Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Valve Position Feedback (Traceability & ATEX Process Safety) — ATEX
Traceability of valve operations
Valve position
Quick Overview
| Problem | Pipeline valves in refineries and process plants control isolation, routing, and safe operation of fluids and gases. A valve left in the wrong position, moved unintentionally, or operated without traceability can lead to flow deviations, safety incidents, non-compliance, or delayed incident response—especially in ATEX-classified pipeline corridors. |
| Solution | Sensa.io’s ATEX-certified valve position sensors provide continuous, real-time feedback on refinery pipeline valve status, enabling full traceability of valve operations and improving safety, control, and compliance in hazardous areas. |
| Value | Improved operational traceability • Reduced process risk • Faster incident response • Stronger compliance posture |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified valve position sensors |
The Operational Challenge
Pipeline valves are critical assets across refineries and process facilities, including:
- Product transfer and distribution pipelines
- Unit isolation and emergency shutdown sections
- Blending, routing, and tank farm connections
- Maintenance and safety isolation points
They operate under strict operational and safety constraints:
- Correct valve position is essential for safe flow routing
- Valves are distributed across large, often hazardous areas
- Manual verification requires physical access to ATEX zones
Common operational issues include:
- Valves left partially open or closed after interventions
- Unauthorised or accidental valve movement
- Lack of centralised visibility across pipeline networks
- Limited traceability for audits or incident investigation
Traditional assurance methods rely on:
- Local mechanical indicators
- Manual walkdowns and checklists
- Verbal or paper-based confirmation
This creates gaps between operations and verified valve status.
Why Valve Position Feedback Matters
Valve position is a fundamental process and safety parameter.
Continuous valve position feedback enables operators to:
- Verify actual valve state at all times
- Detect unintended or unauthorised valve movements
- Maintain a time-stamped record of valve operations
- Improve response speed during abnormal situations
For refinery pipelines, traceability is critical for both operational discipline and regulatory confidence.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe valve position feedback solution designed for refinery and pipeline applications.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Provides discrete or continuous feedback on open, closed, and intermediate valve positions for pipeline isolation and routing valves.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT for integration with refinery SCADA, DCS, and safety systems.
Installation & Power
Battery-powered clamp-on installation on ball, gate, and butterfly valves — no cabling, no hot work, no process interruption.
Operational Benefits
- Continuous verification of valve positions
- Full traceability of valve operations
- Reduced manual inspections in ATEX areas
- Improved process and safety control
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 safe installation on live refinery pipelines in hazardous zones.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| LoRaWAN, Modbus RTU/TCP, MQTT, REST API | SCADA, DCS, safety PLCs, asset management systems |
| Vendors | Siemens, Schneider Electric, ABB, Honeywell |
| Cybersecurity | AES-128 encrypted communication |
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.
