What Is VALVE SENSE?
VALVE SENSE is an internal leak diagnostic system for valves and steam traps that utilizes AE (Acoustic Emission) technology. It detects minute acoustic signals generated inside piping and valves with high precision, enabling non-destructive diagnosis of internal leaks that cannot be confirmed visually.
Designed as a mobile inspection tool, it can be easily carried to the field for diagnosis. Acquired data is immediately evaluated by an AI-powered automatic analysis function that determines the presence and severity of leaks. Dedicated software guides the inspection procedure step by step, enabling accurate diagnosis even without specialized knowledge or experience.
Diagnostic data is stored and managed in the cloud, enabling trend monitoring of changes over time. By comparing with historical data, early detection of equipment degradation trends is possible, supporting the development of preventive maintenance plans.
The Role of Steam Traps
Steam traps play an extremely important role in steam piping systems. Their primary function is to automatically discharge condensate (drain) generated after steam heat energy is used, while retaining useful steam within the piping.
When steam traps function properly, steam thermal efficiency is maintained at maximum levels. In steam-using equipment such as heat exchangers and heaters, condensate accumulation dramatically reduces heat transfer efficiency, making rapid drain discharge by steam traps essential.
Properly functioning steam traps also directly contribute to energy savings. By preventing steam leaks, boiler fuel consumption is reduced, contributing to CO2 emission reductions. Although often overlooked, steam trap management is a very important element in reducing the overall environmental footprint of a factory.
Impact of Steam Leaks
It is estimated that approximately 25% of energy losses in an entire steam piping system are attributable to heat dissipation from piping and steam leaks. This loss rate translates to very significant monetary amounts when converted to a factory's energy costs.
Steam leaks caused by steam trap failure or degradation are often difficult to visually confirm from the outside, and there are many cases where they go unnoticed for extended periods. Steam losses from a single failed steam trap can reach hundreds of thousands of yen annually.
Large factories and plants have hundreds to thousands of steam traps installed. Even if the failure rate is only a few percent, enormous energy losses occur across the entire system. Implementing regular diagnostics can prevent such losses and is expected to yield annual cost savings in the millions of yen.
Diagnostic Method
VALVE SENSE diagnosis of steam traps combines two main approaches.
Temperature Differential Measurement
The temperature difference between the inlet and outlet sides of the steam trap is measured to determine whether the trap is functioning properly. In a normally functioning steam trap, the inlet side shows high temperatures close to steam temperature, while the outlet side shows reduced temperatures due to drain discharge. If this temperature differential deviates from standard values, a trap malfunction is suspected.
Acoustic Detection
An AE sensor is placed in contact with the trap to detect acoustic signals generated internally with high sensitivity. When steam passes through and leaks from a trap, a characteristic acoustic pattern is generated, enabling AI analysis to accurately determine the presence and degree of leakage.
Based on these diagnostic results, repair priorities can be established, allowing countermeasures to be implemented starting with the most impactful locations. This achieves an efficient approach that maximizes energy savings within limited maintenance budgets and personnel.
Selection and Maintenance
To maximize the energy-saving benefits of steam traps, appropriate model selection is essential. By choosing high-efficiency steam traps with minimal leakage suited to usage conditions and installation environments, energy losses can be minimized from the initial stage.
However, even the highest quality steam traps will gradually decline in performance over time. Therefore, in addition to proper model selection, regular inspection and diagnosis is indispensable. By incorporating regular diagnostics using VALVE SENSE into maintenance plans, failures and degradation can be detected early, enabling replacement and repair at optimal timing.
Data accumulated through regular diagnostics can also be used for steam trap life prediction and optimal replacement timing decisions. Trend analysis using the cloud-based database enables long-term energy-saving strategy planning, maintaining steam system efficiency at consistently high levels.