acoustoSENSE™
Reduce inspection costs, prevent lost product and avoid unplanned downtime.
acoustoSENSE™
Reduce inspection costs, prevent lost product and avoid unplanned downtime.
Accurate, real-time performance data for smarter asset management
Unplanned downtime, product loss and manual inspections continue to drive operational & safety risk at industrial facilities, particularly in remote, hazardous, or hard-to-access locations.
acoustoSENSE is a battery powered, wireless, always-on acoustic emissions monitoring system providing continuous visibility of asset status and performance. By sensing at higher frequencies and cutting through background noise to eliminate false positives, acoustoSENSE captures early indicators of mechanical degradation, leaks and abnormal operation before PoF (Probability of Failure) escalates.
The result:
- ROI delivered in months, not years
- Safer plants
- Smart RBI (Risk Based Inspection)
- Reduced maintenance budget, LoC (Loss of Containment) incidents, and unplanned down time
- Fewer site visits
- Assured compliance
- Increased profits
Challenges in plant operations
Operating a plant or facility requires visibility: Mechanical assets have a rated useful life that is consumed as the asset is operated; real-time process conditions and upsets directly impact revenue.
Impacts to profitability include:
- Loss of experienced engineers & plant knowledge from every major engineering industry
- No visibility between scheduled inspections rendering RBI programs toothless
- Undetected continuous leaks with acute product losses
- Long-delayed detection of mechanical faults causing emergency shutdowns
- Heightened safety risks to employees and plants associated with manual inspections
- Dramatic shifts in regulatory and environmental compliance
Periodic manual checks leave critical gaps where early-stage failures go unnoticed. A solution is needed to enable a step change in plant and facility performance. That solution is acoustoSENSE.
Applications
acoustoSENSE monitoring for pressure relief devices
PRDs are process-critical components in complex, pressurized systems. PRD performance directly impacts safety, compliance and the bottom line through, for example, failures going undetected, the need for periodic inspection and product loss.
Unlike conventional remote monitoring systems, acoustoSENSE is a low-power, real-time, 24/365 sensing, high-frequency acoustic solution that eliminates false positives by design and the possibility of missed release events through an always-on architecture. The result is accurate, reliable insights that drive smarter maintenance and more efficient operations.
Learn more about acoustoSENSE for pressure relief device monitoring
acoustoSENSE monitoring for slow-rotating bearings
Failure consequences of slow rotating bearings are often severe, resulting in extensive downtime, secondary damage and safety incidents.
By combining high-frequency sensing with periodic high-resolution monitoring (sleep wake mode only for bearings), our system captures the earliest signs of bearing wear, avoids interference from plant noise and ensures no critical damage is ever missed. The result is a compliant and safer operation, with an improved bottom line, a result that cannot be achieved with other systems.
Contact us for more information on how acoustoSENSE can be used across other applications.
Why choose acoustoSENSE?
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100-500 kHz acoustic sensing range, complies with international ISO, ASME, JP, etc. standards on leak detection.
Highly resistant to false positives.
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Separate sensor and node; a range of mounting configurations.
Simplified sensor installation and positioning of the radio antenna for reliable data transmission.
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Real-time, always-on processing of all acoustic signals providing high resolution data with waveform envelope.
Precision insights into PRD operation, behaviour, performance and health (e.g. simmer, chatter, cycling, flutter).
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Ultra Low Power with up to 10 year battery life and ‘hot swappable’ battery.
No need to remove the unit from a HazLoc environment for battery replacement.
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Wireless LoRaWAN enabling up to 10km transmission distance.
Low gateway to node ratio meaning lower CAPEX and OPEX cost.
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Non-invasive installation, applicable to all PRD sizes & configurations.
No modification required to asset enabling quick installations.
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Over the air configurable and updateable via Bluetooth from mobile devices.
Simple to operate and use with future proof onboard processing capability.
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ATEX, IECEx, UL, INMETRO Intrinsically Safe Hazardous Locations certified
Universally deployable in any customer environment.
Huge opportunity for cost saving and improving our maintenance offshore. Really exciting potential in the technology and detecting valve opening, closing, simmering and chattering.
Senior Technical Adviser for GOM Topside Asset Reliability
The separate, smaller sensor means it is easier to install in difficult locations, and you can visualize the opening event, rather than basic high/low data [that you get with other systems].
Sales Manager, Global Valve Manufacturer
We have a compliance requirement to continuously monitor PRDs across the entire plant. acoustoSENSE is the only solution we have tried that both provides the acoustic waveform of the valve behavior AND is resistant to false positives from typical plant noise & environmental interference.
Lead Process Engineer, Global Chemical Manufacturer
How it works
The acoustoSENSE sensor is very quickly secured to the asset, for example the valve casing, via a mechanical clamp. It continuously listens for acoustic emissions generated by mechanical activity, wear, leaks, or valve events.
Signals from the sensor are captured in the Node that is always-on, listening for acoustic events. The raw signal is automatically processed and the acoustic event metrics are transmitted in a data packet to the Gateway over LoRaWAN (up to 10km distance).
High-resolution acoustic data and analysis is visualized in customer data platforms or Tribosonics’ cloud platform. Real-time customizable alerts allow users to react quickly to active problems on monitored assets. Data is also exportable for further analysis and contextualization.
How one offshore operator is targeting to cut PSV maintenance costs by 65%
For industrial operators, PSV inspection isn’t optional; every valve must be tested each year to verify safety and operational readiness.
But when a single pop-test costs between $3,000 and $10,000, and a platform has more than 1,000 PSVs, routine inspection quickly becomes one of the largest recurring maintenance expenses.
One Gulf State operator faced exactly this challenge where their only annual data point for each valve was the pop-test itself.
They needed a way to maintain safety assurance whilst reducing unnecessary work.
Request a virtual demo
Take control of your production up-time, compliance and maintenance through safe, secure, decision-useful data in real-time via remote, cloud and on-premises solutions.
Complete the form to request a virtual demonstration.
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