Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Acoustic Steam Leak Detection (Energy Loss Reduction & Safety) — ATEX
Detects leaks saving thousands €/month
Acoustic
Quick Overview
| Problem | Steam leaks in refineries often remain undetected for long periods because they are invisible and masked by ambient noise. These leaks cause significant energy losses, safety hazards, and accelerated equipment degradation, particularly in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified acoustic sensors continuously monitor steam lines and equipment to detect the high-frequency acoustic signatures of steam leaks in real time. |
| Value | Reduced energy losses • Improved personnel safety • Lower maintenance cost • Faster leak localisation |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified acoustic sensors |
The Operational Challenge
Steam networks are essential to downstream refinery operations, supplying:
- Process heating
- Distillation and stripping
- Tracing and freeze protection
- Utility services
Steam systems operate at high pressure and temperature, making leaks both dangerous and costly.
Common causes of steam leaks include:
- Corrosion and erosion of piping
- Gasket and flange degradation
- Valve packing failure
- Thermal fatigue and vibration
Traditional detection methods rely on:
- Audible checks during site rounds
- Visual inspection of insulation damage
- Infrared surveys performed periodically
These approaches are intermittent and often fail to detect small or concealed leaks, especially under insulation.
Why Acoustic Steam Leak Detection Matters
Steam escaping through a leak generates ultrasonic acoustic energy well above normal process noise.
Continuous acoustic monitoring enables operators to:
- Detect leaks invisible to the naked eye
- Identify under-insulation steam loss
- Localise leak sources quickly
- Quantify leak severity based on acoustic intensity
Early detection prevents:
- Escalation into major leaks or pipe rupture
- Excessive energy waste
- Burn and scalding hazards for personnel
Acoustic monitoring is one of the most effective techniques for continuous steam leak detection in complex industrial environments.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe acoustic monitoring solution for steam systems in downstream facilities.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Wide-frequency acoustic detection optimised for ultrasonic steam leak signatures.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with refinery SCADA and energy management platforms.
Installation & Power
Battery-powered clamp-on installation on steam lines, valves, traps, or flanges — no insulation removal required.
Operational Benefits
- Early detection of steam leaks
- Reduced energy consumption
- Improved personnel safety
- Faster maintenance response
Results and ROI
ATEX Compliance and Safety
All acoustic sensors for steam leak detection 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 enables safe installation in high-temperature and explosive environments without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, energy management, maintenance platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| 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.
