Leak Detection Inspector

Physical Acoustics Ltd VPAC -
Quantification of Through Valve Gas &

Liquid Losses
Physical
. Acoustics Limited © 2009 1
Overview
 VPAC – Valve leak detection system and technology package.
5131 – is the hardware component made by Physical Acoustics.
 Physical Acoustics developed VPAC with BP and Shell (since

1982). PAL manufacture the hardware and sell package under
licence.
 Identification of leaking/passing valves is important for safety and to

minimise losses.
 Physical Acoustics Ltd, based in Cambridge, provides

- VPAC systems
- Operator training (on and offshore)
- Valve testing services with trained VPAC engineers
- System maintenance, repairs and spare parts
- Consultancy and advice on use and testing strategy
Physical
Principles Of AE Leak Detection
 Acoustic Emission (AE) is Structure Borne Noise.
 AE May Be Generated By:

- Propagating Cracks
- Spalling Corrosion Product
- Turbulent Flow
 VPAC detects leak “hiss” caused by turbulent

flow, which is measured in dB (AE)
Physical
Acoustic Emission Generation
Open Valve Sensor & VPAC
(laminar flow)
If a valve is open there will be laminar flow that generates little or no noise.
Physical
Tight Valve Sensor & VPAC
(little noise)
A tight valve makes very little noise.
Physical
Turbulent Flow Sensor & VPAC
(significant noise)
A passing valve creates turbulent flow and hence acoustic noise. The AE
is transmitted into the valve body and can be detected with the 5131.
Physical
VPAC / 5131
DEVELOPMENT
Physical
B.P. and Shell Development
Program
 1982 - BP evaluation of technologies for valve leak
detection/quantification.
 1984 - BP concentrated on AE technology for laboratory
testing and field trials.
 1984 -1990 BP extensive field trials and database
development.
 1991 - BP/PAL specification of new instrument.
 1994 - BP license technology to PAL.
 1997 - BP & Shell develop liquid & gas ESD/large diameter
valve correlations.
 Physical Acoustics sells and supports VPAC worldwide.
Physical
Database Development
 Identify leaking valves using AE monitor
 Remove leaking valves from service
 Re-test valves in lab. using flow-meter and acoustic

monitor to develop database
 1984-1990 800 valves, up to 18”, plug, gate, ball, globe,

PSV, PCV, and others
 Develop graphical and numeric correlation from the

database
Physical
Physical
VPAC - Field Experience
 5-10% of valves suffer
through-valve leakage.
 1-2% of these passing

valves are responsible for
75% of total losses.
 Leaks can exceed 1000

litres/minute
 Leaks down to <1 litre/min

detectable
Physical
VPAC - Field Uses
 Maintenance planning – identify leaking valves prior

to shut down.
(Safety Issues).
 Reduces losses to atmosphere through vent pipes.

(Environmental Issues).
 Reduce loss to flare (even if there is a gas recovery

system savings can be made).
(Reducing Costs).
Physical
VPAC - Field Uses
 Trouble shooting – tracing leaks and sources of cross

contamination.
 Re-qualifying PSV’s after operation.
 ESD’s testing (save 6-12 hrs production).
Physical
Some VPAC Customers
 Shell Exploration and Production UK, OneGas, Shell
Sweden, Shell Denmark, Shell U.K. Oil
 Sapref, Natref, StatoilHydro, HPCL
 BP, SRC, Nerefco, Petrofac
 Gulf Oil, Total, NAM, OK, Noretyl, Neste Oil
 Lindsey Oil, Natref, ConocoPhillips, Indian Oil
 Phillips Petroleum, Irish refining, BPCL
 British Gas, BSP, Saudi Aramco (Multiple Sites)
 TAKREER, PDO, ChevronTexaco, Occidental, Ras
Gas, Shell Brunei, Oman LNG ………………
Physical
“1993 VOC losses AU$9m [~US$12m], cut to half (14,342
tonnes) by end 1995, by end 1996 cut to 4821 tonnes.”
(28,684 tons per annum to 4821 tons per annum)
Physical
Overview of Shell VPAC Project
 PAL have recently supplied Shell and One Gas with 18 VPAC systems as
part of the UpGrade Project
PAL have trained on the Shell Anasuria, Brent B and C, Dunlin, Eider,
Gannet, Nelson, North Cormorant, Shearwater and Tern platforms.
PAL also have trained and provide VPAC testing services at Shell St
Fergus.
PAL have also trained on the OneGas East AWG-1C, F3-FB-1, K8-FA-1,
K15-FA-1, K15-FB-1, L2-FA-1, L5-FA-1, L9-FF-1 and L13-FC-1 platforms
 PAL are about to start VPAC training campaign in the southern UK north
sea for OneGas West
In total PAL have trained about 400 offshore personnel in VPAC testing
Physical
VPAC SYSTEM
Physical
VPAC – 5131 System
 Portable unit (2kg)

