The first mobile valve inspection system for potentially explosive atmospheres
Leaking valves in industrial plants can not only lead to losses, safety risks and possible contamination and pollution, but can also result in high economic costs. Valves therefore require regular proper inspection and preventive maintenance to ensure their functionality.
Valve Sense is an innovative, intelligent inspection system that has been specially developed for leakage detection in hazardous areas. The software and AI-based intelligent mobile inspection system from i.safe MOBILE and strategy partner Senseven builds on the established method of acoustic emission and combines it with new, digital features to analyse acoustic signals and precisely identify valve leaks. High-quality acoustic emission sensors are connected to the 5G smartphone IS540.1 and a specially developed app.
The Valve Sense system and the IS540.RG 5G smartphone are also available for industrial applications without the necessary explosion protection.
Simple leak testing with the help of algorithms and AI
Valve Sense can be used to quickly and easily check valves for leaks. Specially developed algorithms analyse the sensor data in an app using IS540.1 / IS540.RG in real time. If a leak is detected, the AI calculates the size of the leak based on empirical values. Regular checks enable potential problems to be recognised at an early stage and maintenance measures to be initiated in good time. The cloud-based infrastructure makes it easy to store and analyse the collected data, ensuring a complete overview of the condition of the valves. Thanks to regular in-house maintenance with Valve Sense, valves only need to be replaced in the event of real defects and functioning valves can continue to be used.
Maintenance and inspection during operation
With Valve Sense, valve inspections can be carried out during operation without having to interrupt production processes. The inspection is carried out directly on installed valves so that no leak test on an external test bench is necessary. This avoids production downtime and at the same time achieves significant time and cost savings.
The advantages of Valve Sense at a glance
- Simple, software-guided operation: no prior knowledge required.
- No intervention in the production process: inspections possible during operation.
- Automatic leak detection: algorithms and AI provide immediate results.
- Cloud-based infrastructure: Centralised storage and evaluation of inspection data.
Frequently asked questions about leak detection and valve inspection in hazardous and industrial areas
How does the detection of leaking valves with algorithms and artificial intelligence work?
The detection of leaking valves with algorithms and artificial intelligence (AI) is based on analysing acoustic signals emitted by a valve. If a valve is leaking, it generates high-frequency sound emissions. These signals are recorded by special sensors and then analysed by algorithms and AI. The algorithms recognise the characteristic patterns and frequencies that indicate a leak. This allows the leak to be identified in real time and without expert knowledge. The AI models are constantly being further trained and improved.
How do you recognise valve leaks using acoustic signals?
Valve leaks are recognised by acoustic signals that are generated when gas or liquid escapes through a leak in the valve. This leakage generates high-frequency acoustic emissions that are picked up by a special sensor, the acoustic emission sensor. The signals are then amplified and digitised by our measuring electronics and evaluated in real time in the app. The specific patterns and frequencies of the acoustic emissions can be used to determine whether and to what extent there is a leak.
What is the best method for leak testing valves without a test bench?
The best method for leak testing valves without a test bench is the acoustic emission test. This method makes it possible to detect valve leaks in the installed state and during operation. The acoustic signals generated by a valve are analysed in order to identify leaks. This method is particularly advantageous as it can be carried out quickly, efficiently and without dismantling or interrupting the production process.
How does leakage detection work during operation?
Leakage detection during operation works by using acoustic emission sensors that record acoustic signals generated by leaking valves in real time. These signals are digitised by our measurement electronics and sent to the app, which evaluates them using algorithms and artificial intelligence. As the inspection takes place during normal operation, production processes do not have to be interrupted, which minimises downtimes and increases the efficiency of the system.
Why is regular valve inspection important?
Regular valve inspection is crucial to ensure the safety and efficiency of industrial plants. Leaking valves can lead to energy loss, safety risks, environmental pollution and high repair costs. With regular inspections, potential problems can be recognised early and rectified before they lead to serious malfunctions or accidents. In addition, continuous monitoring and maintenance extends the service life of the valves and helps to avoid unplanned downtime.
