Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Cargo Transfer Pressure & Valve Monitoring (Bunkering & Liquid Transfer Operations) — ATEX
Safety during transfer operations
Pressure
Valve position
Quick Overview
| Problem | Bunkering and liquid cargo transfer operations involve high flow rates, frequent valve operations, and strict safety constraints. Pressure surges, valve misalignment, or uncontrolled flow can cause hose rupture, spills, or emergency shutdowns in ATEX-classified zones. |
| Solution | SENSAiO’s ATEX-certified pressure and valve position sensors continuously monitor transfer line pressure and valve states to ensure safe, controlled, and traceable cargo transfer operations. |
| Value | Reduced spill risk • Improved transfer safety • Fewer operational interruptions • Higher terminal and vessel reliability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure & valve sensors |
The Operational Challenge
Cargo transfer systems are used for:
- Ship-to-ship bunkering
- Ship-to-shore fuel transfer
- Chemical and liquid bulk loading
- Temporary transfer hoses and manifolds
These operations are exposed to:
- Rapid pressure changes during start/stop
- Manual valve sequencing errors
- Hose and coupling fatigue
- Environmental and safety constraints
Common incidents include:
- Overpressure during pump ramp-up
- Valves opened in incorrect sequence
- Undetected pressure loss indicating leaks
- Emergency shutdowns during transfer
Traditional monitoring relies on:
- Local pressure gauges
- Visual valve checks
- Manual supervision throughout transfer
This approach is labour-intensive and leaves little margin for error.
Why Pressure & Valve Monitoring Matters
Pressure and valve position define the safety envelope of any transfer operation.
Continuous monitoring enables operators to:
- Detect pressure surges before hose failure
- Verify correct valve sequencing
- Identify leaks or abnormal pressure loss
- Maintain stable transfer conditions
In ATEX environments, remote monitoring reduces personnel exposure near pressurised and flammable systems.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe monitoring solution for bunkering and liquid cargo transfer.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
Monitors line pressure in real time to detect surges, drops, or instability.
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Provides real-time feedback on valve opening and closing status during transfer.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with terminal SCADA, bunkering control systems, and safety platforms.
Installation & Power
Battery-powered clamp-on or threaded installation on manifolds and valves — no cabling required.
Operational Benefits
- Reduced risk of hose rupture and spills
- Improved transfer sequence control
- Faster incident detection and response
- Simplified post-operation reporting
Results and ROI
ATEX Compliance and Safety
All sensors for bunkering and cargo transfer 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 enables safe deployment during active transfer operations.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Terminal SCADA, bunkering management, CMMS |
| Vendors | ABB Marine, Emerson, Siemens, Honeywell |
| 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.
