Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Heat Exchanger Temperature Monitoring (Efficiency & Fouling Detection) — ATEX
Optimizes energy consumption, identifies fouling early
Temperature
Quick Overview
| Problem | Heat exchangers are critical to refinery energy efficiency and process stability. Fouling, scaling, or flow imbalance gradually reduce heat transfer efficiency, increasing energy consumption and risking process deviations in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified temperature sensors provide continuous, wireless monitoring of inlet and outlet temperatures, enabling early detection of fouling and loss of efficiency. |
| Value | Improved heat transfer efficiency • Reduced energy cost • Early fouling detection • Lower maintenance OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified temperature sensors |
The Operational Challenge
Refinery heat exchangers are used across multiple process units, including:
- Crude preheat trains
- Product coolers and heaters
- Reboilers and condensers
- Utility and energy recovery systems
Over time, exchangers are exposed to:
- Fouling from hydrocarbons, salts, or coke
- Scaling from process water
- Corrosion and erosion
- Uneven flow distribution
These issues lead to:
- Reduced heat transfer efficiency
- Increased fuel or steam consumption
- Temperature deviations affecting downstream units
- Unplanned cleaning or shutdowns
Traditional monitoring often relies on:
- Periodic manual temperature readings
- Laboratory analysis after performance loss
- Reactive cleaning schedules
These approaches frequently detect fouling after efficiency has already degraded significantly.
Why Continuous Temperature Monitoring Matters
Heat exchanger performance is best assessed by temperature differentials and trends, not by single measurements.
Continuous monitoring enables operators to:
- Track inlet and outlet temperature approach
- Detect gradual fouling before major efficiency loss
- Identify abnormal thermal behaviour indicating flow maldistribution
- Optimise cleaning and maintenance intervals
Temperature trend analysis provides actionable insight without intrusive instrumentation or shutdown. In ATEX environments, wireless monitoring also reduces the need for manual measurements near hot and hazardous equipment.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe temperature monitoring solution for refinery heat exchangers.
Core Components
Temperature Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy sensors suitable for high-temperature refinery environments, mounted at exchanger inlets and outlets.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with refinery SCADA and energy management systems.
Installation & Power
Battery-powered clamp-on or surface-mounted installation enables fast retrofit without process interruption.
Operational Benefits
- Early fouling and efficiency loss detection
- Reduced energy consumption
- Optimised exchanger cleaning cycles
- Improved process stability
Results and ROI
ATEX Compliance and Safety
All temperature sensors for heat exchanger 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 exchangers without shutdown, supporting safe operations in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, energy management, process control 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.
