Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Flowline Temperature Monitoring for Hydrate & Wax Prevention — ATEX
Prevents blockages, maintains flow assurance
Temperature
Quick Overview
| Problem | Flowlines transporting multiphase hydrocarbons are vulnerable to hydrate formation and wax deposition when temperatures drop below critical thresholds. Manual checks and indirect inference delay detection, increasing the risk of blockage, pressure build-up, and unplanned shutdowns in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified temperature sensors provide continuous, wireless monitoring of flowline and pipe surface temperature, enabling early detection of cooling trends that lead to hydrate or wax formation. |
| Value | Improved flow assurance • Reduced blockage risk • Early intervention • Lower OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified temperature sensors |
The Operational Challenge
Upstream flowlines transport oil, gas, and multiphase fluids from wellheads to processing facilities under varying ambient and operating conditions.
Key risks include:
- Hydrate formation during low-temperature operation
- Wax precipitation and gradual deposition
- Seasonal or diurnal temperature swings
- Loss of insulation performance over time
Common monitoring practices rely on:
- Sporadic manual temperature readings
- Assumptions based on ambient conditions
- Reactive response after pressure increases or flow restriction
This leads to:
- Late detection of hydrate or wax risk
- Emergency chemical injection or heating
- Unplanned production shutdowns
- Increased personnel exposure during inspections in ATEX zones
Without continuous temperature visibility, operators cannot reliably manage flow assurance risks.
Why Continuous Temperature Monitoring Matters
Temperature is the primary driver of hydrate and wax formation.
Continuous monitoring allows operators to:
- Detect cooling trends before hydrate formation begins
- Validate effectiveness of insulation or heating systems
- Optimise methanol or inhibitor injection timing
- Correlate temperature with pressure and flow behaviour
A gradual temperature decline often precedes:
- Increased pressure drop
- Reduced flow efficiency
- Complete line blockage
Real-time temperature data enables proactive intervention, avoiding costly remediation and production loss.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe temperature monitoring solution tailored for upstream flowline applications.
Core Components
Temperature Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy surface or process temperature measurement for pipelines and flowlines.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT for integration with SCADA and flow assurance systems.
Installation & Power
Battery-powered, clamp-on installation with no hot work, cabling, or production interruption.
Operational Benefits
- Early warning of hydrate and wax risk
- Improved flow assurance control
- Reduced emergency intervention
- Lower inspection frequency in hazardous areas
Results and ROI
ATEX Compliance and Safety
All temperature sensors for flowline 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 supports installation on live flowlines without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, DCS, flow assurance platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| 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.
