SKF Reliability Systems

Using the SKF Microlog for Leak

Detection
By Dr. Robert M. Jones • SKF Reliability Systems

Abstract There was no leak through the valve.

Figure 1 displays a spectrum of that
Every plant has hundreds, or even condition.
thousands, of valves. If leakage occurs in
these valves, the results are always bad; For the next spectrum, the valve was
lost product, contamination, safety opened to allow a measured flow of one-
violations, etc. In addition, one of the eighth of a gallon per minute.
higher cost plant operating systems, plant This proved that we could detect a very
air, is typically one of the systems with the small leakage with a Microlog and
highest leakage. By applying the Microlog accelerometer. However, the question
for valve leakage measurements, leaks can remained: what could be done in the field,
be detected without disassembling the where valve leakage couldn’t easily be
valve. measured?
Discussion The second application is used when
Following are three case studies that the system remains in a constant state.
illustrate Microlog use for detection of In a nuclear power plant, it is critical to
valve leakage. In the first application, we monitor valve leakage inside containment.
review data from tests conducted for the Of course, no one can be inside
U.S. Navy’s submarine service. containment when the plant is operating, so
In every boat, there is always some leakage how does one conduct the monitoring? At
from various valves that penetrate the hull. the time these tests were conducted, the
In 1993, the U.S. Navy, looking for an off- allowable leakage from an unknown source
the-shelf leak detector, asked if the SKF for a boiling water reactor was 1.5 gallons
Microlog was capable of detecting a leak of per minute. This is measured as the
one-eighth gallon per minute (GPM). In a leakage comes out of the containment into
Navy lab, SKF placed an accelerometer on a closed collection system. However, if the
a valve that could be visually observed. leakage source is identifiable, the limit was

Application Note
CM3097 Figure 1. Valve closed, no leak.
 “Using the SKF Microlog for Leak Detection” 2 www.skf.com/reliability

Figure 2: One eighth gallon per minute leak.

2.5 gallons per minute. If able to use the higher figure, the valve body, a standard accelerometer has the ability to
plant could be operated longer and more efficiently between detect this high frequency energy.
shutdowns.
By placing the accelerometer on the valve stem, a direct
A test lab was set up to identify various types of leakage. A vibration measurement path is established to the ball or
variety of potential leakages and their amplitude points were flapper on the end of the stem. A spectrum is collected at
collected using constant operating temperatures and this position. Another characteristic of high frequency
energy is that it will attenuate over distance. Testing by
pressures. When results were plotted, they showed a linear
others has determined that the distance range of this energy
relationship between the noted amplitude and the observed
from the valve body is approximately 10 pipe diameters.
leakage. This data was submitted to the Nuclear Regulatory
Therefore, a second measurement (background reading) is
Commission (NRC), who validated and accepted the test then taken 10 pipe diameters from the valve body, upstream
results. or downstream. If the valve is not leaking, the amplitudes
There were 26 valves inside the containment. An of the background reading and the reading on the valve
body will be approximately equal. However, if the
accelerometer was mounted on each valve body, and
amplitude on the valve body is 20% to 25% higher than that
connected to a data collector outside containment. This
of the background, the valve is probably leaking. The
allowed each valve to be monitored, and its leakage
greater the amplitude difference – the greater the probability
measured. Thereafter, the plant was allowed to continue that a leak exists.
operations to the higher limit of 2.5 gallons per minute.
Note that if the pipe is wrapped, it is necessary to open it so
It must be noted again, for this second application the the accelerometer can be placed directly on the pipe. If a
pressures and temperatures must remain constant. Any standoff must be used on the pipe, then the standoff must
variations would change the results and invalidate the linear also be used when collecting data on the valve stem.
relationship established under constant conditions. Otherwise, you are comparing dissimilar conditions.
The third application is used when the system If you are working in a noisy environment, the numbers may
pressures and temperatures may vary. be large. If it is quiet, as the examples below, the numbers
will be small.
This application takes place in various plant systems: air,
nitrogen, instrument air, natural gas supply lines, etc. At 10 pipe diameters, the overall amplitude was 0.018 gE,
Acoustical energy is generated when any product, liquid or the spectrum is shown in Figure 3.
gas, is emitted through an orifice. Sometimes it can be The reading on the valve, without a leak, is shown below.
heard with the human ear, but often no sound is heard The overall amplitude was 0.017 gE. Since this data was
because the frequency is too high. When mounted on the collected in a lab we knew the valve wasn’t leaking.
 “Using the SKF Microlog for Leak Detection” 3 www.skf.com/reliability

When plotting spectrums be sure to set the “X” and “Y” and data on the second valve is in enveloped acceleration,
axes to the same scale for each plot. This will not affect the “gE”. Both methods of measurement are valid.
amplitudes, but the visual impact can be deceiving if the
The author worked nine years in a pressurized water nuclear
settings are not the same.
plant. One of the systems that had over 20 valves used
Figure 5 shows the spectrum for the measurement taken on borated water for safety purposes. If any of these valves
a valve that was leaking. leaked, the storage tanks would show a decrease in volume.
It seemed that there was always some leakage. The only
On the leaking valve, the overall amplitude was 0.037 gE,
time the valves could be accessed was during a shutdown
well over the 25% target.
when the boron system was shut down. There was no way
Note that the data for the Navy was in acceleration, “G’s”, of knowing which valves needed to be rebuilt, which meant

Figure 3. Measurement taken at a distance of 10 pipe diameters away from the valve.

Figure 4. Measurement taken the valve stem, with no leak.

“Using the SKF
Microlog for Leak
Detection”

By Dr. Robert M. Jones

SKF Reliability Systems

Figure 5. Spectrum of the leaking valve.

that every valve was internally inspected, a constant. The leaking valves had been
process usually taking four to six days. located and repaired. The importance is
Mounting an accelerometer on each valve that on the timeline for start-up, this system
was not practical from a cost and time was prime. By saving two to four days of
standpoint since the valves were in the shutdown, the cost savings was several
SKF Reliability Systems scattered locations and it would take years million dollars.
5271 Viewridge Court
to get Nuclear Regulatory Commission
San Diego, California 92123 Conclusion
USA approval for the cable installation and
Telephone (+1) 858-496-3400 routing. The Microlog can be successfully used to
FAX (+1) 858-496-3531 detect leaking valves for gas or liquid
The solution was to pressurize the system service. If operating conditions are
with nitrogen and take a Microlog reading constant, a linear relationship exists
Web: www.skf.com/reliability on each valve. The amplitudes were then between the reading amplitude and the
listed in descending order. When the volume of leakage. This can be plotted and
variance between consecutive readings used to determine the volume of leakage
showed a sharp drop, only the valves above based on observed amplitudes.
that line were inspected. Using this Alternatively, in variable systems,
method, seven valves were inspected and measuring the amplitude difference of
Although care has been taken to repaired in two days. When the system
assure the accuracy of the data
measurements taken on the valve and up or
compiled in this publication, SKF was again pressurized with borated water, downstream on the pipe allows a logical
does not assume any liability for the level in the storage tanks remained determination to be made.
errors or omissions. SKF
reserves the right to alter any part
of this publication without prior
notice.

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CM3097 (6-04)
Copyright © 2004 by
SKF Reliability Systems
ALL RIGHTS RESERVED SKF’s Micrologs – Portable Data Collectors/Analyzers.