Non-Intrusive

Acoustic Valve
Inspection
(NAVI)

Theory & Applications

Mohammad Nazri Mudin

Amserve Engineering Sdn. Bhd.
 VALVE PASSING
Refers to flow through a valve which is set in the “off” state (closed).

FACTORS IMPACT

• Seat alignment Safety

• Insufficient actuator travel Environment

• Poor maintenance Production

• Corrosive and/or erosive process Asset Integrity

media

• Valve seat is prevented from fully

closed due to dirt/rust.

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 NON-INTRUSIVE ACOUSTIC VALVE INSPECTION (NAVI)

• Technology from France

• Used widely in Nuclear Power Plant to detect

passing valves and steam traps

• Experience more than 20 years

• Europe, North America, Africa

• No permanent installation required

• Inspection is fast and reliable

• Estimation of leak rate based on actual data collected

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 WORKING PRINCIPLES

• Based on passive measurement of ultrasonic acoustic emission. These

sounds are generated by the flow of fluids through leaking valves under
pressure.

• The NAVI hardware takes the sound measurement signals, processes and
displays them as a signature most suitable to identify and quantify the leaks.

• Test requirements
• Valve to be tested must be in closed position
• There is a differential pressure across the valve, at least 1 barg.

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 THEORY OF APPLICATION

• Acoustic emission is a structure borne noise and it is generated by the

process medium flow. NAVI detects leak noise caused by turbulent flow,
which is measured in decibels (dB).

If a valve is in open position, A tight valve makes a very A passing valve creates
there will be laminar flow little or no noise. turbulent flow and acoustic
that generates little or no noise. The AE is transmitted
noise. into the valve body.

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 INSPECTION TOOL

Hardware Software &

• Panasonic Accessories
Toughbook Model • Digital NAVI Analyzer
CF-19/Getac • Contains database,
• Touch-sensitive current and
screen previous.
• Acquisition card • Piezoelectric
up to 2400 kHz accelerometer and
• Intrinsically safe heat sink compound
(Zone II)
Heat Sink
Sensor Compound
Cable/Sensor

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 AE MEASUREMENT

2. Place sensor on the 3. Place sensor on the

upstream piping, take downstream piping,
background noise. take background noise.

1. Place sensor on the

valve body, take
pressure noise.

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 DATA ACQUISTION

Background Noise (Up) Pressure Noise (Body) Background Noise (Dwn)

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 ANALYSIS
Background Noise (Up) Pressure Noise (Body) Background Noise (Dwn)

Differential
Signature
VALVE PASSING

Analysis
• If Pressure Noise is greater than Background Noise, then the valve leaks.
• If Pressure Noise is equal to Background Noise, then the valve is tight.

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 ANALYSIS
Background Noise (Up) Pressure Noise (Body) Background Noise (Dwn)

Differential
Signature
VALVE TIGHT

Analysis
• If Pressure Noise is greater than Background Noise, then the valve leaks.
• If Pressure Noise is equal to Background Noise, then the valve is tight.

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 ANALYSIS

PASSING NO PASSING

Continue Monitoring
Small Medium Large 6-Monthly
Large
Small
Medium
Leak
Leak
Leak
––24
1 –to
dB
109and
to
dB23 above
dB
Valve
Continue
Valverecommended
NeedMonitoring
Repairing
Estimation ofto
6-Monthly
be replaced
Leak Rate
Tolerable Leak Threshold for Various
Type of Valves (Shell IMP 3.02 Table 1)

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 CASE STUDY 1: LAUNCHER PRESSURE BUILT UP
RECTIFICATION (EXTRACT FROM CLIENT REPORT)
JANUARY 2013

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 CASE STUDY 1: LAUNCHER PRESSURE BUILT UP
RECTIFICATION
Trunkline RY (Launcher L-2900) and Trunkline RZ (Launcher
L-2910) found high pressure build-up in launcher barrel (up
to 80 barg/day) after pigging activities.

After lubrication & sealing, RY launcher pressure build up

controlled at 1 – 2 barg/day. RZ launcher pressure build up
higher at 3 – 5 barg/day.

Further rectifications was requested to verify root cause.

Action Items:
• Mobilized Amserve to conduct non-intrusive acoustic valve inspection on MOVs to
determine leakage rate; and check for any passing from kicker line and vent line.
• Mob valve maintenance vendor to conduct MOVs alignment, perform greasing and
sealing.
• Amserve to verify passing valves and final leakage rates.

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 CASE STUDY 1: LAUNCHER PRESSURE BUILT UP
RECTIFICATION

MOV290X2 MOV290X1

Non-Intrusive Acoustic Valve Leak Inspection was performed on

• MOV290X1, MOV290X2
• Kicker Valves (VX-2901, VX-2902)
• Equalizing Line Valves (VX-2904, VX2905)
• Vent Valves (VX-6395, VX6396)

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 CASE STUDY 1: LAUNCHER PRESSURE BUILT UP
RECTIFICATION

NAVI Result for RY (L-2900)

• No serious passing detected from kicker valves, equalizing line valves and vent valves.
Pressure build up not likely contributed from these valves.
• MOV290X2 (riser side/tee) passing rate still within allowable limit, but the high dB
ratio indicate ACTUAL passing rate could be higher than the estimation.
• MOV290X1 (launcher side) passing rate exceeded allowable limit, but lower than
MOV290X2.

