Using the same acoustic emissions (AE) leak detection technology as Score’s portable valve leak detection tool, the MIDAS Meter®, the MIDAS® Sensor is designed for permanent but non-intrusive installation to provide continuous on-line valve condition and performance monitoring in hazardous areas where intrinsically safe certified equipment is required.
The MIDAS® Sensor detects the early onset of leakage so aiding operations to identify, trend and quantify valve leakage and enabling the appropriate operational and remedial actions to be put in place. This intrinsically safe valve condition and performance monitoring solution takes you from reactive to proactive maintenance by engaging in condition based monitoring and predictive maintenance activities. MIDAS® Sensor valve leak detection equipment therefore helps pinpoint losses and focus maintenance budget expenditure and actions on valves where maximum benefits can be achieved.
The unique benefits of this step-change technology for our customers include:
Acoustic Emissions monitoring on flare lines has a proven track record spanning more than 20 years. Major companies in the Oil & Gas and Petrochemical industries benefitted from improved environmental management as well as recovery and minimisation of product losses using MIDAS® Sensor.
The principle application for the MIDAS® Sensor is through valve leak detection. This can be a standalone application with the MIDAS® Sensor interfacing with the plant's Supervisory Control and Data Acquisition (SCADA) system or Site Automation System (SAS) or used as part of Score's V-MAP® G3 system to provide a complete picture of a valve’s condition by also monitoring the valve and actuator operating characteristics of force or torque, pressure, position and speed of operation.
The MIDAS® Sensor design integrates the piezo-electric sensors, filters, amplifiers and processors into a single self-contained housing that is easily mounted on all shapes and sizes of valves and piping. The specification and continuous integrity of the interface between an AE sensor and its mounting surface is critical to the long term reliability and stability of the sensor output. The MIDAS® Sensor design incorporates unique features to assure the long term reliability of its performance.
1. Cable terminations accessible via sealed cap
2. Bellows to provide sensor interface load
3. Piezo-electric AE Sensor
4. Saddle for mounting to valve or pipe
5. IP66 rated 316 stainless steel enclosure
6. Unique latch mechanism for ease of removal of sensor for calibration or maintenance
7. M20 cable entry
The uniquely designed MIDAS® Sensor mounting saddle can be attached in a variety of ways to the valve or pipe by the use of clamps, bolting fixtures or stainless steel banding and tensioning system depending on customer requirements and valve geometry/size. These arrangements make attaching the sensor saddle to the valve or pipework both quick and easy using the four toggle clamps on the sensor body.
Whilst the sensor has been designed for standalone valve leak monitoring, it has also been designed for seamless integration into existing and new plant control systems with simple functions of "Leak" or "No Leak" detection. Further to this for full leak estimation Score recommend this is used with our bespoke market leading valve monitoring system V-MAP® G3. This allows for remote online monitoring which fully determines the condition of your critical valve providing early warning leakage alarms and allows trending of leakage data over time. Further bespoke software tailored to the customer needs and benefits can be discussed with our in-house software team for your specific application.
Valve sizes from ½" to 50" NB can be surveyed
All types of valves which have an isolating function capability can be tested, including :-
See Technical Specifications
When used with our V-MAP G3 software this gives a graphic user interface providing visual indication (and this can be connected to audible alarms if required) of valve performance in accordance with the set acceptance criteria parameters. The visualisation of performance is facilitated by a traffic light system. This can also be connected directly into the Site Automation System to provide and easy "leak" or "No leak" guide to you critical valve performance.
The traffic light system built into the PDA is designed to act as a performance indicator as follows:
Green – Valve performing within end users chosen acceptable limits – No action required
Amber – Leakage noted, but not yet exceeding end-user's chosen "allowable leak rate" – Monitor closely
Red – Leak rate approaching or beyond end users chosen acceptable limits - Immediate action required
Note: Users set "acceptable limits / thresholds" (i.e. it these are user dependant/selectable) and Score Group accept no responsibility for the limits set by any end user.
No – there is a threshold of leak detection. Very small leaks (less than 0.1 litres / min) may not be detected, because they do not make enough noise.
Note: All leak detection methods (such as pressure build up tests or looking for visible leakage) have a threshold of detection and uncertainty attached to the result.
When monitoring valves, the user needs to know if the valve is working on a gas, liquid or steam fluid line. Once known, this allows the correct fluid type to be selected in the management software, to facilitate the automated leak rate calculation.
A valve must be in the closed position to carry out an AE leak detection survey. When the valve is closed, there will be no fluid flow, therefore the valve and piping will act as a separator. From the valve orientation, it can be determined if any leakage could be on gas or liquid during the commissioning phase and installation of the sensors by fully certified / trained Score personnel.
The valve being tested must have isolating capability, it must be in the fully closed position and a differential pressure must exist across the seat to seal interface. This differential pressure must be 1 bar or greater, pressures of 10 bar and over provide more favourable results with regards to quantification. The Acoustic Emissions (AE) Sensor on the front of the MIDAS® Sensor must be in direct contact with the metallic surface of the valve.
MIDAS® Sensor detects acoustic emissions in the frequency range 60kHz to 600kHz. The human hearing range only extends up to 20kHz, so when you can hear noise, then you should have no worries about this interfering with your measured results, as it is in a different frequency range. MIDAS® Sensor does not detect noise below 60 KHz. Concerns about background noise levels usually come from experiences of using lower frequency ultrasonic devices which have been seen in the past to give inconclusive results, since they pick up all low frequency noise (such as vibration and rotating equipment like pumps, bearings etc.), thus masking the high frequency signal that is generated by the leak path.
Yes, whilst the sensor has been designed for standalone valve leak monitoring, it has also been designed for seamless integration into existing and new plant control systems, including bespoke valve monitoring systems such as Score’s market leading V-MAP® G3 system
MIDAS® sensor is designed to work seamlessly with wireless communication devices which can handle its standard 4-20 mA output signal. Options for this can be offered on request.