Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Process Filtration ΔP Monitoring (Predictive Maintenance & Product Quality) — ATEX
Predictive maintenance
Differential Pressure (ΔP)
Quick Overview
| Problem | Process filters are critical to product quality and equipment protection in chemical plants. Progressive clogging increases differential pressure (ΔP), reducing flow, degrading separation efficiency, increasing energy consumption, and risking unplanned shutdowns—often without early warning in ATEX-classified areas. |
| Solution | Sensa.io’s ATEX-certified differential pressure sensors continuously monitor ΔP across process filters, enabling predictive maintenance and stable process performance. |
| Value | Stable product quality • Reduced energy use • Fewer shutdowns • Predictable maintenance |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified differential pressure sensors |
The Operational Challenge
Process filtration is used across chemical industries for:
- Liquid and solvent purification
- Catalyst and resin protection
- Dust and particulate removal
- Downstream equipment protection
Filters operate under variable conditions:
- Changing feed composition
- Temperature and viscosity fluctuations
- Fouling from solids, polymers, or reaction by-products
Common operational issues include:
- Gradual clogging unnoticed until flow drops
- Premature filter replacement based on fixed schedules
- Overpressure events stressing filter housings
- Emergency shutdowns due to sudden blockage
Traditional monitoring methods include:
- Manual pressure gauge readings
- Periodic inspection during maintenance rounds
- Reactive replacement after alarms or trips
These approaches provide limited insight into real filter health.
Why Differential Pressure Monitoring Matters
Differential pressure is the most reliable indicator of filter condition.
Continuous ΔP monitoring enables operators to:
- Track fouling trends over time
- Replace filters at the optimal point
- Maintain stable flow and separation efficiency
- Protect downstream pumps, compressors, and reactors
A gradual ΔP increase often precedes performance loss by days or weeks.
Sensa.io Solution
Sensa.io provides a wireless, intrinsically safe ΔP monitoring solution for chemical process filters.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-resolution ΔP measurement across filter inlets and outlets.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with DCS, SCADA, and maintenance platforms.
Installation & Power
Battery-powered installation using existing pressure taps — no cabling, no hot work.
Operational Benefits
- Predictive maintenance instead of fixed intervals
- Reduced filter replacement cost
- Improved product quality consistency
- Lower energy consumption
Results and ROI
ATEX Compliance and Safety
All ΔP sensors for filtration monitoring comply with:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
The intrinsically safe design allows installation on live filtration systems without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | DCS, SCADA, CMMS |
| Vendors | Schneider Electric, ABB, Siemens, Emerson |
| 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.
