Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Relief Valve Acoustic Monitoring (Early Leakage & Safety Compliance) — ATEX
Detects stuck valves, compliance
Acoustic
Quick Overview
| Problem | Pressure relief valves (PRVs) and safety valves are critical safety barriers in chemical plants. Small leaks, chatter, or partial opening often go unnoticed, causing continuous product loss, energy waste, environmental emissions, and regulatory non-compliance—especially in ATEX-classified areas where manual inspection is limited. |
| Solution | Sensa.io’s ATEX-certified acoustic sensors continuously monitor relief valves to detect leak noise, valve chatter, and abnormal acoustic signatures in real time. |
| Value | Improved safety compliance • Reduced fugitive emissions • Lower energy losses • Early fault detection |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified acoustic sensors |
The Operational Challenge
Relief valves protect process equipment against overpressure in:
- Reactors and pressure vessels
- Solvent and chemical storage systems
- Heat exchangers and pipelines
- Utility and steam networks
However, PRVs are also a frequent source of hidden issues:
- Seat leakage after activation
- Valve chatter due to unstable pressure
- Incomplete reseating
- Undetected continuous venting
Traditional inspection methods rely on:
- Periodic visual or auditory checks
- Infrared or handheld acoustic surveys
- Reactive maintenance after alarms or incidents
These approaches fail to provide continuous assurance, especially in hazardous zones.
Why Acoustic Monitoring Matters
Acoustic emissions are the earliest indicator of relief valve malfunction.
Continuous acoustic monitoring enables operators to:
- Detect very small leaks before visible emissions occur
- Identify valve chatter that accelerates wear
- Correlate acoustic events with pressure and temperature data
- Quantify continuous loss through leaking valves
Even minor PRV leakage can result in significant annual product and energy losses.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe acoustic monitoring solution for relief valves and safety vents.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Wide-frequency detection capable of capturing leak noise, chatter, and flow-induced acoustic signatures.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with DCS, SCADA, and safety platforms.
Installation & Power
Battery-powered clamp-on installation on valve bodies or discharge lines — no wiring, no hot work.
Operational Benefits
- Early detection of PRV leakage
- Reduced fugitive emissions
- Improved safety barrier integrity
- Lower inspection and maintenance effort
Results and ROI
ATEX Compliance and Safety
All acoustic sensors for relief valve monitoring comply with:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
The intrinsically safe design enables safe installation in hazardous zones without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | DCS, SCADA, environmental monitoring platforms |
| Vendors | Siemens, Schneider Electric, ABB, Emerson |
| Cybersecurity | AES-128 encrypted communication |
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.
