Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
< Industries/
agriculture-agritech
ATEX-Certified Remote Monitoring for Hydrogen Production, Storage, and Transfer Infrastructure
Hydrogen infrastructure includes production (electrolysis or reforming), compression, storage, purification systems, pipelines, valve manifolds, and venting networks. Hydrogen presents specific operational challenges due to its low molecular weight, high diffusivity, wide flammability range, and potential material embrittlement effects under pressure.
Assets operate under high-pressure regimes, cyclic loading, and stringent safety requirements. Many components are located in hazardous areas due to hydrogen’s low ignition energy and rapid dispersion characteristics.
While core process parameters are supervised by DCS and safety systems, distributed monitoring coverage at secondary nodes is often limited by installation complexity and hazardous-area constraints.
SENSAiO provides wireless LoRaWAN monitoring sensors for valve position, pressure, temperature, differential pressure, vibration, and acoustic behavior. SENSAiO is monitoring-only. It does not replace hydrogen leak detection systems, pressure relief systems, compressor control logic, or Safety Instrumented Systems. It extends condition visibility on selected physical parameters to support earlier anomaly identification and maintenance planning.
The Operational Challenge
Hydrogen systems experience specific degradation mechanisms:
- Pressure cycling leading to fatigue stress
- Seal degradation due to molecular diffusion
- Compressor vibration growth under high rotational speed
- Filter restriction in purification systems
- Storage overpressure instability
- Intermittent vent line discharge events
Because hydrogen molecules are small and diffuse rapidly, early-stage anomalies may be difficult to localize. Additionally, high-pressure hydrogen increases mechanical stress on valves, piping, and compressors.
Operational priorities include:
- Early detection of pressure instability
- Verification of valve configuration in high-pressure systems
- Mechanical degradation visibility in compressors
- Restriction monitoring in purification filters
- Event correlation in vent discharge systems
The objective is improved distributed monitoring visibility without altering certified safety layers.
Why ATEX and Continuous Monitoring Matter
Hydrogen facilities frequently include classified hazardous areas due to hydrogen’s low ignition energy and wide flammability range.
Equipment installed in these zones must comply with explosion protection regulations.
SENSAiO devices are designed for deployment in hazardous areas in accordance with:
- ATEX Directive 2014/34/EU
- IECEx certification scheme
Certification applies to the equipment category and protection concept defined in product documentation.
Final hazardous-area classification (Zone 0, Zone 1, Zone 2) and installation compliance remain entirely the operator’s responsibility.
Continuous monitoring is particularly relevant in hydrogen systems because:
- Pressure drift may precede seal failure
- Vibration growth may indicate compressor degradation
- Differential pressure may signal purification restriction
- Vent acoustic anomalies may indicate abnormal discharge
Monitoring does not replace engineered protection systems. It provides time-stamped deviation visibility to support earlier investigation.
Core Use Cases for
Hydrogen Infrastructure
Use Case
Sensor Type
ATEX
ROI/Value
Hydrogen Purification Filter Differential Pressure Monitoring
Differential Pressure (ΔP)
Restriction progression tracking
Hydrogen Valve Position Verification
Valve position
Reduced misalignment risk in high-pressure routing
No items found.
Vibration
Acoustic
Differential Pressure (ΔP)
Temperature
Pressure
Valve position
Detailed Use Case Descriptions
1) Hydrogen Valve Position Verification
Hydrogen routing systems rely on correct valve sequencing, particularly in high-pressure manifolds and storage isolation. Misalignment can result in operational instability or extended troubleshooting.
Valve position monitoring provides time-stamped opening percentage confirmation to reduce configuration uncertainty during transitions.
SENSAiO does not actuate valves, does not verify sealing performance under hydrogen service, and does not replace ESD interlocks. It provides monitoring visibility only.
2) Hydrogen Line Pressure Monitoring
High-pressure hydrogen lines are subject to cyclic loading and fatigue stress. Sustained pressure drift or transient instability may indicate regulator malfunction, restriction, or seal degradation.
Continuous pressure monitoring enables earlier detection of deviation patterns. This supports inspection prioritization before anomalies escalate.
SENSAiO does not replace control transmitters or leak detection systems and does not perform mass balance calculations. It provides monitoring data for engineering review.
