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 (Remote Safety & Control) — ATEX
Remote safety control
Valve position
Quick Overview
| Problem | Gas distribution pipelines rely on accurate valve positioning to ensure safe operation, network stability, and regulatory compliance. In remote or hazardous ATEX-classified zones, lack of real-time valve position visibility can lead to delayed response, unsafe operating states, loss of containment risk, or prolonged outages during abnormal events. |
| Solution | Sensa.io’s ATEX-certified valve position sensors provide continuous, remote feedback on pipeline valve status, enabling operators to verify valve operations, maintain safety control, and respond quickly without manual intervention in hazardous areas. |
| Value | Improved operational safety • Remote control visibility • Reduced site visits • Faster incident response |
| ATEX | Improved operational safety • Remote control visibility • Reduced site visits • Faster incident response |
The Operational Challenge
Gas distribution networks form a critical layer of energy infrastructure, delivering fuel to industrial users, power generation assets, and communities. Valve integrity and correct positioning are essential for safe and reliable operation.
Key operational constraints include:
- Remote pipeline locations with limited accessibility
- ATEX-classified environments due to flammable gas presence
- Dependence on manual confirmation of valve position
- High consequences of incorrect valve state during switching operations
Typical operational issues include:
- Uncertainty whether valves are fully open, closed, or partially actuated
- Delayed confirmation after emergency or maintenance operations
- Increased personnel exposure during manual inspections
- Incomplete traceability of valve operations for audits and incident reviews
Traditional approaches rely on:
- Manual site visits for visual confirmation
- Local mechanical indicators with no remote visibility
- Limited integration into central control systems
These methods increase safety risk and slow operational response.
Why Valve Position Feedback Matters
Valve position is a fundamental safety and control parameter in gas distribution systems.
Continuous valve position monitoring enables operators to:
- Confirm correct execution of valve operations remotely
- Detect unintended valve movement or incomplete actuation
- Improve coordination during isolation or restart procedures
- Reduce personnel exposure in hazardous zones
Reliable valve feedback directly supports:
- Safe gas distribution and pressure management
- Faster response during abnormal or emergency conditions
- Improved operational discipline and traceability
- Compliance with safety management and regulatory requirements
Early visibility prevents minor operational errors from escalating into safety incidents.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe valve position monitoring solution designed for gas distribution pipelines in ATEX environments.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Provides clear open/closed or multi-position feedback for manual and actuated pipeline valves in hazardous areas.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT for reliable data transmission across wide-area distribution networks.
Installation & Power
Battery-powered, non-intrusive installation on valve assemblies — no cabling, no hot work, no process interruption.
Operational Benefits
- Remote confirmation of valve status
- Reduced need for hazardous-area site visits
- Faster and safer operational decision-making
- Improved network visibility and control
Results and ROI
ATEX Compliance and Safety
Valve position monitoring supports compliance 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 deployment on live gas pipelines without shutdown or hot work.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Gas SCADA, pipeline monitoring platforms, safety management systems |
| Vendors | Siemens, Schneider Electric, ABB, Honeywell |
| 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.
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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.
