Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Leak Detection (Pressure & Acoustic Monitoring) — ATEX
Early leak localization, prevents product loss & spills
Pressure
Acoustic
Quick Overview
| Problem | Midstream pipelines transport large volumes of hydrocarbons over long distances. Small leaks or mechanical defects may remain undetected for hours or days, leading to product loss, environmental damage, and safety incidents in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified pressure and acoustic sensors provide continuous, wireless monitoring to detect pressure anomalies and acoustic signatures associated with leaks, enabling early localisation and rapid response. |
| Value | Early leak detection • Reduced spill impact • Improved pipeline integrity • Lower inspection OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure & acoustic sensors |
The Operational Challenge
Midstream pipelines are exposed to a wide range of risks throughout their lifecycle:
- Corrosion (internal or external)
- Mechanical damage from third-party interference
- Joint or flange degradation
- Ground movement or vibration-induced fatigue
Traditional pipeline leak detection approaches often rely on:
- Periodic pressure balance checks
- Flow reconciliation at pumping stations
- Aerial or ground patrols
- Reactive alarms triggered by major pressure drops
These methods struggle to detect small or developing leaks, especially on long pipeline sections or low-flow regimes.
In many cases, leaks are only identified after:
- Significant product loss
- Environmental contamination
- Regulatory non-compliance
- Public or operational safety impact
ATEX-classified environments further complicate frequent manual inspection, increasing reliance on remote, continuous monitoring.
Why Pressure & Acoustic Monitoring Matters
Pressure and acoustic measurements provide complementary insight into pipeline health.
Pressure monitoring enables operators to:
- Detect abnormal pressure drops or transient behaviour
- Identify pressure waves caused by sudden flow changes
- Monitor pipeline operating envelopes continuously
Acoustic monitoring detects:
- High-frequency noise generated by escaping gas or liquid
- Changes in vibration or sound patterns caused by structural defects
- Leak-related acoustic signatures even before pressure loss becomes significant
By combining pressure trends with acoustic signatures, operators improve both detection sensitivity and confidence, reducing false positives. Continuous monitoring captures transient events that periodic checks cannot — enabling earlier intervention and limiting spill consequences.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe pipeline monitoring solution combining pressure and acoustic sensing.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
Monitors pipeline pressure continuously at block valves, pumping stations, or strategic points.
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Detects leak-related acoustic emissions and abnormal vibration patterns along the pipeline.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling real-time data transmission to pipeline monitoring systems.
Installation & Power
Battery-powered and non-intrusive, the sensor is installed on tubing or annulus lines without hot work or production shutdown.
Operational Benefits
- Early detection of small and progressive leaks
- Reduced reliance on manual patrols
- Faster localisation of leak events
- Improved environmental and safety performance
Results and ROI
ATEX Compliance and Safety
All pressure and acoustic sensors for pipeline monitoring comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
- ATEX Directive 2014/34/EU
Intrinsically safe design enables installation on live pipelines without shutdown, supporting safe operations in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, pipeline integrity management platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted data with VPN-secured 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.
