Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pig Launcher & Receiver Valve Status Monitoring (Operational Safety & Traceability) — ATEX
Improves operational safety, traceability
Valve position
Quick Overview
| Problem | Pig launching and receiving operations involve multiple isolation valves and pressurised components. Incorrect valve sequencing or unknown valve status can lead to serious safety incidents, delays, and non-compliant operations in ATEX-classified pipeline environments. |
| Solution | SENSAiO’s ATEX-certified valve position sensors provide continuous, wireless monitoring of pig launcher and receiver valve positions, enabling real-time verification and safe, auditable pigging operations. |
| Value | Improved pigging safety • Reduced human error • Faster operations • Full traceability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified valve position sensors |
The Operational Challenge
Pig launcher and receiver stations are among the most safety-critical assets in midstream pipeline operations.
Each pigging sequence requires strict adherence to valve opening and closing procedures to avoid:
- Accidental pressurisation of open barrels
- Uncontrolled gas or liquid release
- Personnel exposure to hazardous atmospheres
- Damage to pigging equipment
Operational challenges commonly include:
- Manual confirmation of valve positions
- Reliance on procedural checklists alone
- Limited remote visibility during pigging operations
- Human error during valve sequencing
In ATEX-classified areas, manual verification increases risk and slows down pigging campaigns, especially across large pipeline networks.
Why Continuous Valve Status Monitoring Matters
Pigging safety depends on absolute certainty of valve position.
Continuous valve position monitoring enables operators to:
- Verify correct valve sequencing before pressurisation
- Detect unintended valve movement during pigging
- Confirm isolation before opening launcher or receiver barrels
- Maintain a digital record of valve operations
Unlike pressure inference, valve position feedback provides direct mechanical confirmation, eliminating ambiguity during high-risk operations. When combined with procedural controls, continuous monitoring significantly reduces the probability of pigging-related incidents.
SENSAiO Solution
SENSAiO provides a wireless, intrinsically safe valve position monitoring solution tailored for pig launcher and receiver stations.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Non-intrusive sensor detecting valve movement and final position. Suitable for block valves, kicker valves, bypass valves, and vent valves.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with pipeline SCADA and pigging management systems.
Installation & Power
Battery-powered, clamp-on installation without valve modification or production interruption.
Operational Benefits
- Enhanced pigging safety
- Reduced human error during valve sequencing
- Faster pigging preparation and execution
- Improved compliance and traceability
Results and ROI
ATEX Compliance and Safety
All valve position sensors for pig launcher and receiver 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 installation on live pigging stations without shutdown, supporting safe operations in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, pigging management 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.
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Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
