Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Pressure Profiling (Transient & Surge Detection) — ATEX
Detects water hammer, prevents rupture
Pressure
Quick Overview
| Problem | Rapid pressure transients, surges, or water hammer events in midstream pipelines can cause fatigue, joint failure, or rupture. These events are often too short to be captured by periodic measurements or standard alarms. |
| Solution | SENSAiO’s ATEX-certified pressure sensors provide continuous, high-resolution pressure profiling along pipelines to detect transient events, surges, and abnormal pressure dynamics in real time. |
| Value | Early surge detection • Reduced rupture risk • Improved pipeline integrity • Fewer emergency interventions |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure sensors |
The Operational Challenge
Midstream pipelines operate under varying flow conditions driven by:
- Pump start/stop sequences
- Compressor trips or restarts
- Valve closures or openings
- Batch changes and flow reversals
These operations generate pressure transients that propagate along the pipeline.
If unmanaged, transient pressure spikes may exceed design limits, causing:
- Fatigue damage to pipes and welds
- Gasket and flange leaks
- Valve and instrumentation damage
- Long-term reduction of pipeline integrity
Traditional monitoring approaches include:
- Static pressure measurement at limited locations
- Standard SCADA alarms with low temporal resolution
- Post-incident analysis after equipment damage
These methods often miss short-duration pressure spikes, leaving operators blind to repeated transient stress.
Why Continuous Pressure Profiling Matters
Pressure profiling focuses not only on absolute pressure but on dynamic behaviour over time.
Continuous monitoring enables operators to:
- Detect rapid pressure spikes and drops
- Identify water hammer and surge events
- Analyse pressure wave propagation along the pipeline
- Correlate transients with operational actions (valve or pump events)
Repeated transient exposure accelerates fatigue even when pressure remains below nominal limits. By capturing high-resolution pressure data, operators gain insight into hidden integrity threats that static monitoring cannot reveal.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe pressure profiling solution for midstream pipelines.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy pressure measurement capable of capturing dynamic pressure variations. Installed at strategic points such as pump stations, block valves, and critical pipeline sections.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling near-real-time data transmission to SCADA and pipeline integrity systems.
Installation & Power
Battery-powered design eliminates cabling.Threaded or clamp-on installation supports rapid retrofit.
Operational Benefits
- Early detection of surge and water hammer events
- Reduced risk of rupture and fatigue damage
- Improved understanding of pipeline dynamics
- Optimised operating procedures
Results and ROI
ATEX Compliance and Safety
All pressure sensors for pressure profiling 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 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 and hydraulic modelling 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.
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.
