Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Solvent Pressure Monitoring & Leak Detection (Process Safety & Compliance) — ATEX
Safety, regulatory compliance
Pressure
Acoustic
Quick Overview
| Problem | Solvents used in chemical and process industries are often flammable, toxic, or volatile. Undetected pressure deviations or small leaks can lead to safety incidents, product losses, environmental non-compliance, and costly shutdowns—especially in ATEX-classified areas. Manual inspections are infrequent and expose personnel to risk. |
| Solution | Sensa.io’s ATEX-certified pressure sensors, combined with optional acoustic detection, provide continuous monitoring of solvent lines and vessels to detect pressure anomalies and leaks in real time. |
| Value | Improved process safety • Reduced solvent losses • Regulatory compliance • Lower inspection effort |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure (and acoustic) sensors |
The Operational Challenge
Solvents are widely used in process industries for:
- Chemical synthesis and reactions
- Extraction and separation processes
- Cleaning-in-place (CIP) and flushing operations
- Storage and transfer between units
These solvents often present multiple hazards:
- High flammability
- Toxic vapours
- Environmental contamination risk
Typical operational challenges include:
- Slow detection of small leaks on transfer lines
- Pressure fluctuations caused by blockages or valve malfunction
- Limited instrumentation on secondary or legacy lines
- Manual patrols in hazardous ATEX zones
Consequences of inadequate monitoring can be severe:
- Fire or explosion risk
- Product loss and contamination
- Regulatory penalties and reporting obligations
- Unplanned production shutdowns
Traditional approaches relying on periodic checks leave long blind spots.
Why Continuous Pressure & Leak Monitoring Matters
Pressure is a primary indicator of process integrity in solvent handling systems.
Continuous monitoring enables operators to:
- Detect abnormal pressure drops indicating leaks
- Identify overpressure conditions before relief events
- Correlate pressure changes with valve or pump behaviour
- Detect micro-leaks long before they become visible
When combined with acoustic monitoring, even very small solvent leaks can be detected early—reducing risk and loss.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe monitoring solution for solvent pressure and leak detection.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy pressure measurement suitable for solvent lines, manifolds, and storage vessels.
Optional Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Detects leak-related sound signatures on pipes, flanges, and valves.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with DCS, SCADA, and safety systems.
Installation & Power
Battery-powered clamp-on or threaded installation — no cabling, no hot work, minimal disruption.
Operational Benefits
- Early leak detection
- Reduced solvent losses
- Improved worker safety
- Enhanced environmental compliance
Results and ROI
ATEX Compliance and Safety
All sensors for solvent 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 enables installation on live solvent systems without shutdown or hot work permits.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | DCS, SCADA, environmental monitoring platforms |
| Vendors | Siemens, Schneider Electric, ABB, 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.
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.
