Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Tank Differential Pressure & Level Monitoring (Overfill Prevention & Storage Integrity) — ATEX
Prevents overfill and spills
Differential Pressure (ΔP)
Quick Overview
| Problem | Refinery storage tanks require accurate level and pressure monitoring to prevent overfill, structural stress, and vapour release. Traditional level gauges may fail or provide limited redundancy, while manual checks are unsafe and insufficient in ATEX-classified zones. |
| Solution | SENSAiO’s ATEX-certified differential pressure (ΔP) sensors provide continuous, wireless monitoring of tank hydrostatic pressure, enabling reliable level estimation and early detection of abnormal tank behaviour. |
| Value | Overfill prevention • Improved storage safety • Reduced spill risk • Lower inspection OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified differential pressure sensors |
The Operational Challenge
Downstream refineries operate large tank farms storing crude oil, intermediates, and refined products.
These tanks are exposed to multiple operational risks, including:
- Overfill during transfer or blending operations
- Uneven filling causing structural stress
- Vapour pressure buildup due to temperature changes
- Instrumentation failure on legacy tanks
Common limitations of traditional monitoring include:
- Single-point level measurements without redundancy
- Limited visibility of pressure behaviour inside the tank
- Manual verification in hazardous areas
- Late detection of abnormal filling conditions
In ATEX environments, relying solely on manual or single-instrument monitoring significantly increases operational risk.
Why Differential Pressure Monitoring Matters
Differential pressure measurement provides a direct physical relationship between liquid level and hydrostatic pressure.
Continuous ΔP monitoring enables operators to:
- Estimate liquid level independently of mechanical gauges
- Detect abnormal pressure behaviour indicating overfill risk
- Identify blocked vents or vapour imbalance
- Validate safe operating envelopes during transfers
ΔP monitoring adds a critical layer of redundancy to level measurement systems and improves overall tank safety.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe differential pressure monitoring solution for refinery storage tanks.
Core Components
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy ΔP sensors measuring pressure difference between tank bottom and reference point.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling seamless integration with tank management systems and SCADA.
Installation & Power
Battery-powered design supports retrofit installation without tank modification or cabling.
Operational Benefits
- Reliable overfill prevention
- Improved tank integrity monitoring
- Reduced reliance on manual inspections
- Enhanced safety and compliance
Results and ROI
ATEX Compliance and Safety
All differential pressure sensors for tank 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 tanks without shutdown, supporting safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, tank gauging and terminal management 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.
