessary to remove lagging and gain direct access to the measurement points before the
condition of the valve can be determined.

Some indication of the valve condition can be gained from measurements on the valve body or stem
that protrudes through the insulation. The signal is likely to be significantly attenuated and thus
cannot be used reliably for quantification purposes. It may however permit condition monitoring.

7.6 Gas Type

The predictive equation has been developed using air or nitrogen as the test gas. Theoretical
considerations and experimental work indicate that the equations can be reliably applied to all
common process plant gases without correction.

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7.7 Liquid Type

The predictive equations have been developed using water as the test fluid. Provided the liquid
viscosity being measured does not vary widely from that of water the equation should be reliable. For
high viscosity liquids the predictive equations will underestimate leak rates.

7.8 Frequency of Survey

The frequency of surveys depends on the application

7.8.1 Loss Control.

Where loss control is the principal driver a balance needs to be established between, the cost of the
leak detection survey and maintenance work to rectify valves, compared to savings in lost product.
Consideration should be given to the practicalities of eliminating leaking valves, for instance if relief
valves are spared maintenance can be carried out without a shutdown. In general experience has
shown that surveys can usefully be carried out every two years and as a minimum a survey should be
carried out prior to a plant shutdown.

7.8.2 Maintenance

Frequencies of surveys should accommodate maintenance and inspection strategies.

Where a risk based maintenance philosophy is employed AE surveys should be integrated with this
philosophy

7.8.3 Valve Condition Monitoring

Where critical valves are being condition monitored, frequency of measurements should be related to
measured leak rates and trends compared to any statutory/safety case levels which require to be
satisfied.

8 GUIDANCE IN APPLICATION OF TECHNIQUE

8.1 Loss Control Surveys

The technique has been widely used in loss control surveys for refinery gas duties by BP Oil and a
high level of confidence can be placed in the technique. Though leakage predictions for a specific
valve are subject to errors as detailed in section (6.4) total predicted losses for a large number of
valves is subject, due to averaging of a large number of readings, to far smaller errors.

8.2 Relief Valve Condition Monitoring

For a relief valve to function effectively it must lift at the set pressure and must not leak when shut.
The BP Relief Valve Work Group Report and Proposals (Ref 3) commended AE valve leak testing to
the attention of sites and facilities and initiated a programme to assess the confidence that could be
placed in on line set point verification. AE leak detection can be used to demonstrate the leakage
integrity of relief valves and on line set point verification (Trevitest) has been shown to be an effective
technique (Ref 4). The condition of relief valves, for which an endorsement extension is being
considered, can be assessed on line using these techniques. For relief valves on clean duties where
there is no risk of valve fouling or corrosion, on line condition monitoring is a viable option to assess
valve condition, eliminating the need to remove valves for conventional maintenance/inspection and
offering cost savings and a reduction in plant down time.

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8.3 ESDV Leakage Measurements

8.3.1 Reliability of Prediction

Where leakage predictions are used to assure the leakage integrity of ESDVs due account should be
taken of potential errors in the prediction of leakage. Where a statutory or safety case leakage rate has
to be met, any predicted leakage based on AE leak detection measurement should be multiplied by a
factor to account for statistical uncertainties. Where physical leakage measurements have been made
in parallel with acoustic measurements a high degree of confidence can be placed on predictions.
Where correlation equations are used directly to assess leakage, best advice to date suggests that any
predicted leakage should be multiplied by a factor of 5 to account for statistical uncertainty. On this
basis there is a small likelihood ( less than 5%) that the actual leak rate will exceed the predicted leak
rate based on the AE measurement.

At low differential pressures (of the order of 1 bar), particularly on liquid the sensitivity of the
technique is reduced. This is discussed further in section 8.3.2. Measurement of liquid leakage at
differential pressures below 1 bar is not recommended.

8.3.2 Threshold Leakage Level Detectable

Due account should be taken of threshold leakage levels that are detectable.

