Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Tank Farm Overfill & Pressure Monitoring (Storage Safety & Compliance) — ATEX
Prevents spills, meets HSE standards
Pressure
Temperature
Quick Overview
| Problem | Tank farms store large volumes of hydrocarbons under variable temperature and pressure conditions. Undetected overpressure, abnormal temperature rise, or filling anomalies can lead to overfill events, leaks, or catastrophic incidents in ATEX-classified zones. |
| Solution | SENSAiO’s ATEX-certified pressure and temperature sensors continuously monitor tank pressure behaviour and thermal conditions, enabling early detection of overfill risks and abnormal operating states. |
| Value | Overfill prevention • Reduced spill risk • Regulatory compliance • Lower inspection OPEX |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure & temperature sensors |
The Operational Challenge
Midstream tank farms are critical assets used for buffering, blending, and storage of crude oil, refined products, and intermediate streams.
They are exposed to multiple operational risks, including:
- Overpressure during filling or transfer operations
- Thermal expansion due to ambient temperature changes
- Vapour accumulation in fixed or floating roof tanks
- Malfunctioning vents or pressure relief devices
Common operational limitations include:
- Reliance on periodic manual checks
- Limited instrumentation on legacy tanks
- Delayed detection of abnormal pressure or temperature trends
In ATEX environments, manual inspection increases personnel exposure and may not provide sufficient early warning to prevent incidents.
Why Continuous Pressure & Temperature Monitoring Matters
Pressure and temperature trends provide early indicators of abnormal tank behaviour.
Continuous monitoring enables operators to:
- Detect abnormal pressure rise during filling
- Identify blocked vents or malfunctioning breather valves
- Monitor thermal expansion effects
- Validate safe operating envelopes during transfer operations
Pressure deviations often precede visible overfill or leakage, making continuous monitoring essential for prevention rather than reaction. By combining pressure and temperature data, operators gain a comprehensive view of tank behaviour under real operating conditions.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe tank monitoring solution for midstream storage facilities.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy pressure monitoring of vapour space or tank connections to detect overpressure and abnormal trends.
Temperature Sensor
Monitors product or shell temperature to detect thermal stress and expansion effects.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with tank management systems and SCADA.
Installation & Power
Battery-powered design supports retrofit installation without cabling or tank modification.
Operational Benefits
- Early overfill risk detection
- Reduced spill and emission risk
- Improved storage safety
- Lower inspection and maintenance costs
Results and ROI
ATEX Compliance and Safety
All pressure and temperature 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 operations 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.
