Sensor Solution for Digitization of manually operated industrial valves
Challenge
Manually operated valves must be checked and inspected regularly. Reliable information on valve status forms the basis for optimal decisions, efficiency and safety and prevents unwanted contamination. This can be efficiently facilitated by digitalisation. The 5G SENS with TURN firmware configuration can provide this information on the status of manual valves and gate valves.
Solution
The 5G SENS TURN is attached to the handwheel or lever of a manual valve and can monitor the position (open or closed) of the valve in real time and send status changes to the cloud backend via mobile radio. The sensor remains in a battery-saving deep sleep mode until a status change is detected. The sensor is activated by movement and monitors the changes that occur. Once the movement has been completed, the sensor transmits the result to the cloud before switching back to sleep mode. In addition to the valve status, the sensor also transmits the GPS location and temperature.
Data is transmitted via LTE-M or NB-IOT to save energy, while complying with the relevant data protection guidelines regarding encryption and authentication. Both mobile radio standards offer the best network coverage even in remote locations. Sensor operation is optimised to enable several years of operation on a single battery. The 5G SENS TURN is suitable for use in potentially explosive atmospheres.
The cloud backend offers various dashboards for analysing the valve statuses, including an overview of all installed sensors with the following features:
- Map with sensor positions
- Current valve status
- Time history of status changes
- Battery status
- Cellular network coverage
All data collected by the sensor can be forwarded to the production process information system via standard REST interfaces. The corresponding integration services are offered by Exelonix.
Advantages
- Compact sensor
- Use mobile network for communication (no LoRa network needs to be maintained)
- Runs for several years on a single battery charge
- E2E security of data transmission
- ATEX-certified
Customers
5G SENSE VALVE enables valve position monitoring in the following industries:
- Oil and gas refineries & related distribution network operators
- Chemical industry
- Food and beverage industry
- Pharmaceutical industry
- Water / waste water industry
- Municipal utilities operators
