Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Produced Water Filtration ΔP Monitoring (Clogging Detection & Process Reliability)
Maintains process reliability, optimizes filter change cycles
Differential Pressure (ΔP)
Quick Overview
| Problem | Produced water treatment systems rely on filtration units to protect downstream equipment and ensure discharge or reuse compliance. Filter clogging, fouling, or media degradation can develop gradually, causing pressure buildup, flow restriction, reduced separation efficiency, and unplanned process interruptions—often detected too late through manual checks. |
| Solution | Sensa.io’s wireless differential pressure (ΔP) sensors continuously monitor pressure drop across produced water filtration units, providing early detection of clogging and enabling optimised filter change cycles without disrupting operations. |
| Value | Stable water treatment • Optimised filter replacement • Reduced downtime • Lower operating cost |
| ATEX | Generally non-ATEX; ATEX-certified ΔP sensor variants available if required in classified areas |
The Operational Challenge
Produced water filtration is critical for:
- Oil & gas produced water treatment
- Separation and polishing before discharge
- Water reuse and reinjection systems
- Protection of downstream membranes, pumps, and valves
Filtration systems operate under challenging conditions:
- Variable solids loading
- Oil, sand, and scale contamination
- Fluctuating flow rates and pressures
- Continuous or semi-continuous operation
Common operational issues include:
- Progressive filter clogging and fouling
- Sudden pressure increase leading to bypass or shutdown
- Premature filter replacement based on time, not condition
- Undetected restriction impacting upstream and downstream assets
Traditional monitoring approaches rely on:
- Local pressure gauges
- Periodic manual readings
- Reactive maintenance after alarms or flow loss
This creates limited visibility into real filter condition.
Why ΔP Monitoring Matters
Differential pressure is the most direct indicator of filter health.
Continuous ΔP monitoring enables operators to:
- Detect filter clogging early and progressively
- Identify abnormal fouling or solids loading
- Optimise filter change and backwash cycles
- Maintain stable flow and treatment efficiency
Condition-based monitoring replaces fixed-interval maintenance with data-driven decisions.
Sensa.io Solution
Sensa.io delivers a wireless differential pressure monitoring solution designed for produced water filtration systems.
Core Components
Differential Pressure Sensor
High-resolution ΔP measurement across filters, strainers, and cartridge or media units to detect clogging and restriction trends.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT for integration with produced water SCADA and treatment monitoring systems.
Installation & Power
Battery-powered installation across filter inlet and outlet — no cabling, no process interruption.
Operational Benefits
- Early detection of filter clogging
- Reduced unplanned filtration shutdowns
- Optimised filter replacement intervals
- Improved water treatment reliability
Results and ROI
ATEX Compliance and Safety
Produced water filtration ΔP monitoring supports alignment with:
- Environmental discharge and water treatment regulations
- Operator integrity and process safety management requirements
- Facility reliability and operational compliance programs
ATEX-certified differential pressure sensor variants are available when monitoring points are located in hazardous or classified zones.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Produced water SCADA, treatment control systems, CMMS |
| 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.
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.
