Detailed Overview

This is a continuous sensor-based system designed for monitoring the operational health of industrial valves. It collects data on acoustic, vibration, and temperature signatures to detect early signs of valve leaks. The system provides a predictive maintenance solution for valve assets, minimizing unplanned downtime and optimizing system efficiency by leveraging advanced diagnostics and wireless data transmission.

Permanent, non-invasive acoustic monitoring for real-time tracking of valve performance and leak detection.

• This system attaches externally to industrial valves and uses sophisticated acoustic and vibration sensors to listen for internal leaks, seat wear, or operational issues without interrupting the process.
• It provides continuous, predictive maintenance data for critical assets using IIoT (Industrial Internet of Things) principles.
• The system includes the acoustic sensor units, a wireless data logger/transmitter, and cloud-based analysis software featuring AI and Machine Learning algorithms for anomaly detection.
• The non-invasive installation minimizes impact on process integrity and does not require process shutdown.

Top Features & Benefits

• System for continuous monitoring and diagnostics of industrial valves.
• Uses acoustic and/or vibration sensors for non-invasive data collection.
• Detects internal leakage.
• Predictive maintenance solution to schedule service before failure.
• Wireless data transmission for remote monitoring and centralized control.
• Integrates with existing industrial control systems (e.g., DCS, SCADA).
• Reduces maintenance costs and prevents unexpected, costly shutdowns.

Primary Uses & Functions

A system used for monitoring the operational status and condition of industrial valves, typically for predictive maintenance, process safety, and optimizing asset lifespan. Its primary function is the early quantitative detection of through-valve leakage and mechanical performance degradation.

Real-World Applications

• Condition Monitoring of Industrial Valves (e.g., Acoustic Emission)
• Detection of internal leaks (through-valve leakage in control, block, and on/off valves).
• Tracking valve operational status, identifying performance degradation, and quantifying leak severity.
• Monitoring steam trap performance to prevent energy loss.
• Detecting issues like cavitation or improper stroke/positioning.

Industry Solutions

• Oil & Gas (Pipelines, Refineries)
• Petrochemical (Chemical Processing Plants)
• Power Generation (Nuclear, Fossil Fuel, Renewables)
• Manufacturing (Process Control, Water/Wastewater)
• Water Distribution and Chemical Processing.

Technical Specifications

Compatibility

• Continuous and real-time monitoring of valve condition (e.g., leaks, cavitation, passing) using acoustic or vibration analysis.
• The sensors attach directly to the valve body (non-intrusively) and connect to a central monitoring/data acquisition system, which can interface with plant DCS/SCADA via standard protocols (e.g., OPC UA, Modbus).
• Compatible with virtually all valve types: Ball, Gate, Globe, Control Valves, etc.

What’s In The Box?

• Valve Sense Sensor Unit(s).
• Mounting hardware and connection cables.
• Data Acquisition and Wireless Transmission module (Gateway).
• Monitoring Software license (Cloud/Server-based platform).
• Instruction manual and Quick Start Guide.

Also Known As

Acoustic Leak Detector, Process Condition Monitor, Steam Trap Monitor, Valve Health Monitoring System, Non-Intrusive Valve Diagnostic System, Through-Valve Leak Detector.