Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Burner Fuel Pressure & Temperature Monitoring (Heaters & Boilers Performance & Safety) — ATEX
Improves combustion efficiency, safety
Pressure
Temperature
Quick Overview
| Problem | Refinery heaters and boilers rely on stable fuel pressure and temperature to ensure safe combustion. Pressure drops, overheating, or unstable fuel conditions can cause flame instability, efficiency losses, emissions exceedances, or safety shutdowns in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified pressure and temperature sensors provide continuous, wireless monitoring of burner fuel lines, enabling real-time detection of abnormal conditions and safer combustion control. |
| Value | Improved combustion stability • Reduced safety trips • Lower fuel consumption • Enhanced compliance |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure & temperature sensors |
The Operational Challenge
Downstream refineries operate multiple fired heaters and boilers for:
- Crude and product heating
- Steam generation
- Process temperature control
These systems depend on precise fuel conditions.
Typical operational challenges include:
- Fuel pressure fluctuations causing flame instability
- Fuel temperature deviations affecting viscosity and atomisation
- Fouled burners increasing pressure drop
- Valve or regulator malfunction
- Delayed detection of unsafe combustion conditions
Traditional monitoring approaches often rely on:
- Centralised pressure transmitters with limited coverage
- Periodic manual checks
- Burner trips after flame instability occurs
Such methods may detect issues after combustion efficiency has already degraded or safety systems have tripped.
Why Fuel Pressure & Temperature Monitoring Matters
Fuel pressure and temperature directly influence combustion quality.
Continuous monitoring enables operators to:
- Detect pressure drops indicating regulator or filter issues
- Identify abnormal fuel heating or cooling
- Maintain stable flame conditions
- Reduce incomplete combustion and excess emissions
Stable combustion improves:
- Heater efficiency
- Fuel utilisation
- Equipment lifetime
- Compliance with emission limits
In ATEX environments, remote monitoring also reduces operator exposure near hot and hazardous equipment.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe fuel monitoring solution for refinery heaters and boilers.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy pressure monitoring on burner fuel supply lines.
Temperature Sensor
Monitors fuel temperature upstream of burners to detect abnormal conditions affecting combustion.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with refinery SCADA and burner management systems.
Installation & Power
Battery-powered threaded or clamp-on installation allows rapid retrofit without heater shutdown.
Operational Benefits
- Early detection of unstable combustion conditions
- Reduced burner trips and shutdowns
- Improved heater efficiency
- Enhanced operational safety
Results and ROI
ATEX Compliance and Safety
All sensors for burner fuel 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 heaters and boilers without shutdown, ensuring safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, burner management systems (BMS), energy 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.
