Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Cryogenic Filter Differential Pressure Monitoring
Restriction progression tracking
Differential Pressure (ΔP)
Quick Overview
| Problem | Filter fouling in cryogenic systems develops progressively and may not be continuously monitored. |
| Solution | SENSAiO differential pressure sensors track pressure drop across cryogenic filters in real time. |
| Value | Improved visibility on filter loading, supporting earlier detection of restriction and maintenance planning. |
| ATEX | Suitable for LNG and cryogenic hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Cryogenic filtration is used in LNG systems to protect downstream equipment by removing:
- Solid contaminants
- Ice particles or hydrates
- Process debris
Filters are typically installed in:
- LNG transfer lines
- Pump suction or discharge lines
- Boil-off gas handling systems
During operation, particles accumulate on the filter media, leading to:
- Progressive restriction of flow
- Increase in upstream pressure
- Decrease in downstream pressure
This results in a rising differential pressure (ΔP) across the filter.
Cryogenic conditions introduce additional complexities:
- Low temperatures affect fluid properties (density, viscosity)
- Potential formation of ice or hydrates increases fouling risk
- Material contraction may influence sealing and flow paths
Detection challenges include:
- Gradual fouling progression
- Limited instrumentation at filter level
- Distributed assets across LNG facilities
- Manual readings at low frequency
As a result, filters may become partially blocked before detection.
Why Differential Pressure Monitoring Matters
Differential pressure is a direct measure of resistance to flow across the filter.
By continuously monitoring ΔP:
- Clean filter baseline conditions can be established
- Fouling trends can be tracked over time
- Deviations from expected behavior can be identified
Typical interpretations include:
- A gradual increase in ΔP may indicate normal particle accumulation
- A rapid increase may suggest accelerated fouling or blockage
- A sudden decrease in ΔP may indicate bypass, media damage, or leakage
ΔP provides a physically meaningful and direct indicator of filter condition.
SENSAiO Solution
SENSAiO deploys wireless differential pressure sensors installed across filter inlet and outlet points.
Sensors continuously measure ΔP and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous monitoring of differential pressure trends
- Detection of abnormal increases or deviations
- Alerts based on threshold exceedance or unusual patterns
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not determine optimal replacement timing automatically
- It does not control process flow or filtration systems
- It does not diagnose the specific cause of fouling
The system supports maintenance planning and operational awareness.
Results and ROI
ATEX Compliance and Safety
Cryogenic LNG environments are classified hazardous due to flammable gas presence. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for operation in low-temperature and gas-rich environments
- Can be installed on process piping associated with filtration systems
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace filtration safeguards or process protection systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with LNG monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing cryogenic filters |
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.
