Valve Position & State Monitoring AI
Automated valve position detection, safety compliance monitoring, and real-time alerts for industrial process control and safety systems.
Manual Valve Inspection Challenges
- • Human error in position verification during rounds
- • Safety exposure in hazardous areas during inspection
- • Delayed detection of unauthorized valve operations
- • Incomplete LOTO compliance documentation
- • No real-time alerts for safety-critical valve positions
AI Vision Solution
GaugeSnap deploys computer vision cameras to continuously monitor valve positions, lever angles, and indicator states. AI models classify positions with high accuracy and provide instant alerts for any unauthorized changes.
Edge processing ensures low latency + redundant backup systems maintain compliance during network outages.
Supported Valve Types
Gate Valves
Fully open / closed position detection
Ball Valves
Quarter-turn handle position monitoring
Butterfly Valves
Lever angle & throttle position detection
Control Valves
Actuator position & percentage opening
Globe Valves
Stem position & handwheel turns count
Check Valves
Swing disc position (if visible indicator)
Safety Relief Valves
Lift indicator & discharge state
Solenoid Valves
Electrical status LED & manual override
Indicators & Status Systems
Position Indicators
Visual valve position markers & flags
Status Light Towers
Red/green/amber operational status
Limit Switch Boxes
Mechanical position switch indicators
Sight Glasses
Flow/no-flow visual confirmation
Key Capabilities
97%+ Position Accuracy
Robust detection across lighting conditions and viewing angles.
Real-time Monitoring
Continuous position tracking with instant state change alerts.
Safety Compliance
LOTO verification, unauthorized change detection.
Historical Analytics
Position history, change frequency, and operational patterns.
System Integration
SCADA, DCS, and safety system connectivity.
Mobile Alerts
Instant notifications for unauthorized valve operations.
Critical Use Cases
Process Safety
Critical valve position verification for safety interlocks and emergency shutdown systems.
LOTO Compliance
Lockout/Tagout verification ensuring valves remain in required positions during maintenance.
Unauthorized Access
Detect tampering or unauthorized valve operations outside scheduled maintenance.
Operational Verification
Ensure valve lineup matches operational procedures and design intent.
Technical Implementation
Detection Methods
- • Object detection & geometric analysis
- • Handle/lever angle measurement (±5°)
- • Color & pattern recognition for indicators
- • Multi-view fusion for occluded valves
Integration & Alerts
- • SCADA/DCS integration via OPC-UA/Modbus
- • Mobile push notifications & email alerts
- • Configurable alarm delays & escalation
- • Audit logs with timestamp & user tracking
Industry Applications
Safety & Compliance Impact
- • Reduce safety incidents from valve misalignment
- • Automated LOTO compliance verification
- • Instant alerts for critical valve state changes
- • Complete audit trail for regulatory compliance
- • Reduce manual inspection labor costs
- • Enhanced operational reliability & safety