 I.S. Sealed unit
 Battery charger
 2 x HF sensor
 Case
 Wave guide
 User manuals
 Leak rate
calculation excel
Physical
Using VPAC
 To turn on, press Enter.
 Wait until Auto Ranging completed.
 Make measurements.
Stored Memory Point (1-300) Current Measured Value
1 13 50
Stored Value At Memory Point

 Record dB value in excel work sheet against valve I.D. along with
differential pressure.
 Hold down M button for a few seconds to power down (or system
has auto switch off in 2mins).
 Enter record into excel SW table for permanent records.
Physical
Testing Process
 Ensure the valve is closed.
 Valve must be subject to differential pressure 0.5 bar

gases, 3 bar liquids (these are minimum pressures as flow
must be turbulent).
 Clean away loose rust and scale.
 Hold sensor on valve body using grease as acoustic

couplant.
 Let measurement stabilise - take reading.
 Take upstream and downstream readings to check valve

is source.
Physical
Measurement Positions Valves <24”
Note it is good practise to make several

Physical
. Acoustics Limited © 2009 measurement per valve 21
Measurement Positions Valves over 24”
• Make a measurement
approximately every
300mm across the body
of the valve and flanges
• Use the highest VPAC

reading the loss control
equation
Physical
Plant Noise
• <10% of plant valves may have noise from other site
processes and you will experience it.
• VPAC measurements upstream and down stream ensure

that VPAC reading at valve is leak and not false.
• Valve reading must be 6dB+ than upstream/down stream

reading to be used in the leak rate equation.
• No compensation is required in the spread sheet - use peak

VPAC reading from valve
Physical
Noise Measurement Positions
Ideally noise check measurements are 0.5 -1m from valve
0.5 -1m 0.5 -1m
Noise check point
ONLY USE VALVE MEASUREMENT IN LEAK CALCULATION

Physical
Plant Noise – Example Results
Up stream Valve Down stream Result

13dB 13dB 13dB No leak
19dB 52dB 19dB Leak
62dB 72dB 23dB Leak
71dB 52dB 52dB Noise
Remember – there is no need to compensate for up/down stream

readings if measurement at valve is 6dB bigger.
Physical
5131 Menu Functions
 For normal operation use as delivered.
 There are option changes that can be

made – But these have no benefit to
testing.
 No Need to Change Settings!
Physical
VPAC LOSS CALCULATION
SPREADSHEETS
Physical
Spreadsheet Calculation of Losses
4 leak rate equations
- Gases <18 Inch
- Liquid <18 Inch
- Gas ESD, large
valves 18< and soft
seat valves
- Liquid ESD, large
valves 18< and soft
seat valves
Physical
Using Estimation Software
 Simple Excel format.

 Calculations built In.
 Make sure correct spreadsheet is used GAS,
LIQUID, ESD.
 During Measurement Note:
- Valve ID -5131 Reading
- Inlet Valve Size -Valve Type
- Differential Pressure - Product
Physical
Which Spreadsheet?
There are four pages in the Shell platform specific

Excel spreadsheet – make sure you use the
correct one.
 VPAC Gas – Gas up to 10” diameter
 VPAC Liquid – Liquid up to 10” diameter
 VPAC Gas – Gas over 10” diameter
 VPAC Liquid – Liquid over 10” diameter
Physical
Other Considerations
 Safety
 Intrinsic Safety
 Operating temperatures and use of wave guides
 Trouble shooting
 Lagging / Insulation
 Online monitoring
Physical
Safety
 Consider if you need to raise a permit to carry out VPAC testing.
 Always carry VPAC system in the case with sensors pre-connected

and stored in the front pouch. This will protect the system and stop it
catching on plant and scaffold etc.
 Climb ladders with 2 hands with the case over your shoulder.
 If using the wave guide fit it in a leather sheath – if not needed leave it
behind.
 Never put the wave guide in your pocket as it could spear your leg or
fall out.
 Wash our hands and wipe down sensors/cable to remove grease.
Physical
Intrinsic Safety
 The unit is IS certified as long as its not tampered
with.
 This unit Cannot be user serviced.
 If unit malfunctions contact PAL. Do not open the

casing, this will invalidate the IS certification.
 Remember to connect and disconnect the sensor

only in a safe, gas free environment
Physical
Surface Temperatures
 Probe will operate at temperatures up to

