Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Acoustic Monitoring of Flare & Vent Stacks (Abnormal Venting & Leak Detection) — ATEX
Detects abnormal venting or leaks
Acoustic
Quick Overview
| Problem | Offshore flare and vent stacks are critical safety systems. Abnormal venting, continuous pilot issues, or unintended gas releases are difficult to detect visually and often go unnoticed, increasing safety risks, emissions, and regulatory exposure in ATEX-classified zones. |
| Solution | SENSAiO’s ATEX-certified acoustic sensors continuously monitor flare and vent stacks, detecting abnormal acoustic signatures associated with leaks, unintended venting, or combustion instability in real time. |
| Value | Early detection of abnormal venting • Reduced emissions • Improved safety • Stronger regulatory compliance |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified acoustic sensors |
The Operational Challenge
Flare and vent systems are designed to safely release hydrocarbons during:
- Process upsets
- Start-up and shutdown sequences
- Emergency pressure relief events
However, offshore operators face several challenges:
- Continuous low-rate venting that is difficult to detect
- Leaks in flare headers or vent lines
- Pilot flame instability or partial extinction
- Mechanical degradation due to vibration and corrosion
Traditional monitoring methods rely on:
- Visual inspection (often impossible offshore)
- Flow calculations or indirect indicators
- Periodic inspection campaigns
These approaches are intermittent and may miss early or low-level abnormal venting.
Why Acoustic Monitoring Matters
Gas flow through vents and flare headers generates distinct acoustic signatures, even at low flow rates.
Continuous acoustic monitoring enables operators to:
- Detect unintended venting events in real time
- Identify abnormal combustion or pilot instability
- Distinguish normal operational noise from leaks
- Correlate venting events with process conditions
Early detection helps prevent prolonged emissions, safety hazards, and unplanned regulatory non-compliance.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe acoustic monitoring solution for offshore flare and vent systems.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Wide-band acoustic detection optimised for gas flow, venting noise, and combustion-related signals.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with offshore SCADA, emissions, and safety systems.
Installation & Power
Battery-powered clamp-on installation on flare headers or vent piping — no process interruption required.
Operational Benefits
- Continuous visibility of flare and vent activity
- Early detection of leaks or unintended releases
- Reduced emissions and environmental impact
- Improved safety assurance
Results and ROI
ATEX Compliance and Safety
All acoustic sensors for flare and vent monitoring comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
- ATEX Directive 2014/34/EU
The intrinsically safe design allows installation in explosive offshore zones without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, emissions monitoring, HSE platforms |
| Vendors | Honeywell, ABB, Emerson, Siemens |
| Cybersecurity | AES-128 encrypted communication with secure transport |
FAQ - Common Questions
Are Sensa.io sensors compatible with any gateway or network?
What ATEX certifications apply to Sensa.io devices?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.
What is the typical battery life?
Up to 10 years at 15-minute intervals, depending on signal strength and environment.
How are the sensors integrated into existing systems?
Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.
How does predictive maintenance reduce OPEX?
Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.
What does the Sensa.io Valve Position Sensor actually measure?
The device detects real-time valve position states—open, closed, or intermediate—with high accuracy. It continuously sends this information wirelessly to your monitoring dashboard.
Can this sensor detect partial valve movement or stuck valves?
Yes. The sensor identifies irregular patterns such as partial movement, delayed response, or stuck valves, enabling early maintenance before failure occurs.
Is this sensor suitable for manual, motorized, and actuated valves?
Yes. It supports a wide range of valve types including ball, gate, butterfly, actuator-driven, and manual valves.
How fast does it update the valve position?
You can configure the reporting interval—from seconds to minutes—depending on your operational and battery needs.
How long does installation take?
Most installations take under 10 minutes. The sensor mounts using brackets or clamps without modifying existing valves.
Explore Our Sensors
Valve position
The Sensa iO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
Pressure
A rugged, industrial-grade pressure sensor designed for high-demand oil & gas applications. Provides continuous gas and liquid pressure monitoring, with ATEX intrinsic safety, IP67 housing, and LoRaWAN® connectivity.
Temperature
Sensa iO’s temperature sensor delivers precise temperature data for process lines, steam systems, heat exchangers, and storage assets.
Differential Pressure (ΔP)
A compact DP solution using dual synchronized pressure inputs to deliver accurate differential pressure data for filters, heat exchangers, separators, and manifolds.
Vibration
A high-resolution vibration sensor built for predictive maintenance of pumps, motors, compressors, and rotating equipment.
Acoustic
The Sensa iO acoustic sensor identifies ultrasonic leak signatures, gas escape, steam trap failures, and flare noise anomalies.
Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
