Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Biogas Upgrading Differential Pressure Monitoring
Filter loading and restriction progression visibility
Differential Pressure (ΔP)
Quick Overview
| Problem | Filtration and upgrading stages in biogas treatment are not always continuously monitored for pressure drop, limiting visibility on fouling or restriction. |
| Solution | SENSAiO differential pressure sensors monitor pressure drop across upgrading and filtration systems. |
| Value | Improved detection of clogging, fouling, or abnormal flow resistance through pressure differential trends. |
| ATEX | Designed for biogas environments, compliant with ATEX / IECEx requirements for explosive gas atmospheres. |
The Operational Challenge
Biogas upgrading systems are used to:
- Remove impurities (CO₂, H₂S, moisture, particles)
- Improve gas quality for injection or use
- Protect downstream equipment
These systems often include:
- Filters
- Membrane systems
- Scrubbers or adsorption units
From a physical perspective:
- Gas flows through media or equipment that create resistance
- This resistance results in a pressure drop between inlet and outlet
- The differential pressure (ΔP) reflects flow conditions and system cleanliness
Typical issues include:
- Filter clogging due to particulates
- Fouling of membranes or adsorption media
- Condensation or liquid accumulation
- Flow restriction within the system
Detection challenges include:
- Limited instrumentation across all stages
- Gradual pressure increase difficult to detect manually
- Variability in operating conditions
- Lack of continuous trend analysis
As a result, degradation of upgrading performance may not be immediately visible.
Why Differential Pressure Monitoring Matters
Differential pressure is a key indicator of system condition.
By continuously monitoring ΔP:
- Flow resistance can be tracked
- Fouling or clogging can be identified
- Performance degradation can be observed over time
Typical interpretations include:
- Increasing ΔP may indicate fouling or blockage
- Stable low ΔP may indicate normal operation
- Sudden ΔP changes may correlate with process disturbances
Differential pressure reflects how easily gas flows through the upgrading system.
SENSAiO Solution
SENSAiO deploys wireless differential pressure sensors installed across:
- Filters
- Membrane units
- Gas treatment stages
Sensors measure pressure at two points (upstream and downstream) and transmit data via LoRaWAN to a centralized platform.
The system provides:
- Continuous differential pressure monitoring
- Trend analysis for fouling detection
- Alerts on abnormal pressure drop behavior
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control upgrading processes
- It does not clean or regenerate filters or media
- It does not optimize gas treatment automatically
The system supports operational awareness and maintenance planning.
Results and ROI
ATEX Compliance and Safety
Biogas upgrading systems operate in explosive gas atmospheres. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Are suitable for hazardous gas environments
- Are designed for industrial use in classified zones
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace gas treatment protections, safety valves, or regulatory requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with biogas upgrading and maintenance platforms |
| Deployment | Suitable for retrofit on existing filtration and upgrading systems |
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.
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Trusted by a Worldwide Network
With partners in over 20 countries, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