1250C (not continuous contact).
 Above this temperature use a waveguide.
 But there will be a loss of signal through

waveguide – small leaks will not be
detectable.
Physical
Waveguide Correction
 When you find a leaking valve – note reading.
 Retest using waveguide – note reading.
 Make a note of difference, this gives

correction for waveguide.
 However, the readings will be unreliable and cannot be used to

estimate leak rates, they can only be used as a guide.
Physical
Lagging & Insulation
 Hot valves may well have lagging or jackets on
them.
 Customer must consider any preparation of

lagged valves in advance of test
 Never modify or cut off lagging without

permission - it may have trace element heating
underneath
 Jackets must be put back on post test and

sealed properly
Physical
Troubleshooting
 If the 5131 is used correctly faults are not common.
 Most common is probe damage due to impact damage

or at connector due to heavy handed connection /
disconnection.
 If damaged probe reads (in air) 16+dB or 6-11dB

replace probe and retest with sensor clasped in your
hand (this shields it from electric noise).
 If problem is not resolved call PAL who can advise.
Physical
VPAC Permanent Leak Sensor System
 There are many situations when intermittent
surveys are undesirable and ‘Real Time ‘ leak
monitoring is required.
 To achieve this we supply a sensor and amplifier
unit which has an industry standard 4-20 mA
output.
 This provides an intrinsically safe solution for leak
detection in hazardous environments. 1276 zener
Barrier – 1278 galvanic barrier.
Physical
VPAC ONLINE IS Sub System
4-20 MA
output to
DCS or
turnkey
system
Physical
What next - Hands On!
Physical
VPAC Training Course
Thank you for your attention.
Do you have any questions?
Physical

Leak Detection Inspector

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Leak Detection Inspector

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Physical Acoustics Ltd VPAC -

Quantification of Through Valve Gas &

 Physical Acoustics developed VPAC with BP and Shell (since

 Identification of leaking/passing valves is important for safety and to

 Physical Acoustics Ltd, based in Cambridge, provides

 Acoustic Emission (AE) is Structure Borne Noise.

 AE May Be Generated By:

 VPAC detects leak “hiss” caused by turbulent

A tight valve makes very little noise.

 Remove leaking valves from service

 Re-test valves in lab. using flow-meter and acoustic

 1984-1990 800 valves, up to 18”, plug, gate, ball, globe,

 Develop graphical and numeric correlation from the

 1-2% of these passing

 Leaks can exceed 1000

 Leaks down to <1 litre/min

 Maintenance planning – identify leaking valves prior

 Reduces losses to atmosphere through vent pipes.

 Reduce loss to flare (even if there is a gas recovery

 Trouble shooting – tracing leaks and sources of cross

 Re-qualifying PSV’s after operation.

 ESD’s testing (save 6-12 hrs production).

 Portable unit (2kg)

Stored Memory Point (1-300) Current Measured Value

Stored Value At Memory Point

 Valve must be subject to differential pressure 0.5 bar

 Clean away loose rust and scale.

 Hold sensor on valve body using grease as acoustic

 Let measurement stabilise - take reading.

 Take upstream and downstream readings to check valve

Note it is good practise to make several

• Use the highest VPAC

• VPAC measurements upstream and down stream ensure

• Valve reading must be 6dB+ than upstream/down stream

• No compensation is required in the spread sheet - use peak

0.5 -1m 0.5 -1m

Noise check point

ONLY USE VALVE MEASUREMENT IN LEAK CALCULATION

Up stream Valve Down stream Result

Remember – there is no need to compensate for up/down stream

 For normal operation use as delivered.

 There are option changes that can be

 No Need to Change Settings!

 Simple Excel format.

There are four pages in the Shell platform specific

 Always carry VPAC system in the case with sensors pre-connected

 Wash our hands and wipe down sensors/cable to remove grease.

 This unit Cannot be user serviced.

 If unit malfunctions contact PAL. Do not open the

 Remember to connect and disconnect the sensor

 Probe will operate at temperatures up to

 Above this temperature use a waveguide.

 But there will be a loss of signal through

 When you find a leaking valve – note reading.

 Retest using waveguide – note reading.

 Make a note of difference, this gives

 However, the readings will be unreliable and cannot be used to

 Customer must consider any preparation of

 Never modify or cut off lagging without

 Jackets must be put back on post test and

 If the 5131 is used correctly faults are not common.

 Most common is probe damage due to impact damage

 If damaged probe reads (in air) 16+dB or 6-11dB