Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Burner Fuel Pressure Monitoring
Improved stability visibility and faster investigation of combustion anomalies
Pressure
Quick Overview
| Problem | Fuel pressure instability at burners can affect combustion quality and is not always continuously monitored at the point of use. |
| Solution | SENSAiO pressure sensors monitor fuel supply pressure to burners in real time. |
| Value | Improved visibility on fuel delivery conditions, supporting earlier detection of pressure deviations. |
| ATEX | Suitable for hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Burners are used in furnaces, heaters, and process units to generate controlled heat through fuel combustion.
Proper combustion depends on maintaining stable fuel supply conditions, including:
- Consistent fuel pressure
- Correct air-to-fuel ratio
- Stable flow regime
Fuel is typically supplied through distribution headers and control valves to multiple burners.
Several issues may affect fuel pressure at the burner level:
- Pressure drops due to upstream restrictions or valve issues
- Fluctuations caused by demand variations across multiple burners
- Partial blockage or fouling in fuel lines
- Regulator or control valve instability
From a physical perspective, pressure variations impact:
- Fuel flow rate delivered to the burner
- Atomization quality (for liquid fuels)
- Mixing conditions with combustion air
Detecting these deviations is challenging because:
- Pressure is not always measured at each burner
- Variations may be transient or localized
- Control systems may only monitor header-level conditions
- Manual checks are limited
As a result, combustion performance issues may not be immediately linked to pressure instability.
Why Pressure Monitoring Matters
Pressure is a direct indicator of fuel supply conditions at the burner.
By continuously monitoring pressure:
- Stable operating ranges can be established
- Deviations and fluctuations can be detected
- Pressure trends can be analyzed over time
Typical interpretations include:
- A pressure drop may indicate restriction, valve malfunction, or upstream supply limitation
- Pressure fluctuations may correlate with unstable control behavior or varying demand
- Sustained low pressure may impact combustion efficiency
Pressure data provides a direct and measurable insight into burner fuel supply behavior.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors installed on fuel lines close individual burners or burner groups.
Sensors continuously measure pressure and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous pressure trend monitoring
- Detection of abnormal pressure deviations
- Alerts based on thresholds or abnormal patterns
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control fuel flow or combustion systems
- It does not regulate burner performance
- It does not replace burner management or safety systems
The system supports operational awareness and troubleshooting.
Results and ROI
ATEX Compliance and Safety
Burner systems operate in environments with flammable fuels and gases. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for installation on fuel gas or liquid lines
- Can operate in high-temperature industrial environments
All equipment is provided with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace burner management systems, interlocks, or regulatory safety requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with plant monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing burner fuel lines |
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 SENSAiO 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
SENSAiO’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 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.
