Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Ballast Tank Valve Position Monitoring (FPSO & Platform Stability) — ATEX
Avoids ballast imbalance, safety-critical
Valve position
Quick Overview
| Problem | On FPSOs and offshore platforms, incorrect ballast valve positions can lead to stability issues, trim imbalance, and safety risks. Manual verification is slow, error-prone, and often performed in hazardous ATEX zones. |
| Solution | SENSAiO’s ATEX-certified valve position sensors provide continuous, remote visibility of ballast valve status, ensuring correct ballast operations and platform stability. |
| Value | Improved stability • Reduced human error • Faster operations • Enhanced safety |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified valve position sensors |
The Operational Challenge
Ballast systems are critical for:
- Maintaining platform trim and stability
- Compensating for cargo and process weight changes
- Ensuring safe offshore operations in varying sea states
Challenges faced by operators include:
- Valves left partially open or closed
- Incorrect valve sequencing during ballast transfer
- Limited visibility of valve status in remote or confined areas
- Manual checks requiring personnel entry into hazardous zones
Traditional approaches rely on:
- Local mechanical indicators
- Manual verification during rounds
- Limited feedback to control rooms
These methods increase the risk of operational errors and delayed response, especially during dynamic offshore conditions.
Why Valve Position Monitoring Matters
Valve position directly determines ballast flow and tank levels.
Continuous valve monitoring enables operators to:
- Verify correct valve alignment in real time
- Prevent unintended ballast transfer
- Ensure compliance with stability procedures
- Respond immediately to abnormal valve movement
Remote visibility reduces the need for manual intervention and improves operational confidence during ballast operations.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe valve position monitoring solution for offshore ballast systems.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Provides clear open/closed or continuous position feedback for ballast valves.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with offshore control and ballast management systems.
Installation & Power
Battery-powered clamp-on installation on manual or actuated valves — no wiring or hot work required.
Operational Benefits
- Real-time visibility of ballast valve status
- Reduced risk of stability incidents
- Faster ballast operations
- Improved safety and compliance
Results and ROI
ATEX Compliance and Safety
All valve position sensors for offshore ballast 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 supports installation on live ballast systems without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Ballast control systems, SCADA, marine automation platforms |
| Vendors | Kongsberg, ABB, Siemens, Emerson |
| 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.
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Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
