Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Reactor Valve Position Monitoring (Process Safety & Traceability) — ATEX
Safety & traceability
Valve position
Quick Overview
| Problem | In chemical and process plants, reactor valves control critical steps such as feed injection, isolation, venting, and emergency shutdown. A valve left in the wrong position—or moving unintentionally—can lead to runaway reactions, overpressure, product quality issues, or severe safety incidents in ATEX-classified environments. |
| Solution | Sensa.io’s ATEX-certified valve position sensors provide continuous, wireless monitoring of reactor valve status, ensuring real-time visibility, safe operation, and full traceability across chemical processes. |
| Value | Improved process safety • Reduced human error • Better batch quality • Full audit traceability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified valve position sensors |
The Operational Challenge
Chemical reactors rely on precise valve positioning to manage:
- Raw material dosing
- Isolation between process steps
- Pressure relief and venting
- Emergency shutdown sequences
These valves are often located:
- In hazardous ATEX zones
- On hot, pressurised, or corrosive lines
- In areas with limited access
Typical challenges faced by operators include:
- Manual verification of valve positions
- Reliance on mechanical indicators or procedural checks
- Limited feedback for manually actuated valves
- Human error during batch changeovers or maintenance
Consequences of incorrect valve positioning can be severe:
- Unsafe reaction conditions
- Batch rejection or off-spec production
- Equipment damage
- Regulatory non-compliance
Traditional approaches leave critical gaps between inspections.
Why Continuous Valve Position Monitoring Matters
Valve position is a direct safety and quality parameter in chemical processing.
Continuous monitoring enables operators to:
- Confirm correct valve configuration before batch start
- Detect unintended valve movement during operation
- Ensure isolation before maintenance or cleaning
- Maintain digital records of all valve state changes
Unlike inferred measurements (pressure or flow), valve position feedback provides explicit mechanical confirmation, reducing ambiguity in high-risk operations.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe valve position monitoring solution designed for chemical reactors and process valves.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Non-intrusive sensor detecting open/closed and intermediate valve positions on manual or automated valves.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with DCS, SCADA, and batch control systems.
Installation & Power
Battery-powered clamp-on installation — no wiring, no hot work, no process interruption.
Operational Benefits
- Enhanced reactor safety
- Reduced risk of operator error
- Faster batch verification
- Improved process traceability
Results and ROI
ATEX Compliance and Safety
All valve position sensors for chemical reactor monitoring comply with:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
The intrinsically safe design allows installation on live reactors without shutdown or hot work permits.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | DCS, SCADA, batch management systems |
| Vendors | Schneider Electric, ABB, Siemens, Emerson |
| 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.
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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.
