Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Dust Filtration ΔP Monitoring (Baghouse Performance & Explosion Risk Reduction) — ATEX
Compliance, maintenance planning
Differential Pressure (ΔP)
Quick Overview
| Problem | Dust filtration systems (baghouses, cartridge filters) are critical safety barriers in chemical, powder, and bulk processing. Progressive clogging increases differential pressure (ΔP), reducing airflow, overheating fans, and dramatically increasing dust explosion risk—especially in ATEX-classified environments where failures escalate rapidly. |
| Solution | Sensa.io’s ATEX-certified differential pressure sensors continuously monitor ΔP across dust filters, enabling predictive maintenance, stable ventilation, and compliance with ATEX dust regulations. |
| Value | Reduced explosion risk • Stable airflow • Lower fan energy use • Predictable maintenance |
| ATEX | Dust Zones 20–22 • Ex ia IIIC T135°C Db certified ΔP sensors |
The Operational Challenge
Dust filtration systems are used to control airborne particles from:
- Powder handling and mixing
- Drying and milling operations
- Packaging and conveying systems
- Reactor charging and discharge
Key challenges include:
- Progressive filter clogging reducing airflow
- Overloaded fans and motors
- Increased dust concentration inside enclosures
- Loss of explosion protection effectiveness
Typical failure scenarios:
- Filter rupture due to excessive ΔP
- Dust accumulation beyond ATEX limits
- Emergency shutdowns triggered by airflow loss
- Increased ignition risk from overheating equipment
Traditional monitoring methods rely on:
- Local manometers
- Periodic inspection during maintenance rounds
- Reactive intervention after alarms
These approaches provide limited early warning and inconsistent documentation.
Why Differential Pressure Monitoring Matters
ΔP is the most reliable indicator of dust filter health.
Continuous ΔP monitoring enables operators to:
- Track clogging trends in real time
- Maintain stable ventilation and capture efficiency
- Prevent fan overload and overheating
- Reduce dust explosion risk by maintaining design airflow
Maintaining correct ΔP is a core requirement in ATEX dust safety strategies.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe ΔP monitoring solution for dust filtration systems.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIIC T135°C Db)
High-resolution measurement across baghouse or cartridge filters in dust environments.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with SCADA, EHS, and maintenance platforms.
Installation & Power
Battery-powered installation on existing pressure taps — no cabling, no hot work.
Operational Benefits
- Early detection of filter clogging
- Reduced explosion and fire risk
- Optimised fan operation
- Predictable filter replacement cycles
Results and ROI
ATEX Compliance and Safety
All ΔP sensors for dust filtration comply with:
- ATEX Directive 2014/34/EU
- Ex ia IIIC T135°C Db (Dust Zones 20–22)
- IECEx certification for dust atmospheres
The intrinsically safe design supports installation in explosive dust environments without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, EHS, ventilation control platforms |
| Vendors | Siemens, Schneider Electric, ABB, Honeywell |
| Cybersecurity | AES-128 encrypted communication |
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.