CONCLUSION: Build up of pressure in launcher is likely from MOV290X1 and

MOV290X2.

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 CASE STUDY 1: LAUNCHER PRESSURE BUILT UP
RECTIFICATION
TOLERABLE LEAK THRESHOLD (SHELL IMP 3.02 TABLE 1)
Tolerable Leak Threshold Warning Limit
Item Types of Valves (% TLT)
Gas service (kg/s) Oil service (kg/s)
1 Riser ESD Valves (1) 0.1 0.1 75
2 Launcher/Receiver 1st MOV (at barrel) (1) 0.01 0.01 50
3 Launcher/Receiver 2nd MOV (at barrel) (1) 0.1 0.1 75
4 Process ESD Valves (SDV, ROV) (2) 0.1-0.3 0.1-0.3 75
5 Depressurization or Blow-down valves (3) 0.03 0.03 75
6 Motorized Isolation Valves (MOV) (4) 0.01, 0.1 0.01, 0.1 50, 75
7 Process Control Valves and FCV (5) 0.1-0.3 0.1-0.3 75
8 Mechanical Isolation Valves (6) 0.01, 0.1 0.01, 0.1 50, 75
9 Integral DBB Valves (7) 0.01 0.01 75
10 Non Return or Check Valves (8) 0.3 0.3 75
Note:
•Based on consequence of 2 mm pinhole leak with 5 m jet fire as per Riser Tolerable Leak Rate Study Rev.0 Mar 2008.
•Rate of 0.1 kg/s is based on the worst case consequence similar to Riser ESD valves with blow-down duration of 15 min or more and 0.3 kg/s for case with depressurization
less than 10 min from maximum operating pressure to 7 barg.
•Rate is based on flaring limit of 0.1 MMscfd of one valve or 2.0 MMscfd for total valves of the platform.
•Rate is based on consequence cases similar to Pig-trap valve, i.e. last barrier 0.01 kg/s and otherwise 0.1 kg/s.
•Only for FCV and those process control valves that serve also as shutdown valves (no other Process ESD valves) and rate shall follow the Process ESD valves.
•Rate is based on consequence cases similar to Motorized isolation valves.
•Rate is based on consequence case similar to last barrier of MOV, i.e. 0.01 kg/s
•Rate is based on the consequence of blow-down valves.

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 CASE STUDY 1: LAUNCHER PRESSURE BUILT UP
RECTIFICATION

Result after cleaning and re-sealing

• Pressure built up contained to 0 barg after 2 days of monitoring (2 barg after 4
days).

• NAVI was conducted again, result shows MOV290X2 is still passing and confirmed
by continuous passing of gas at body vent.

• MOV290X1 shows minimal passing, and greatly reduced passing from body vent.
Most of riser pressure is being contained by MOV290X1.

• MOV290X2 shall be replaced as soon as possible.

• MOV290X1 shall also be considered for replacement. Without sealant, leakage

will become worst.

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 CASE STUDY 3: TO IDENTIFY PASSING
CHECK VALVES FOR P-6250
JAN 2013

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 CASE STUDY 2: CHECK VALVES

System Area: M1 P-6250

Situation: Pump suction check valves and pump
discharge check valves were suspected passing,
however could not be identified.

Action Items:
Amserve to carry out NAVI. Pump was let run until
reach consistent desired discharge pressure, then
stopped to create backflow.

Result:
Passing valves were identified. Leak severity ranged
from small to medium leak, however estimated leakage
rates are still within tolerable leak threshold for check
valves (0.3 kg/s).

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 CASE STUDY 3: VALVE PASSING VERIFICATION FOR A
NEWLY INSTALLED VALVE AT TML PLATFORM
MAY 2012

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 CASE STUDY 3: TML NEWLY INSTALLED VALVE

System Area: TML’s BR-A Pipeline Isolation Valve

Situation: During recent shutdown, a new valve was
installed to replace previously reported passing valve.
During pressurization, pressure build-up was observed
at the downstream. Client requested for verification
and estimation of leak rate, as not to exceed the
standard allowable leak rate* (1 kg/min for natural gas).

Action Items:
Amserve was notified on the situation and was
mobilized to site.

Result:
It is found that the valve passing and the estimated leak
rate is still within the allowable leak rate. OIM and
maintenance team were notified on our findings.

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 BENEFITS

Identify passing valves.

• Avoid unnecessary valve repair

• Identify repeat leaking valves
• Identify leaking valves to increase efficiency

Safety

• During maintenance, ensure effective isolation.

Environment

• Reduced flaring/emission

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