Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Hydrogen Injection Valve Position Monitoring (Distribution & Safety Control) — ATEX
Safety & compliance
Valve position
Quick Overview
| Problem | Hydrogen injection points rely on precise valve positioning to control flow, pressure, and blending ratios. A valve left partially closed, incorrectly positioned, or unintentionally isolated can cause pressure instability, safety incidents, or non-compliance with grid or process requirements—especially in ATEX-classified environments. |
| Solution | Sensa.io’s ATEX-certified valve position sensors provide continuous, real-time visibility of hydrogen injection valve status, ensuring safe distribution, traceability, and regulatory compliance. |
| Value | Improved injection safety • Reduced operational risk • Better traceability • Faster incident response |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified valve position sensors |
The Operational Challenge
Hydrogen injection valves are used in:
- Hydrogen blending into gas grids
- Injection into storage or distribution manifolds
- Safety isolation points upstream of consumers
- Pilot and demonstration hydrogen networks
These valves operate under strict constraints:
- Precise control of flow and pressure
- Compliance with blending and injection limits
- Continuous availability for emergency isolation
Common operational issues include:
- Valves unintentionally left closed after maintenance
- Partial closure due to vibration or mechanical wear
- Lack of remote visibility across distributed injection points
- Reliance on manual checks in hazardous areas
Traditional assurance methods often involve:
- Local mechanical indicators
- Periodic visual inspections
- Manual confirmation during audits
This creates a gap between inspections where valve status is unknown.
Why Valve Position Monitoring Matters
Valve position is a critical safety and process parameter for hydrogen injection.
Continuous monitoring enables operators to:
- Verify that injection valves are fully open or correctly positioned
- Detect unauthorised or accidental valve movements
- Trigger alarms if a valve deviates from its required position
- Maintain continuous proof of compliance and readiness
For distributed hydrogen networks, remote valve visibility is essential to ensure safe and controlled operation.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe valve position monitoring solution designed for hydrogen injection systems.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Provides discrete or continuous feedback on valve open/closed status and intermediate positions.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with hydrogen SCADA, EMS, and safety systems.
Installation & Power
Battery-powered clamp-on installation on ball, gate, or butterfly valves — no cabling or process interruption required.
Operational Benefits
- Continuous verification of valve status
- Reduced manual inspections in ATEX zones
- Faster response to mispositioned valves
- Improved safety and regulatory confidence
Results and ROI
ATEX Compliance and Safety
All valve position sensors for hydrogen injection 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 hydrogen injection systems.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Hydrogen SCADA, EMS, safety PLCs |
| Vendors | Siemens Energy, ABB, Schneider Electric, 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.
