Valve Internal Leak Diagnosis Service
Using ValveSense AI ultrasonic technology, we instantly diagnose invisible internal valve leaks. Non-destructive, non-invasive detection that visualizes steam loss and energy waste.
Are You Inspecting Your Valves?
It is estimated that 5-10% of valves in a factory are leaking. Internal valve leaks cannot be identified by external appearance, and traditional methods required pipe disassembly or process shutdown. Approximately 25% of energy loss in steam systems is attributed to heat dissipation from piping and steam leaks, and it is not uncommon for faulty steam traps alone to cause losses of hundreds of thousands of yen annually.
Proprietary software developed by Senseven (Austria) guides the inspection procedure and analyzes sensor signals. Using algorithms and AI, it provides immediate results on-site. All inspection data is stored in a structured format in the cloud, enabling detailed analysis and report generation.
This solution eliminates dependence on specialists, improving process efficiency, preventing serious equipment damage, and reducing safety risks for employees. ValveSense is a mobile inspection system utilizing ultrasonic (AE) technology that can function as a standalone evaluation tool or as a cloud-based package for storing multiple tests and tracking valve trends over time.
Comparison with Traditional Methods
Traditional Methods
- Requires a test bench and two workers for inspection
- Inspection results can take several days
- Significant losses from factory downtime during inspection
With ValveSense
- Single-operator inspection dramatically reduces labor
- Shortened work time eliminates unnecessary costs
- Detects potential defects in just seconds
Service Features
Easy Operation
The dedicated app runs on smartphones, eliminating time-consuming employee training. The software guides the inspection procedure step by step, enabling anyone to perform diagnoses with the same level of accuracy.
Rapid Inspection
Flexibly inspect valves and detect potential defects in just seconds. With approximately 3 minutes per valve, diagnosis can be performed on running production lines without process shutdown.
Automation
Automated leak detection and report generation reduce inspector workload. AI algorithms analyze sensor signals in real time, delivering objective diagnoses free from subjective judgment.
Automated Report Generation
Automatically generated reports make it easy to review and share inspection results. Cloud-stored data can also be used for time-series trend analysis and optimization of future inspection schedules.
Inspectable Valve Types
ValveSense can inspect valves of all types and applications. In addition to detecting internal leaks (seat leaks), it can also detect abnormal sounds inside piping.
As a non-fixed device, a single unit can inspect all valves throughout an entire factory.
Steam Trap Inspection
By using the TrapSense mode, steam trap diagnosis is also possible.
The system performs ultrasonic and temperature measurements to diagnose steam trap conditions on a 5-level scale. Results such as normal, caution, or faulty are confirmed instantly on-site, enabling early detection and correction of energy losses from steam leaks.
Service Specifications & Coverage
- Detection MethodUltrasonic (AE: Acoustic Emission)
- EquipmentValveSense LL-VS1 (manufactured by Senseven)
- Diagnosis MethodAI algorithm + guided software
- Diagnosis TimeApproximately 3 minutes per valve
- Supported ValvesButterfly, gate, ball, plug, control, safety, and check valves
- Supported MediaSteam, compressed air, nitrogen, various gases, liquids
- Data ManagementCloud-based (time-series trend tracking)
- ReportsDiagnosis result report (with leak assessment and recommended actions)
- Supported SizesCompatible with all valve sizes
Visualize internal leaks & steam loss
A report that sets your repair priorities
We submit a complete report: a summary of results, repair priorities, lists and drawing maps of the valves and steam traps measured, an individual report for each unit (with photos, thermal camera images and comments), and estimated losses and improvement effects. Use it as-is for repair planning and internal approval.
View sample report (PDF, Japanese)
Case Studies
Paper Mill - Seat Leak Detection
Verifying the operation of valves installed in large valves and complex piping systems previously required shutting down equipment and physically disassembling the valve body. With sensor-based diagnosis, even large valves affected by contamination and corrosion can be diagnosed simply by applying a sensor externally. The inspection process was completed in under one minute, dramatically improving productivity by minimizing plant downtime.
Thermal Power Plant - Steam Trap Detection
A specific valve in the steam piping system was not fully closing, causing continuous high-temperature, high-pressure steam leakage. The escaping steam condensed into water, resulting in annual losses of 19.2 million JPY. If left unaddressed, the condensate could be pushed through by steam pressure, creating a serious risk of pipe and equipment damage, making early detection and correction essential.
Learn More About Our Valve Internal Leak Diagnosis Service
We offer on-site diagnosis demos and quotes. If you are concerned about valve or steam trap leaks, please feel free to contact us.