Chemical plant environments are characterized by high temperature, high pressure, flammability, explosiveness, and toxic hazards. Routine inspections of process units, tank farms, and pipe racks expose personnel to significant safety risks. Traditional manual inspections suffer from low efficiency, numerous blind spots, and put frontline workers in harm's way. Industry statistics show that a considerable portion of safety incidents caused by gas leaks and equipment failures each year are linked to inadequate inspections and delayed fault detection.
Under Industry 4.0, unmanned inspection technologies are fundamentally reshaping industrial maintenance protocols. Quadruped robots (robotic dogs) are increasingly deployed in chemical scenarios, equipped with multi-sensor fusion systems for autonomous inspection missions. The integration of HERTZINNO's HZ-FA-371T Acoustic Thermal Imaging Online Monitoring System with quadruped robots establishes a continuous, objective data acquisition mechanism for predictive maintenance in petrochemical facilities.
The HERTZINNO HZ-FA-371T fuses acoustic imaging with high-resolution infrared thermography, providing a multi-dimensional "visual + auditory + thermal" health assessment of industrial assets.
| Parameter | Specification |
|---|---|
| Acoustic Array | 128-channel MEMS microphones |
| Acoustic Bandwidth | 2 kHz ~ 65 kHz |
| Thermal Resolution | 640 × 512 (NETD < 40mk) |
| Detection Range | 0.3m ~ 150m |
| Video Streaming | RTSP / H.264 (up to 1920×1080) |
| Communication | Ethernet / HTTP / WebSocket |
| Protection Rating | IP65/IP66 |
| Explosion-Proof | Ex ib IIC T4 Gb / Ex ib IIIC T80℃ Db |
The HZ-FA-371T supports dual-mode imaging: infrared and acoustic imaging seamlessly integrate for simultaneous identification of thermal anomalies and acoustic sources (leaks or discharges). It features a web-based management interface requiring no specialized software for configuration and monitoring, simplifying remote operations. For standardized integration, the device connects seamlessly to third-party platforms via HTTP and RTSP protocols, ensuring high-quality real-time streaming.
Flanges, valves, fittings, and seals in chemical process units are high-risk points for gas leaks. Compressed and process gas leaks generate high-frequency ultrasonic signals (2 kHz ~ 65 kHz) beyond human hearing range—completely undetectable by manual inspection.
The robotic dog carries the HZ-FA-371T on autonomous patrol along preset routes. The 128-channel MEMS microphone array continuously scans the surrounding acoustic field. When a leak's ultrasonic signal is detected, the system instantly overlays an acoustic image on the live video, pinpointing the leak location. The AI-powered leak rate estimation function automatically assesses leak severity, helping maintenance teams prioritize repairs.
Chemical plant pipe racks are dense and complex, making comprehensive manual coverage nearly impossible. Early signs of loose pipe supports, worn hangers, or abnormal flow often manifest as weak acoustic signatures before escalating.
The HZ-FA-371T captures these abnormal acoustic signals, enabling rapid anomaly localization during pipe rack inspections. Simultaneously, the thermal module monitors pipeline surface temperatures, identifying localized anomalies caused by insulation damage or media leaks.
Substations, switchgear rooms, and motor control centers in chemical plants operate in high-temperature, high-humidity, corrosive environments, accelerating insulation aging and increasing partial discharge (PD) risk.
The robotic dog equipped with the HZ-FA-371T performs autonomous electrical equipment inspections. The acoustic array captures high-frequency ultrasound emitted by PD. The system locates the acoustic source in real-time, generates PRPD patterns, and automatically identifies discharge types—corona, floating, or surface discharge. Meanwhile, the high-resolution thermal imager monitors equipment temperature distribution, detecting abnormal heating from loose cable joints or poor switchgear contacts even with temperature rises as low as 0.04°C.
Tank farm components—tank bodies, piping, valves, and floating roof seals—are critical safety monitoring points. Issues like tank corrosion, seal aging, and foundation settlement can lead to media leaks or safety incidents.
The robotic dog performs autonomous tank farm inspections with the HZ-FA-371T operating from a safe distance. Acoustic imaging detects weak ultrasound signals from seal leaks or internal valve leakage. Thermal imaging monitors tank surface temperatures to identify abnormal hot spots. Dual-modal data fusion provides round-the-clock tank farm safety assurance.
Sensor fusion: Integrated acoustic + thermal in a single device
Robotic integration: Native HTTP/RTSP/WebSocket support with complete API/SDK
Edge AI: Onboard AI for real-time analysis; only critical alerts sent to controllers
Explosion-proof: ATEX certified (Ex ib IIC T4 Gb) for Zone 2 hazardous areas
Low power: Optimized for robotic platforms, ROS-compatible
Background: A large petrochemical enterprise operates dozens of process units with dense pipe racks and numerous equipment. Manual inspections required 4-6 hours daily, exposing personnel to high temperatures, noise, and potential leak risks.
Challenges:
Dense equipment layout with extensive blind spots
Small gas leaks often undetected until they become significant
Electrical PD not detectable through visual inspection
Weak night and holiday inspection coverage
Solution: Deploy quadruped robots equipped with HZ-FA-371T for two daily autonomous patrols covering process units, pipe racks, and substations. Data transmitted to the central control room via 4G/5G.
Results:
7 compressed air/nitrogen leaks detected in the first month (4 previously missed)
3 PD signals identified and verified during outage maintenance
2 insulation damage points detected via thermal imaging and repaired
400% inspection efficiency increase, 95% manual intervention reduction
Comprehensive, auditable equipment health records
Approximately 800 hours of annual personnel exposure eliminated
The integration of HERTZINNO HZ-FA-371T with autonomous quadruped robotics establishes a continuous, objective data acquisition mechanism for predictive maintenance in chemical plants. This unmanned strategy mitigates personnel safety risks, eliminates inspection blind spots, and systematically reduces unplanned downtime in petrochemical environments.
Learn More about our acoustic camera from here
