Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Valve Automation & Position Feedback (Remote Isolation & Safety) — ATEX
Enables remote isolation, improves safety
Valve position
Quick Overview
| Problem | Midstream pipelines rely on isolation and block valves to control flow and mitigate incidents. Without reliable position feedback, operators must assume valve status or dispatch field crews, increasing response time and risk in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified valve position sensors provide continuous, wireless feedback on pipeline valve status (open / closed / intermediate), enabling remote verification and faster, safer isolation via SCADA. |
| Value | Faster incident response • Reduced spill impact • Verified isolation • Lower HSE exposure |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified valve position sensors |
The Operational Challenge
Pipeline block valves, sectionalising valves, and emergency isolation valves are critical safety components across midstream networks. They are used to isolate pipeline sections during maintenance, leaks, or emergency events.
Operational challenges commonly include:
- Unknown or assumed valve position between inspections
- Delayed confirmation of isolation during incidents
- Manual valve checks requiring site access
- Limited traceability of valve operations
In the event of a leak or abnormal pressure event, response time is often dictated by how quickly operators can confirm valve position and isolate the affected section. Manual verification is slow and exposes personnel to hazardous ATEX environments, particularly at remote valve stations.
Why Continuous Valve Position Feedback Matters
Valve position feedback provides direct confirmation of mechanical state, which is essential for pipeline safety.
Continuous monitoring enables operators to:
- Verify that isolation valves are fully closed when commanded
- Detect unintended valve movement or partial closure
- Confirm valve status before restarting operations
- Maintain an auditable history of valve operations
Unlike pressure or flow inference, valve position feedback removes ambiguity and reduces human error during critical operations. When combined with leak detection systems, valve position data significantly improves incident response effectiveness.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe valve position monitoring solution for midstream pipeline applications.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Non-intrusive sensor detecting valve movement and final position. Suitable for manual, motorised, and hydraulically actuated valves.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with pipeline SCADA and control systems.
Installation & Power
Battery-powered, clamp-on installation without valve modification or process interruption.
Operational Benefits
- Continuous remote verification of valve position
- Faster isolation during incidents
- Reduced need for field verification
- Improved safety and compliance
Results and ROI
ATEX Compliance and Safety
All valve position 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
The intrinsically safe design enables installation on live pipeline assets without shutdown, supporting safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, pipeline control and integrity 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.
