Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Differential Pressure Monitoring Across Filter Trains (Diesel, Solvent & Process Filtration) — ATEX
Predictive maintenance, ensures product quality
Differential Pressure (ΔP)
Quick Overview
| Problem | Filter trains in refineries progressively clog due to particulates, waxes, or catalyst fines. Without continuous visibility, clogging is detected too late, leading to pressure loss, reduced throughput, off-spec products, or forced shutdowns in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified differential pressure (ΔP) sensors continuously monitor pressure drop across filter trains, enabling early detection of fouling and condition-based maintenance. |
| Value | Predictive maintenance • Stable throughput • Improved product quality • Reduced unplanned shutdowns |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified differential pressure sensors |
The Operational Challenge
Refinery filtration systems are used across multiple units, including:
- Diesel and gasoline polishing filters
- Solvent and additive filtration
- Lube oil and hydraulic oil filtration
- Catalyst and fines removal
As filters load with contaminants, pressure drop increases, causing:
- Reduced flow and throughput limitations
- Increased pump energy consumption
- Risk of filter collapse or bypass
- Contamination of downstream equipment
Traditional monitoring often relies on:
- Periodic manual pressure readings
- Fixed maintenance intervals
- Reactive filter replacement after alarms
These approaches either replace filters too early (wasting consumables) or too late (causing process disruption).
Why Differential Pressure Monitoring Matters
Differential pressure is the most reliable indicator of filter condition.
Continuous ΔP monitoring enables operators to:
- Detect gradual clogging trends early
- Identify abnormal fouling rates
- Optimise filter replacement timing
- Prevent sudden pressure loss or bypass events
By tracking ΔP trends, maintenance can be scheduled based on actual filter condition, not conservative time-based rules. In ATEX environments, remote monitoring also reduces manual intervention near pressurised and hazardous equipment.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe ΔP monitoring solution for refinery filter trains.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy ΔP measurement across filter housings, suitable for liquid and gas service.
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 filter clogging
- Stable process flow and pressure
- Reduced risk of unplanned shutdowns
- Optimised filter consumption
Results and ROI
ATEX Compliance and Safety
All differential pressure sensors for filtration 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 allows installation on live filtration systems without shutdown, ensuring safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, CMMS, asset performance 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.
