Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Block Valve Station Pressure Monitoring
Earlier detection of abnormal deviations and improved event localization
Pressure
Quick Overview
| Problem | Block valve stations are critical isolation points, but local pressure conditions are not always continuously monitored. |
| Solution | SENSAiO pressure sensors provide continuous monitoring of upstream and downstream pressure at valve stations. |
| Value | Improved visibility on pipeline conditions at isolation points, supporting faster identification of abnormal situations. |
| ATEX | Designed for hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Block valve stations are installed along pipelines to allow isolation of specific sections for maintenance or emergency response.
Under normal operation, pressure conditions upstream and downstream of a closed or open valve should follow expected profiles depending on flow conditions.
However, several abnormal situations may occur:
- Pressure imbalance across a closed valve
- Unexpected pressure drop downstream
- Pressure buildup upstream due to flow restriction
- Leakage across a valve that is intended to be closed
These conditions can be difficult to detect because:
- Valve stations are often located in remote areas
- Instrumentation is limited or non-existent at these points
- Pressure data is typically available only at major facilities (pump stations, terminals)
As a result, deviations at valve stations may go unnoticed until they manifest elsewhere in the system.
Why Pressure Monitoring at Valve Stations Matters
Pressure measurement at block valve stations provides direct insight into local pipeline conditions.
Monitoring both upstream and downstream pressure enables:
- Detection of abnormal pressure differentials across the valve
- Identification of pressure drops that may indicate downstream issues
- Observation of pressure buildup that may result from flow restrictions
- Verification of pressure equalization during operational sequences
Typical interpretations include:
- A sustained pressure difference across a closed valve may indicate leakage through the valve
- A pressure drop downstream may correlate with a leak or flow restriction
- Unexpected pressure increase upstream may reflect blockage or operational constraints
These measurements help operators understand how the pipeline behaves locally at critical isolation points.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors at block valve stations, typically installed:
- Upstream of the valve
- Downstream of the valve
Sensors continuously measure pressure and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Real-time visibility on pressure conditions at valve stations
- Historical pressure trends for analysis
- Detection of deviations from expected pressure relationships
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control valve operation
- It does not confirm valve sealing integrity
- It does not replace pipeline integrity or safety systems
The data supports investigation and operational decision-making.
Results and ROI
ATEX Compliance and Safety
Block valve stations are typically located in hazardous environments due to the presence of hydrocarbons. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for remote outdoor installations
- Are designed to operate under harsh environmental conditions
All equipment is supplied with relevant certification and installation documentation.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with SCADA and pipeline monitoring systems |
| Deployment | Suitable for retrofit at existing valve stations or integration into new infrastructure |
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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The SENSAiO 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, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
