Senseven’s mobile inspection system Valve Sense, developed in collaboration with i.safe MOBILE, can be used with the IS540.1 smartphone to monitor critical valves in international explosive hazardous areas. This solution uses advanced sensor technology based on the proven acoustic emission method, which can be easily applied by maintenance personnel via software guidance—without special training or expert knowledge.
Companies can use the mobile inspection set consisting of a smartphone, measuring electronics, waveguide, sensors, and a software package to regularly check their plants themselves during ongoing production, thus saving time and money. Intact valves ensure smooth operation, guarantee product quality and also provide safety for employees. Valve Sense helps to detect valve leakage of water, gas, steam or air at an early stage and to react promptly. With the combined expertise of both companies, Valve Sense meets the high demands of customers in the chemical, pharmaceutical, oil and gas sector, and other demanding industries in explosive areas.
With the launch of Valve Sense for Ex-zones, i.safe MOBILE and Senseven are pioneers in the market applying today’s digital capabilities to an inspection system for leak detection in valves. The user-friendly kit easily connects acoustic emission sensors to i.safe MOBILE’s innovative 5G smartphone IS540.1 and transforms it into a smart valve inspection system through Senseven software. The software guides the user through the inspection process in a self-explanatory way and algorithms and artificial intelligence help with data analysis and provide immediate results on site. All data is automatically stored in a back office—a cloud-based platform for the structured management of all inspection data—for use in further analysis and reporting.
In manufacturing plants, valve inspection is an important part of the maintenance program. Depending on the production process, there are often harsh operating environments with high temperatures, corrosive chemicals, and abrasive particles. This can lead to damage on the valve and associated unplanned machine downtime. An estimated five to ten percent of all industrial valves leak. Undetected leaks caused by non-regular or improper maintenance can result in serious consequences such as injuries, raw material losses, or contamination/environmental pollution.
By performing regular in-house valve maintenance with Valve Sense, companies have the option of only having to replace valves when they really have a defect. Functioning valves can continue to be used. And this can be done during the production process without having to test the valve functionality on an external test bench. This avoids a production standstill and at the same time ensures considerable cost and time savings.
“Thanks to the cooperation with Senseven and the new, joint Valve Sense technology solution, we can now also offer our customers the most innovative mobile solution currently available on the market for valve monitoring in hazardous areas—with our usual reliable safety standards. The combination of Senseven’s technology with our 5G smartphone IS540.1 offers our customers an enormous increase in efficiency in the area of maintenance,” comments Martin Haaf, CEO of i.safe MOBILE.
“Valve Sense is a revolutionary technology that will change the way industrial valves are monitored and maintained in hazardous environments. Our team of experts has worked tirelessly to develop a system that is safe, reliable and easy to operate,” says Michael Hettegger, CEO of Senseven.
The Valve Sense set consists of a case containing the IS540.1 smartphone equipped with the Senseven software, the IS-VS1A.1 measurement electronics, a waveguide, and acoustic emission sensors.
The Senseven Expert Suite elevates valve monitoring to a new level, providing power users with an array of tools for detailed diagnostics and analysis. Designed to integrate with the Valve Sense Inspection System, this advanced suite empowers users with professional-grade insights to optimize maintenance strategies, reduce downtime, and ensure peak operational efficiency.
One of the standout features of the Senseven Expert Suite is its live view functionality. This feature enables users to visualize data in real time during inspections. Amplitude and RMS values are displayed dynamically, allowing for immediate assessment of valve performance. Whether monitoring minor deviations or identifying significant issues, live view ensures that no critical information is missed during operations.
For a more immersive approach to valve inspection, the live audio feature transforms ultrasonic signals into audible frequencies. This capability allows maintenance professionals to listen to real-time changes in valve behavior, aiding in the detection of anomalies such as leaks, cavitation, or blockages. By incorporating auditory monitoring, the Senseven Expert Suite provides an additional layer of insight that is both intuitive and effective.
The Senseven Expert Suite features tools for in-depth diagnostics, including Fast Fourier Transform (FFT) analysis. This powerful capability enables users to break down ultrasonic signals into their frequency components to enable precise identification of irregularities. With FFT analysis, users can pinpoint issues like structural degradation, resonance, or noise sources with unparalleled accuracy. This feature is particularly valuable in environments where subtle variations in performance can have significant operational consequences.
Predictive maintenance becomes effortless with the trend over time feature. By analyzing historical data collected from previous inspections, users can identify patterns and deviations, ensuring early detection of wear or damage before it becomes critical. This capability not only enhances the reliability of maintenance schedules but also helps in allocating resources more efficiently. Monitoring trends over time is vital for maintaining the long-term health of critical assets and optimizing operational workflows.
The Senseven Expert Suite simplifies asset management by integrating inspection results into existing maintenance systems. Detailed reports, offering structured and actionable insights, can be generated with just a few clicks. By combining time data with diagnostic tools like FFT analysis and live audio, the Expert Suite provides a wide-ranging picture of valve performance.
The Senseven Expert Suite is versatile and adaptable, making it an invaluable tool across a variety of industries. From chemical processing plants to oil and gas facilities, this advanced software ensures that valves operate safely and efficiently, even in the most demanding environments. By leveraging its powerful features, organizations can achieve significant cost savings, enhance safety protocols, and minimize environmental impact.
For maintenance professionals seeking unparalleled control and insight, the Senseven Expert Suite is a game-changer. With intuitive features and easy integration, the Expert Suite delivers exceptional value to power users who demand precision and reliability.
By choosing the Senseven Expert Suite, businesses can unlock the full potential of their Valve Sense Inspection System, achieving a level of performance and efficiency that sets them apart in their industry.
If you have further questions, feel free to contact Exloc at 281-978-2040.
Exloc Instruments, Inc., is a one-stop-shop for instruments and electrical equipment for hazardous and classified locations.
15584 Summit Park, Suite 303
Montgomery, TX 77356
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