Generally for valves on gas service detectable leak rates are likely to be well below safety case levels
or statutory levels (e.g. SI1029 base level leakage of 6 Standard m3/min (6000 litres/min)). For valves
on liquid service, particularly at low differential pressures threshold leak levels are significant and can
be comparable to statutory levels ( e.g. SI1029 leakage of 6 Kg/min (~7 litres/min))

Threshold leak rates detectable can be determined by back substitution in the correlation equation
using a signal level of 14 dB. Leak rates for large ball valves on gas and liquid are tabulated below.

GAS GAS LIQUID


Plastic seat Rubber Seat
SIZE” 1 bar 10 bar 100bar 1 bar 10 bar 100bar 1 bar 10 bar 100bar
10” 12 18 25 45 75 80 1 0.2 0.03
20” 23 32 45 75 120 180 4 0.6 0.10
36” 32 46 68 120 180 250 10 1.6 0.25

Detectable leak rates litres/min for various ball valve sizes and types
against differential pressure (bar)

The relatively high threshold detectable leak rates for valves on liquid service at low differential
pressures should be noted. Measurement of liquid leakage at differential pressures below 1 bar is not
recommended.

8.3.3 Assurance of the Leak Integrity of ESDVs.

On many ESDVs the reading obtained will be that of the threshold of the instrument or the
background noise level. From the correlation equation an estimate of the potential threshold leak
level can be made.

Where statutory leak limits are in place for the valves, back substitution in the equation for valve size,
type and operating conditions can be used to establish action limits.

If there is any doubt about potential leak rate through an ESDV a conventional leakage
measurement should be made. Record actual leak rate and results of AE measurement to further
develop the data base.

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8.3.4 Data Base of ESDV AE Leakage Measurements

Confidence in the use of the technique can be further increased by further developing the data base of
conventional leakage measurements compared to AE leakage predictions. To further develop
confidence in the technique it is recommended that where a conventional ‘SI1029 type test’ physical
leakage measurement is carried out a parallel AE noise measurement should be taken. Results should
be forwarded to Edwin Smith at BP Amoco Sunbury.

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APPENDIX 1

REFERENCES

1. E Smith S/UTG/131/99 Valve Leak Detection Using Acoustic Emission – Close Out Report D.
Harrison. December 1999.

2. VPAC Valve Leakage Technology Package Vol 1- Vol 3 Physical Acoustics Ltd.

3. E. Smith, BP Relief Valve Work Group Report and Proposals, ESR.96.ER.059 8 July 1996.

4. E Smith, J McAleese, On line set point verification of relief valves, S/UTG/094/99 August 1999.

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LIST OF FIGURES

FIGURE 1 (PART 1) VPAC LITERATURE ........................................................................................ 13


FIGURE 1 (PART 2) VPAC LITERATURE ........................................................................................ 14
FIGURE 2 (PART 1) LISTEN UP ........................................................................................................ 15
FIGURE 2 (PART 2) LISTEN UP ........................................................................................................ 16
FIGURE 3 SCHEMATIC OF FRONT PANEL OF LEAK DETECTOR ............................................. 17
FIGURE 4 RECOMMENDED MEASUREMENT POSITIONS ......................................................... 18
FIGURE 5 VALVE READINGS LOG SHEET .................................................................................... 19
FIGURE 6 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION.............................. 20
FIGURE 7 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION.............................. 21
FIGURE 8 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION.............................. 22
FIGURE 9 LEAK CALCULATION FOR 5131 &D9203IS ................................................................. 23

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FIGURE 1 (PART 1) VPAC LITERATURE

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FIGURE 1 (PART 2) VPAC LITERATURE

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FIGURE 2 (PART 1) LISTEN UP

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FIGURE 2 (PART 2) LISTEN UP

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FIGURE 3 SCHEMATIC OF FRONT PANEL OF LEAK DETECTOR

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FIGURE 4 RECOMMENDED MEASUREMENT POSITIONS

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FIGURE 5 VALVE READINGS LOG SHEET

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FIGURE 6 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION
INLET PRESSURE 1 BAR

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FIGURE 7 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION
INLET PRESSURE 10 BAR

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FIGURE 8 PREDICTED THRESHOLDS VALVE LEAKAGE CORRELATION
INLET PRESSURE 100 BAR

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EMISSION
FIGURE 9 LEAK CALCULATION FOR 5131 & D9203IS

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EMISSION

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