Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump Station Differential Pressure Monitoring (Filter Clogging & Throughput Protection) — ATEX
Predicts maintenance, avoids throughput loss
Differential Pressure (ΔP)
Quick Overview
| Problem | In midstream pump stations, gradual filter clogging increases pressure losses, reduces throughput, and accelerates pump wear. Manual inspections are infrequent and often occur after performance degradation or equipment stress has already occurred. |
| Solution | SENSAiO’s ATEX-certified differential pressure (ΔP) sensors continuously monitor pressure drop across pump station filters, strainers, and protection systems to detect clogging and abnormal flow resistance in real time. |
| Value | Protected throughput • Reduced pump damage • Predictive maintenance • Lower unplanned downtime |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified differential pressure sensors |
The Operational Challenge
Pump stations are critical nodes in midstream infrastructure, ensuring stable transport of hydrocarbons across long distances. Their reliability depends on maintaining clean flow paths and protecting pumps from debris, solids, and contaminants.
Over time, filters and strainers may experience:
- Progressive clogging due to solids or corrosion debris
- Wax, scale, or particulate accumulation
- Reduced effective filtration area
- Increased hydraulic resistance
Typical monitoring practices rely on:
- Periodic manual differential pressure checks
- Visual inspection during maintenance stops
- Reactive intervention after flow reduction or pump alarms
These approaches often fail to detect early-stage clogging, leading to:
- Reduced pipeline throughput
- Increased pump load and energy consumption
- Accelerated wear on seals and bearings
- Higher risk of pump failure or cavitation
In ATEX-classified pump stations, frequent manual inspection also increases personnel exposure to hazardous areas.
Why Differential Pressure Monitoring Matters
Differential pressure across filters is a direct indicator of flow resistance and filter condition.
Continuous ΔP monitoring enables operators to:
- Detect early filter clogging before throughput is impacted
- Correlate pressure loss with flow rate and pump performance
- Schedule maintenance based on actual condition rather than fixed intervals
- Protect pumps from excessive load or cavitation
Unlike absolute pressure measurements, ΔP directly reflects filter health. Gradual ΔP increase signals progressive fouling, while sudden changes may indicate partial blockage or structural failure of filter elements.
SENSAiO Solution
SENSAiO provides a wireless, intrinsically safe differential pressure monitoring solution designed for midstream pump station environments.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy ΔP measurement suitable for hydrocarbon liquids and multiphase service. Designed for harsh industrial conditions and outdoor installation.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling real-time data transmission to SCADA and pump station monitoring systems.
Installation & Power
Battery-powered design eliminates cabling. Compact installation across filter inlets and outlets enables rapid retrofit.
Operational Benefits
- Early detection of filter clogging
- Stable pump operation and protected equipment
- Reduced unplanned shutdowns
- Optimised maintenance planning
Results and ROI
ATEX Compliance and Safety
All differential pressure sensors for pump station 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 supports installation on live equipment without shutdown, ensuring safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, pump monitoring, asset management platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted data 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
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A high-resolution vibration sensor built for predictive maintenance of pumps, motors, compressors, and rotating equipment.
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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.
