Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Biogas Upgrading Filter ΔP Monitoring (Membrane & PSA Protection) — ATEX
Predicts maintenance, protects quality
Differential Pressure (ΔP)
Quick Overview
| Problem | Biogas upgrading systems rely on filters, membranes, or PSA units to remove CO₂, H₂S, moisture, and impurities. Progressive clogging or fouling increases differential pressure (ΔP), reducing methane purity, increasing energy consumption, and risking unplanned shutdowns—often without early warning in ATEX zones. |
| Solution | Sensa.io’s ATEX-certified differential pressure sensors continuously monitor ΔP across biogas upgrading filters and membranes, enabling predictive maintenance and stable gas quality. |
| Value | Improved methane purity • Reduced energy consumption • Fewer shutdowns • Predictable maintenance |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified differential pressure sensors |
The Operational Challenge
Biogas upgrading plants use multiple filtration and separation stages, including:
- Pre-filters for dust and condensates
- Activated carbon filters for H₂S removal
- Membrane separation units
- Pressure Swing Adsorption (PSA) systems
These components are highly sensitive to fouling.
Common operational issues include:
- Gradual clogging of filters increasing ΔP
- Reduced gas flow and methane recovery
- Increased compressor workload and energy use
- Sudden membrane damage if clogging is not detected
In many plants, filter condition is still assessed by:
- Fixed maintenance intervals
- Manual pressure readings
- Reactive intervention after performance loss
This approach leads to inefficient maintenance and avoidable production losses.
Why Differential Pressure Monitoring Matters
Differential pressure is the most reliable indicator of filter and membrane condition.
Continuous ΔP monitoring enables operators to:
- Detect fouling trends long before blockage
- Optimise filter replacement timing
- Maintain stable gas flow and purity
- Prevent membrane stress and irreversible damage
A small increase in ΔP often precedes major performance degradation by days or weeks.
Sensa.io Solution
Sensa.io provides a wireless, intrinsically safe ΔP monitoring solution for biogas upgrading units.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-resolution measurement of pressure drop across filters, membranes, or PSA stages.
Wireless Communication
Compatible with LoRaWAN, Modbus, and MQTT for seamless SCADA and EMS integration.
Installation & Power
Battery-powered installation using existing pressure taps — no cabling, no hot work.
Operational Benefits
- Predictive maintenance instead of fixed schedules
- Protection of membranes and PSA units
- Stable methane concentration at outlet
- Reduced compressor energy consumption
Results and ROI
ATEX Compliance and Safety
All ΔP sensors for biogas upgrading 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 in gas processing areas without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Biogas SCADA, EMS, upgrading skid PLCs |
| Vendors | Bright Renewables, Greenlane, Wärtsilä, DMT |
| 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.
