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.
The HZ-FA-371T is also the world's first explosion‑proof acoustic imager designed for industrial robots, purpose‑built for wheeled robots and robotic dogs, enabling safe deployment in hazardous oil & gas areas and chemical plant process units.
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) that are completely beyond human hearing – 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.
Value: Upgrades leak detection from "human ear + soap water" to "machine‑automated scanning", dramatically improving detection efficiency and accuracy, preventing gas leaks from escalating into safety incidents.
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 or vibration 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.
Value: Completes dual acoustic+thermal scanning in a single inspection, eliminating pipe rack blind spots and eliminating hazards in their infancy.
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.
Value: Acoustic imaging "hears" discharges, thermal imaging "sees" heating – dual‑modal fusion dramatically improves diagnostic confidence, enabling early warning of electrical equipment faults.
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.
Value: Complete safety monitoring without personnel entering the tank farm, completely eliminating exposure risks.
| Aspect | HERTZINNO HZ-FA-371T | Other Acoustic/Thermal Solutions |
|---|---|---|
| Sensor Fusion | Integrated acoustic + thermal in a single device | Acoustic and thermal often in separate devices |
| Robotic Integration | Native HTTP/RTSP/WebSocket support, complete API/SDK | Mostly handheld design; robotic integration requires custom development |
| Edge AI | Onboard AI for real‑time analysis; only critical alerts sent to controller | Typically relies on host PC processing |
| Explosion‑Proof | ATEX certified (Ex ib IIC T4 Gb), suitable for Zone 2 hazardous areas | Most products lack explosion‑proof certification |
| Power Optimization | Optimized for robotic platforms, ROS‑compatible | Power parameters not optimized for robotics |
HERTZINNO's HZ-FA-371T is purpose‑built for robotic integration – open protocols, standardized API, low power consumption, and full explosion‑proof certification – solving the integration challenge from the ground up.
The chemical industry has an urgent need for unmanned inspection:
High safety risks: Process units and tank farms contain toxic, flammable, and explosive hazards; manual inspection involves long exposure times.
Large coverage area: Large chemical complexes have vast areas; manual inspection is inefficient with many blind spots.
Increasing regulations: Safety regulations are becoming stricter, demanding higher inspection frequency and coverage.
The core value of the robotic dog + acoustic thermal imaging solution:
Zero personnel exposure: Robotic dogs enter hazardous areas; personnel stay away from danger.
24/7 continuous operation: Autonomous patrols are not limited by shift schedules, enabling round‑the‑clock monitoring.
Multi‑dimensional sensing: Acoustic + thermal + visual fusion captures equipment condition comprehensively.
Traceable data: Each inspection’s data is automatically archived, building equipment health records.
The evolution path of industrial inspection is clear: from manual handheld → drone inspection → quadruped robot with multi‑sensor fusion. The HZ-FA-371T is a key piece of this evolution, giving robotic dogs the true ability to "hear" hidden faults.
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. The company sought to introduce unmanned inspection technology to improve efficiency and reduce safety risks.
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
The enterprise deployed quadruped robots equipped with the HZ-FA-371T for two daily autonomous patrols covering process units, pipe racks, and substations. The HZ-FA-371T streamed real‑time acoustic and thermal data back to the central control room via 4G/5G.
7 compressed air/nitrogen leaks detected in the first month, 4 of which had been missed by manual inspections for a long time
3 PD signals identified in electrical cabinets, verified and repaired during outage maintenance, preventing potential failures
2 insulation damage points detected via temperature anomalies, repaired promptly to reduce heat loss
400% increase in inspection efficiency, 95% reduction in manual intervention
Comprehensive, auditable equipment health records automatically generated
Approximately 800 hours of annual personnel exposure in high‑risk areas eliminated
*"The HZ-FA-371T has turned our robotic dog from a 'walking camera' into a true 'inspection expert'. Those leaks and discharges that we could neither hear nor see are now captured automatically every day. Especially during night patrols, the combination of robotic dog and acoustic camera plays an irreplaceable role."*
– Head of Equipment Management, the enterprise
The integration of HERTZINNO HZ-FA-371T with autonomous quadruped robotics establishes a continuous, objective data acquisition mechanism for predictive maintenance in the chemical industry. The core value of this solution lies in:
More comprehensive: Acoustic + thermal dual‑modal fusion gives robotic dogs both "bionic hearing" and "hawk‑eyes".
More reliable: AI‑powered real‑time diagnosis automatically classifies fault types, reducing human error.
Safer: ATEX explosion‑proof certification + IP66 protection enables robotic dogs to enter hazardous areas unreachable by humans.
More efficient: 24/7 uninterrupted inspection frees maintenance personnel from repetitive tasks, shifting them to decision‑making roles.
From oil refineries to chemical plants, from process units to tank farms, the global chemical industry is accelerating toward a new era of unmanned, intelligent inspection. By integrating high‑precision acoustic imaging, high‑resolution thermal imaging, and advanced AI edge computing, HERTZINNO provides a true "smart hearing + vision" system for inspection robots worldwide, offering solid technical support for the transition from "reactive maintenance" to "predictive maintenance" of industrial equipment.
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