Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Leak Detection (Topside & Subsea) Using Acoustic & Pressure Monitoring — ATEX
Detects leaks within minutes, reduces spill risk
Acoustic
Pressure
Quick Overview
| Problem | Offshore pipelines—both topside and subsea—operate under extreme pressure, vibration, and corrosive conditions. Small leaks often go undetected until they escalate into spills, shutdowns, or major safety incidents in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified acoustic and pressure sensors continuously monitor pipelines to detect early leak signatures, pressure anomalies, and abnormal flow behaviour in real time. |
| Value | Early leak localisation • Reduced spill risk • Faster response time • Improved regulatory compliance |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified acoustic & pressure sensors |
The Operational Challenge
Offshore pipelines connect critical assets such as:
- Wells to platforms
- Platforms to FPSOs
- FPSOs to export lines
- Utility and fuel distribution networks
These pipelines are exposed to:
- Corrosion and erosion
- Fatigue due to waves and vibration
- Thermal expansion and contraction
- Mechanical damage during operations
Typical leak detection methods include:
- Periodic pressure testing
- Mass balance calculations
- Visual inspection (limited offshore)
These methods often fail to detect small or developing leaks, especially subsea or insulated lines.
In offshore environments, delayed detection increases:
- Environmental impact
- Production losses
- Repair complexity and cost
- Regulatory exposure
Why Acoustic & Pressure Monitoring Matters
Pipeline leaks generate distinct acoustic signatures caused by turbulent fluid escape, long before pressure drops become visible.
Combining acoustic and pressure monitoring enables operators to:
- Detect micro-leaks early
- Localise leak position along the pipeline
- Differentiate leaks from normal flow noise
- Detect sudden rupture or pressure transients
This dual-sensor approach provides faster and more reliable detection than pressure-only systems. In ATEX offshore zones, wireless monitoring also reduces personnel exposure and inspection frequency.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe pipeline monitoring solution for offshore and subsea applications.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Detects ultrasonic and audible leak signatures in pressurised pipelines.
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
Monitors static and transient pressure changes for confirmation and localisation.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with refinery SCADA and energy management platforms.
Installation & Power
Battery-powered clamp-on installation on steam lines, valves, traps, or flanges — no insulation removal required.
Operational Benefits
- Early detection of pipeline leaks
- Faster leak localisation and response
- Reduced environmental risk
- Lower inspection and intervention costs
Results and ROI
ATEX Compliance and Safety
All sensors for offshore pipeline 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 safe deployment in explosive offshore environments without process shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, pipeline integrity management, HSE platforms |
| Vendors | Honeywell, ABB, Emerson, 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.