3) Hydrogen Storage Overpressure Monitoring
Hydrogen storage vessels operate under strict pressure limits. Additional distributed monitoring can provide event timestamps and trend context.
Monitoring supports investigation of pressure deviation patterns and improved correlation with operational changes.
SENSAiO does not replace certified pressure relief devices, tank protection systems, or regulatory safety instrumentation. It provides visibility only.
4) Hydrogen Purification Filter Differential Pressure Monitoring
Hydrogen purification systems often include particulate or membrane filtration. Progressive restriction increases differential pressure over time.
Continuous DP monitoring supports tracking of restriction rate-of-change and optimized maintenance scheduling.
Differential pressure monitoring does not identify contaminant type or membrane degradation mechanism. It provides resistance trend visibility requiring interpretation.
5) Hydrogen Compressor Vibration Monitoring
Hydrogen compressors operate under high rotational speed and pressure. Bearing wear, imbalance, and structural stress generate measurable vibration deviation.
Vibration monitoring establishes baseline behavior and highlights progressive change.
SENSAiO does not provide automated fault diagnosis or predict failure timing. It supports condition-based maintenance planning.
6) Hydrogen Vent Line Acoustic Monitoring
Hydrogen vent systems manage controlled discharge events. Abnormal acoustic patterns may indicate instability or unintended release.
Acoustic monitoring detects changes in sound energy that may correlate with such events.
SENSAiO does not measure hydrogen concentration, confirm leak rate, or replace certified gas detection systems. It provides anomaly indicators requiring engineering assessment.
How SENSAiO Technology Works
| Open Wireless Architecture | LoRaWAN enables distributed monitoring across hydrogen facilities without expanding signal cabling. Transmission intervals are configurable. Network validation remains site-specific. |
| Sensor Design | Industrial battery-powered sensors measure valve position, pressure, differential pressure, vibration, acoustic behavior, and temperature where required. Devices transmit measurement data only and do not execute control logic. |
| Integration | SENSAiO integrates alongside DCS, SCADA, and reliability systems without modifying control architecture. It is not a component of Safety Instrumented Systems. |
| Data Intelligence | Baseline establishment and deviation detection support earlier investigation. Indicators highlight measurable change but do not provide automatic diagnosis. |
ATEX Compliance and Safety
Hydrogen infrastructure frequently includes hazardous areas due to hydrogen’s low ignition energy and wide flammability range.
SENSAiO devices are designed for deployment in hazardous areas in accordance with:
- ATEX Directive 2014/34/EU
- IECEx certification scheme
Certification applies to equipment category and protection concept defined in product documentation.
Hazardous-area classification, equipment selection, and installation responsibility remain entirely with the operator.
SENSAiO sensors are intrinsically safe monitoring instruments intended exclusively for condition visibility. They do not:
- Replace hydrogen leak detection systems
- Replace Safety Instrumented Systems
- Replace pressure relief devices
- Provide risk reduction credit under IEC 61508 / IEC 61511
- Function as engineered protection layers
They contribute to safer operations by improving anomaly visibility—not by replacing certified safety mechanisms.
Proven ROI and Field Results
In hydrogen infrastructure, ROI is driven by earlier anomaly detection and improved maintenance timing.
Potential Value Areas
- Reduced compressor unplanned intervention
- Earlier identification of pressure instability
- Optimized purification filter maintenance
- Faster vent anomaly investigation
- Reduced configuration errors during routing transitions
Conservative, Site-Dependent Performance Ranges
Operators may observe:
- 10–30% reduction in non-critical verification trips
- 15–35% earlier identification of mechanical degradation trends
- 10–25% increase in maintenance planning lead time
- 20–40% faster anomaly investigation cycles
These ranges are indicative and depend on deployment density and operational discipline. SENSAiO does not eliminate hydrogen leakage risk or replace safety systems. It supports earlier evidence-based intervention.
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.
General & Functionality
No items found.
Specific Technical Questions/
Hydrogen Infrastructure
No items found.
Protect Critical Hydrogen Infrastructure
Deploy ATEX-certified wireless sensors to continuously monitor pressure, temperature, and leak conditions across hydrogen production and storage systems.
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