Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Separator Differential Pressure Monitoring (Filter Fouling & Process Stability) — ATEX
Avoids process upsets, reduces maintenance downtime
Differential Pressure (ΔP)
Quick Overview
| Problem | In upstream oil & gas separation systems, fouled filters, demisters, or internals gradually increase pressure losses, reducing separation efficiency and creating safety and production risks. Manual inspection is intermittent and reactive. |
| Solution | SENSAiO’s ATEX-certified differential pressure (ΔP) sensors continuously monitor pressure drop across separators, filters, and internals to detect fouling, blockage, or abnormal process behaviour in real time. |
| Value | Improved separation efficiency • Reduced unplanned shutdowns • Predictive maintenance • Lower OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified differential pressure sensors |
The Operational Challenge
Oil & gas separators are critical assets used to split multiphase production into oil, gas, and water streams. Their performance depends heavily on clean internals, stable flow conditions, and controlled pressure losses.
Over time, separators commonly experience:
- Filter or demister fouling
- Wax, sand, or scale accumulation
- Progressive blockage of internals
- Reduced effective cross-sectional flow area
These phenomena increase differential pressure (ΔP) across the separator or its internal elements.
Typical monitoring practices rely on:
- Periodic manual readings
- Visual inspection during shutdowns
- Reactive maintenance after performance degradation
This approach leads to:
- Undetected efficiency losses over weeks or months
- Higher pressure drop increasing upstream backpressure
- Reduced production throughput
- Elevated risk of liquid carryover or gas entrainment
In ATEX-classified upstream environments, frequent manual inspection increases personnel exposure and operational risk.
Why Differential Pressure Monitoring Matters
Differential pressure is one of the most reliable indicators of separator health.
Continuous ΔP monitoring allows operators to:
- Detect early fouling of filters or demisters
- Identify abnormal accumulation of solids or liquids
- Correlate pressure losses with flow rate and composition changes
- Anticipate maintenance before separator efficiency degrades
Unlike absolute pressure alone, ΔP directly reflects flow resistance inside the separator.
Rising differential pressure typically indicates:
- Progressive clogging of internals
- Reduced separation efficiency
- Increased energy losses across the system
By trending ΔP over time, operators gain predictive insight into separator condition — enabling planned intervention instead of emergency shutdowns.
SENSAiO Solution
SENSAiO provides a wireless, intrinsically safe differential pressure monitoring solution designed for upstream separation systems.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy ΔP measurement suitable for gas, oil, and multiphase service. Designed for harsh upstream conditions with corrosion-resistant materials.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with SCADA and process monitoring platforms.
Power & Installation
Battery-powered and compact, eliminating cabling and reducing installation complexity in hazardous areas.
Operational Benefits
- Early detection of fouling and blockage
- Stable separator performance over time
- Reduced unplanned shutdowns
- Improved production throughput consistency
Results and ROI
ATEX Compliance and Safety
All differential pressure sensors for separator 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 process equipment without shutdown, supporting safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, DCS, production and integrity monitoring platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted communication with VPN-secured 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.
