Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Slurry Pipeline Pressure & Differential Pressure (ΔP) Monitoring (Blockage & Rupture Prevention)
Detects blockages, prevents pipe rupture
Pressure
Differential Pressure (ΔP)
Quick Overview
| Problem | Slurry pipelines transporting ore, tailings, or concentrate are exposed to abrasion, sedimentation, and variable flow conditions. Undetected pressure increase, blockage formation, or pipe wear can rapidly lead to ruptures, spills, and forced production shutdowns. Manual inspection offers limited visibility over long distances. |
| Solution | Sensa.io’s wireless pressure and differential pressure (ΔP) sensors continuously monitor slurry pipeline conditions, detecting blockages, abnormal friction, and rupture risk early—without cabling or intrusive installation. |
| Value | Spill prevention • Reduced pipeline downtime • Improved transport reliability • Lower maintenance cost |
| ATEX | Generally non-ATEX • ATEX-certified pressure & ΔP sensor variants available where required |
The Operational Challenge
Slurry pipelines are critical to mining operations, transporting:
- Crushed ore and concentrate
- Tailings and process by-products
- High-density abrasive slurries
They operate under challenging conditions:
- Variable solids concentration
- High abrasion and erosion
- Long distances with limited access
- Changes in slope and elevation
Common failure modes include:
- Progressive sediment buildup and blockage
- Localised pressure increase
- Accelerated pipe wear
- Sudden rupture or leak
Traditional monitoring relies on:
- Sparse pressure gauges
- Periodic flow checks
- Visual inspection after incidents
These approaches rarely provide early warning of developing issues.
Why Pressure & ΔP Monitoring Matter
Pressure and differential pressure trends are the earliest indicators of pipeline health.
Continuous monitoring enables operators to:
- Detect blockage formation via rising ΔP
- Identify abnormal friction or sedimentation
- Detect leaks or rupture through sudden pressure drops
- Optimise flow velocity to reduce wear
Reliable slurry transport is essential to production continuity and environmental protection.
Sensa.io Solution
Sensa.io delivers a wireless monitoring solution designed for abrasive slurry pipelines.
Core Components
Pressure Sensor
Monitors absolute pipeline pressure to detect rupture, leakage, or abnormal operating conditions.
Differential Pressure (ΔP) Sensor
Measures pressure drop between two points to identify blockages, sediment buildup, or increased friction.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for remote pipeline routes.
Installation & Power
Battery-powered threaded or clamp-on installation — no wiring, minimal disruption.
Operational Benefits
- Early detection of blockages and rupture risk
- Reduced spill and environmental impact
- Improved pipeline availability
- Lower maintenance and clean-up cost
Results and ROI
ATEX Compliance and Safety
Where required, Sensa.io sensors support:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
This enables safe monitoring in hazardous or mixed-use mining environments.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Mining SCADA, pipeline monitoring, EHS platforms |
| Deployment | Along pipeline routes or central control rooms |
| 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.
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.
