Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Relief Valve Acoustic Monitoring (Safety Valve Integrity & Compliance) — ATEX
Detects stuck valves or leaks
Acoustic
Quick Overview
| Problem | Pressure relief valves (PRVs/PSVs) are critical safety devices in refineries. Stuck-open, leaking, or chattering valves often go undetected, leading to continuous product loss, emissions, safety risks, and non-compliance in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified acoustic sensors continuously monitor relief valve acoustic signatures to detect leakage, chatter, or unintended opening events in real time. |
| Value | Early leak detection • Reduced emissions & product loss • Improved safety compliance • Lower inspection OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified acoustic sensors |
The Operational Challenge
Pressure relief valves protect downstream equipment and personnel from overpressure events. However, once installed, their actual operating condition is often unknown between inspections.
Common issues include:
- Valve stuck partially open after an overpressure event
- Seat leakage due to wear or corrosion
- Valve chatter caused by unstable pressure conditions
- Incorrect reseating after activation
Traditional detection methods rely on:
- Periodic manual inspection
- Audible checks during site rounds
- Emission monitoring after visible loss
These methods are intermittent and frequently detect issues long after leakage has started, especially in noisy refinery environments. In ATEX zones, frequent manual checks also increase personnel exposure to hazardous areas.
Why Acoustic Monitoring Matters
Relief valve leakage and malfunction generate distinct acoustic signatures that differ from background process noise.
Continuous acoustic monitoring enables operators to:
- Detect continuous low-rate leakage invisible to pressure sensors
- Identify valve chatter and unstable operation
- Confirm whether a valve has reseated properly
- Detect unintended opening events in real time
Acoustic monitoring provides direct insight into valve behaviour, even when pressure remains within normal limits. This makes it one of the most effective methods for continuous PRV integrity monitoring.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe acoustic monitoring solution for relief and safety valves in downstream facilities.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Wide-frequency acoustic detection optimised for valve noise, leakage flow, and mechanical vibration.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with refinery SCADA and HSE monitoring systems.
Installation & Power
Battery-powered, clamp-on installation on valve body or downstream piping — no process interruption required.
Operational Benefits
- Continuous verification of relief valve integrity
- Early detection of emissions and product loss
- Reduced manual inspection frequency
- Improved safety and regulatory compliance
Results and ROI
ATEX Compliance and Safety
All acoustic sensors for relief valve 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 allows installation on live relief valves without shutdown, ensuring safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, emissions monitoring, HSE platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| 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.
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.
