Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Marine Fuel Filter Differential Pressure Monitoring (Predictive Maintenance & Fuel Quality) — ATEX
Predicts maintenance, ensures clean fuel
Differential Pressure (ΔP)
Quick Overview
| Problem | Marine engines and port fuel systems rely on clean fuel supply. Progressive clogging of fuel filters often goes unnoticed until pressure loss causes engine derating, shutdowns, or injector damage—especially critical in ATEX-classified fuel handling areas. |
| Solution | SENSAiO’s ATEX-certified differential pressure (ΔP) sensors continuously monitor pressure drop across marine fuel filters, enabling early detection of clogging and condition-based maintenance. |
| Value | Prevented engine stoppages • Improved fuel quality • Reduced maintenance OPEX • Higher vessel & terminal availability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified differential pressure sensors |
The Operational Challenge
Marine and port fuel systems include:
- Ship fuel supply lines (diesel, HFO, MGO)
- Port bunkering stations
- Fuel polishing and filtration skids
- Emergency generator fuel systems
Fuel quality variability, contamination, and biofouling lead to:
- Progressive filter clogging
- Reduced fuel flow to engines
- Increased pump load and energy use
- Risk of injector and engine damage
Traditional monitoring typically relies on:
- Manual gauge readings
- Fixed maintenance intervals
- Alarms triggered only after severe restriction
These methods are reactive and often detect problems after operational impact has already occurred.
Why Differential Pressure Monitoring Matters
Differential pressure across a filter is the most reliable indicator of its condition.
Continuous ΔP monitoring enables operators to:
- Detect gradual clogging trends early
- Identify abnormal contamination events
- Optimise filter replacement intervals
- Prevent sudden fuel starvation
In marine propulsion and port operations, early detection protects engines, avoids unplanned downtime, and maintains safe operations during manoeuvring or cargo handling. In ATEX fuel handling zones, remote monitoring also reduces manual checks near flammable products.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe ΔP monitoring solution for marine and port fuel filtration systems.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy ΔP measurement across fuel filters, suitable for diesel, HFO, and marine gas oil.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with ship automation systems, port SCADA, and maintenance platforms.
Installation & Power
Battery-powered installation on upstream and downstream filter taps — no cabling or shutdown required.
Operational Benefits
- Early detection of filter clogging
- Stable fuel flow to engines
- Reduced risk of engine derating or shutdown
- Optimised filter consumption
Results and ROI
ATEX Compliance and Safety
All differential pressure sensors for marine fuel filtration 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 enables safe installation in fuel handling and bunkering areas without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Ship automation systems, port SCADA, CMMS |
| Vendors | Kongsberg, ABB Marine, Wärtsilä, Siemens |
| 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.
