Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Chemical Injection Skid Monitoring (Methanol & Inhibitors) — ATEX
Ensures consistent dosing, prevents corrosion and plugging
Pressure
Valve position
Quick Overview
| Problem | Chemical injection skids are critical for flow assurance and asset protection, yet failures often go undetected between inspections. Blocked lines, pump malfunction, or empty tanks can compromise corrosion control, hydrate prevention, and production safety — especially in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified pressure and temperature sensors provide continuous, wireless monitoring of chemical injection skids, enabling early detection of injection loss, blockage, or abnormal operating conditions. |
| Value | Improved flow assurance • Reduced integrity risk • Early fault detection • Lower OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure & temperature sensors |
The Operational Challenge
Chemical injection systems deliver methanol, corrosion inhibitors, scale inhibitors, and hydrate inhibitors to critical upstream assets such as flowlines, wellheads, and separators.
Despite their importance, injection skids often suffer from:
- Blocked or partially blocked injection lines
- Pump degradation or failure
- Frozen or waxed injection points
- Empty or depleted chemical tanks
- Incorrect injection pressure or temperature
Typical monitoring practices rely on:
- Periodic manual checks
- Local gauges with no remote visibility
- Reactive maintenance after failure
This leads to:
- Undetected loss of chemical protection
- Increased corrosion, scaling, or hydrate risk
- Unplanned shutdowns or asset damage
- Frequent personnel exposure in ATEX zones
Without continuous monitoring, operators lack confidence that chemicals are being injected as designed.
Why Continuous Skid Monitoring Matters
Injection pressure and temperature provide direct insight into skid health and injection effectiveness.
Continuous monitoring enables operators to:
- Detect blocked or restricted injection lines
- Identify pump performance degradation
- Confirm injection pressure is within design range
- Detect freezing or thermal anomalies at injection points
- Verify continuous chemical delivery between site visits
A sudden pressure increase may indicate blockage, while pressure loss can signal pump failure or empty tanks. Temperature trends help identify freezing risk or abnormal operating conditions. Together, pressure and temperature data transform chemical injection from assumption-based to verified.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe monitoring solution tailored for upstream chemical injection skids.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
Monitors injection line pressure to detect blockage, pump failure, or abnormal operation.
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
Monitors skid, line, or injection point temperature to detect freezing, wax risk, or abnormal thermal behaviour.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT for integration with SCADA and chemical management systems.
Installation & Power
Battery-powered, retrofit-friendly installation with no cabling or production interruption.
Operational Benefits
- Verified chemical injection continuity
- Early detection of skid and line faults
- Reduced chemical-related flow assurance incidents
- Lower inspection and maintenance effort
Results and ROI
ATEX Compliance and Safety
All sensors used for chemical injection skid monitoring comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
- ATEX Directive 2014/34/EU
Intrinsically safe design enables installation on live injection skids without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, DCS, chemical management 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.
