Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Flare & Torch Acoustic Monitoring (Abnormal Venting & Emissions Control) — ATEX
Detects leaks and venting issues
Acoustic
Quick Overview
| Problem | Flares and torches in biogas and hydrogen facilities are critical safety devices. Abnormal venting, continuous pilot loss, partial blockage, or unexpected flow can go unnoticed between inspections—leading to emissions exceedance, safety exposure, or regulatory non-compliance in ATEX-classified zones. |
| Solution | Sensa.io’s ATEX-certified acoustic sensors continuously monitor flare and torch sound signatures to detect abnormal venting, ignition issues, or flow anomalies in real time. |
| Value | Emissions control • Improved flare reliability • Reduced inspection effort • Compliance assurance |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified acoustic sensors |
The Operational Challenge
Flares and torches are used in renewable gas facilities to:
- Safely burn excess biogas during upsets
- Manage hydrogen venting during maintenance
- Protect process equipment from overpressure
- Comply with safety and environmental regulations
Operational constraints include:
- Intermittent operation with long idle periods
- Harsh outdoor conditions (wind, rain, temperature)
- Limited access for frequent inspection
- ATEX restrictions on instrumentation
Common failure or deviation modes include:
- Continuous low-flow venting not detected visually
- Pilot flame instability or extinction
- Partial blockage or valve malfunction upstream
- Increased venting due to upstream process issues
Traditional monitoring relies on:
- Visual inspection
- Flame presence detectors only
- Emissions checks after incidents
This provides limited insight into flare performance between inspections.
Why Acoustic Monitoring Matters
Acoustic signatures provide real-time information about gas flow and combustion behaviour.
Continuous acoustic monitoring enables operators to:
- Detect abnormal venting even at low flow rates
- Identify ignition instability or pilot loss
- Differentiate normal purge noise from abnormal events
- Correlate flare activity with upstream process deviations
Acoustic monitoring offers a non-intrusive way to supervise flares continuously without interfering with safety functions.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe acoustic monitoring solution for flares and torches in renewable energy facilities.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Wide-band acoustic measurement capable of detecting flow noise, combustion noise, and abnormal sound patterns.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with SCADA, EMS, and environmental monitoring systems.
Installation & Power
Battery-powered clamp-on or bracket-mounted installation near flare stacks or vent lines — no cabling required.
Operational Benefits
- Early detection of abnormal venting
- Improved flare availability and reliability
- Reduced manual inspection frequency
- Enhanced emissions and safety oversight
Results and ROI
ATEX Compliance and Safety
All acoustic sensors for flare and torch 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 safe installation near active flares and venting systems.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, EMS, environmental monitoring platforms |
| Vendors | Siemens Energy, ABB, Schneider Electric, Honeywell |
| 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.
