Acoustic Emission-Based Offshore Pipeline Valve Leakage Detection Toward Enhanced Process Safety

Valve leakage in marine oil and gas pipelines is a critical failure mode that threatens operational safety, ecological integrity and production economic benefits, creating an urgent demand for accurate, real-time and robust fault diagnosis systems. Acoustic Emission (AE) technology captures transient acoustic signatures generated by leakage to enable non-intrusive online monitoring, while deep learning supports intelligent analysis through automatic signal feature extraction. Nevertheless, traditional AE-based leakage diagnosis methods rely heavily on manual feature engineering and fixed signal processing rules. Existing AE-driven deep learning methods fail to simultaneously deliver high detection accuracy, low inference latency and strong noise immunity, hindering their practical deployment on offshore platforms. To address these limitations, this paper proposes a Parameter-free Star-shaped Attention Fusion Network (SAFNet) for lightweight valve leakage localization using AE signals. Centered on the Temporal Pyramid Encoder (TPE) and Progressive Lightweight Star-shaped Attention (PLSA) module, SAFNet integrates Dual Bilinear Star Mapping (DBSM), Energy-Driven Feature Refiner (EDFR) and Multi-Scale Gated Attention Fusion (MS-GAF) modules. This architecture achieves efficient multi-scale temporal feature extraction, parameter-free nonlinear enhancement, noise-resistant refined feature processing and adaptive hierarchical feature fusion. The proposed method is applicable to valve leakage diagnosis of marine oil and gas pipelines under variable pressure and complex marine noise conditions. Comprehensive experiments are conducted on a dataset constructed by combining laboratory controlled leakage signals with real marine background noise recorded from the Liwan 3−1 offshore platform. The experimental results reveal that SAFNet balances high detection accuracy, compact model size and low inference latency simultaneously. Specifically, the network maintains a stable detection accuracy above 95% under pipeline pressures ranging from 2 MPa to 5 MPa, and exhibits excellent stability under extreme heavy noise environments. Ablation experiments further validate the synergistic performance gain brought by all core modules. The presented network delivers an efficient lightweight solution for valve leakage localization under simulated marine acoustic conditions, promotes the development of intelligent monitoring technologies for marine pipeline systems, and comprehensively improves offshore operational safety and marine ecological protection capacity.