Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Cargo Transfer Valve Position Monitoring
Reduced configuration errors during loading operations
Valve position
Quick Overview
| Problem | Valve positions in cargo transfer systems are not always continuously verified, creating uncertainty during critical operations. |
| Solution | SENSAiO valve position sensors provide continuous monitoring of valve open/closed status. |
| Value | Improved visibility of valve states, supporting operational verification and reducing configuration errors. |
| ATEX | Available in ATEX / IECEx versions for hazardous cargo and fuel transfer environments. |
The Operational Challenge
Cargo transfer systems in marine and port environments rely on complex valve networks to:
- Route fluids between tanks, pipelines, and vessels
- Isolate sections during maintenance or emergency
- Control flow paths during loading and unloading
From a physical standpoint:
- Valves act as mechanical barriers or flow regulators
- Their position directly determines whether fluid can pass through a line
Typical issues include:
- Incorrect valve alignment during transfer operations
- Valves left partially open or closed unintentionally
- Manual valve operations without centralized verification
- Miscommunication between operators in distributed systems
These issues can lead to:
- Flow disruption
- Incorrect routing of cargo
- Increased operational risk
Detection challenges:
- Valve position is often verified manually
- Visual confirmation may not be possible for remote or inaccessible valves
- Control room visibility may not include all manual valves
- Errors may only be detected after operational impact
Why Valve Position Monitoring Matters
Valve position directly defines system configuration.
By monitoring valve position:
- Line routing can be verified in real time
- Operational configurations can be validated
- Deviations from expected states can be identified
Typical interpretations include:
- Valve reported open when expected closed may indicate configuration error
- Unexpected state change may indicate human intervention or mechanical issue
- Stable position confirms consistency with operational plan
Valve position data provides discrete but critical insight into system status.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors installed on:
- Manual valves
- Actuated valves
- Critical isolation points
Sensors detect valve position (open/closed state) and transmit data via LoRaWAN to a centralized monitoring platform.
The system enables:
- Continuous visibility of valve states
- Remote verification of system configuration
- Alerts on unexpected position changes
Clarifications:
- SENSAiO is a monitoring-only system
- It does not actuate or control valves
- It does not enforce interlocks or sequencing
- It does not replace control systems or safety logic
It provides data to support operational verification.
Results and ROI
ATEX Compliance and Safety
Cargo transfer operations involve flammable fluids and hazardous atmospheres. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Suitable for Zone 1 / Zone 2 installations depending on configuration
- Designed for marine and industrial environments
The system does not provide safety interlocks, not trigger shutdown actions or not replace certified safety systems
It complements operational procedures with additional monitoring data.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard industrial LoRaWAN infrastructure |
| Systems | Integration with terminal management and SCADA systems |
| Deployment | Retrofit on existing valves without modification of process flow |
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.
