Name: Valve Sense
Brand: Senseven
Author: Senseven GmbH

Question 1

What does your solution include?

Accepted Answer

Valve Sense is a complete inspection kit shipped in a hard-shell case. It includes an i.safe MOBILE smartphone (IS540.1 for ATEX Ex zones or IS540.RG for industrial use), acoustic emission sensors, a waveguide for hot and cold surfaces, the Senseven app for leak detection and quantification, and access to the Senseven Backoffice for data storage, automated reporting, and analysis.

Question 2

What is acoustic emission testing?

Accepted Answer

Acoustic emission testing (AET) is a non-destructive method that detects high-frequency stress waves generated when a fluid leaks through a closed valve under pressure. Sensors placed on the valve body capture these signals, which the Valve Sense AI analyzes to determine whether a leak is present and estimate its size – without interrupting production.

Question 3

Can I use my own smartphone?

Accepted Answer

No. Valve Sense requires the i.safe MOBILE IS540.1 (for ATEX Ex Zone 1/21) or IS540.RG (for non-Ex industrial areas). These devices are certified for hazardous environments and have the processing power required to handle the acoustic emission data in real time. Both are included in the delivery.

Question 4

Which types of valves can be inspected?

Accepted Answer

Valve Sense works with all on/off, control, and safety valves of any size. For valves larger than DN 100, multiple measurement points on the valve body are required. Small leaks in very large valves may be harder to detect due to the greater distance between the leak source and the sensor.

Question 5

Do I need process information before performing the inspection?

Accepted Answer

You need to confirm that the valve is closed and that a pressure differential exists across it. Before starting, you select the medium type and enter the valve size for leak quantification. All other information is optional.

Question 6

For which valve materials does the system work?

Accepted Answer

Valve Sense works with virtually all valve materials. The only exceptions are grey cast iron and glass valves, which can dampen acoustic emission signals and make small leaks harder to detect.

Question 7

Which media can be measured?

Accepted Answer

Valve Sense is optimized for water, gas, steam, and pressurized air. It also works with other media such as viscous liquids, though the minimum detectable leak size may be larger compared to the optimized media.

Question 8

What are the required steps to test a valve for leakage?

Accepted Answer

Three conditions must be met: (1) the valve must be fully closed, (2) a pressure differential of at least 1 bar must exist across the valve, and (3) insulation must be removed or direct access to the pipe must be possible. The app then guides you through the 4-step measurement process.

Question 9

Can you identify leaks in high pressure environments?

Accepted Answer

Yes – high pressure is actually advantageous for Valve Sense. The higher the pressure differential, the stronger the acoustic emission signal generated by the leaking medium. A minimum of 1 bar pressure differential is required.

Question 10

What is the smallest leak that can be detected?

Accepted Answer

The minimum detectable leak depends on valve type and size, pressure differential, medium, material, and ambient noise. For a DN25 gas valve at 3 bar, Valve Sense detects leaks as small as 50–100 ml/min. Higher pressure improves detection of smaller leaks.

Question 11

Does the software calculate the leak rate?

Accepted Answer

Yes. Valve Sense provides an AI-based estimation of the leak rate in real time directly on the smartphone screen. The result is automatically included in the generated inspection report.

Question 12

Is the software only available on smartphones?

Accepted Answer

The Valve Sense measurement app runs on the included i.safe MOBILE smartphone. All inspection data is automatically synced to the Senseven Backoffice, which is accessible from any browser on desktop or tablet – for reporting, filtering, analysis, and CMMS export.

Question 13

Is there any operator certification?

Accepted Answer

Yes. After purchasing Valve Sense, you receive an online product introduction. After completing a short test, you receive an operator certification – no prior NDT experience or classroom training required.

Question 14

How long does a valve inspection take with Valve Sense?

Accepted Answer

A complete valve inspection with Valve Sense takes approximately 2 minutes. The app guides operators step by step and delivers an immediate result on-site – including an estimated leak rate if a leak is detected.

Question 15

Can Valve Sense be used in ATEX Zone 1/21 hazardous areas?

Accepted Answer

Yes. Valve Sense Ex is specifically designed for ATEX Zone 1/21 and IECEx-certified hazardous areas. It runs on the i.safe MOBILE IS540.1 – a certified explosion-proof smartphone for environments with flammable gases or dusts.

Question 16

What ROI can I expect from valve leak detection?

Accepted Answer

A single steam valve leaking at 100 kg/h causes losses of over €30,000 per year. A typical plant has hundreds of valves. One customer reduced valve inspection time by 95% with Valve Sense, while detecting leaks that had previously gone unnoticed for months.

Question 17

How does Valve Sense compare to traditional ultrasonic testing?

Accepted Answer

Traditional ultrasonic testing uses airborne sound and requires trained NDT personnel. Valve Sense uses acoustic emission sensors placed directly on the valve body, delivering automated AI-based results without specialist knowledge – significantly faster and accessible to all plant personnel.

Question 18

Which industries use Valve Sense?

Accepted Answer

Valve Sense is used in oil and gas, chemicals, pharmaceuticals, food and beverage, pulp and paper, steel, and power generation. Customers include Shell, Bayer, Exolum, and Montrose – across Europe, Asia, and the Middle East.

Question 19

Does Valve Sense integrate with asset management systems (CMMS/SAP)?

Accepted Answer

Yes. The Senseven Backoffice supports integration with CMMS/EAM systems such as SAP PM. Inspection results, reports, and action plans can be exported directly to trigger maintenance workflows based on actual leak data.

Question 20

Is Valve Sense ISO certified?

Accepted Answer

Yes. Senseven's quality management system is certified to ISO 9001:2015, independently audited by an accredited certification body. The certificate can be downloaded directly from the Senseven website.

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