Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Cryogenic Valve Position Verification
Reduced misalignment risk during transfer and isolation
Valve position
Quick Overview
| Problem | The actual position of cryogenic valves is not always continuously verified, especially in remote or hazardous LNG areas. |
| Solution | SENSAiO valve position sensors provide continuous monitoring of valve open/closed status. |
| Value | Improved operational visibility, reducing uncertainty in valve state during LNG operations. |
| ATEX | Suitable for LNG hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Cryogenic valves are critical components in LNG infrastructure, used to control flow in:
- Transfer lines
- Storage systems
- Boil-off gas handling lines
- Process isolation points
Correct valve positioning is essential for:
- Maintaining proper flow paths
- Ensuring safe isolation during operations or maintenance
- Avoiding unintended flow or pressure buildup
However, several factors can affect valve position awareness:
- Manual operation without continuous feedback
- Limited instrumentation in remote areas
- Harsh cryogenic conditions affecting mechanical behavior
- Human error during operation
From a physical standpoint:
- A valve that is partially open may restrict flow and create pressure drop
- A closed valve in a flowing system may lead to pressure buildup upstream
- Incorrect alignment of valves can disrupt process flow
Detection challenges include:
- Lack of real-time confirmation of valve position
- Reliance on manual checks or control room assumptions
- Inaccessibility of valves in hazardous or cryogenic zones
As a result, discrepancies between intended and actual valve position may persist.
Why Valve Position Monitoring Matters
Valve position is a discrete but critical operational parameter.
By continuously verifying valve state:
- Operators can confirm that flow paths are correctly configured
- Unexpected changes in valve position can be detected
- Operational sequences can be validated
Typical interpretations include:
- A valve reported as open but physically closed may indicate mechanical or operational discrepancy
- A partially actuated valve may correlate with abnormal pressure or flow behavior
- Unexpected valve movement may indicate external intervention or mechanical issues
Valve position data provides a direct indication of system configuration.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors mounted directly on cryogenic valves.
Sensors detect valve state (open / closed or position change) and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous valve position monitoring
- Real-time visibility of valve state across LNG infrastructure
- Alerts on unexpected position changes
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not actuate or control valves
- It does not enforce interlocks or safety logic
- It does not replace control or safety systems
The system supports verification 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 suitable for installation on cryogenic valves
- Are designed to operate in harsh LNG conditions
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace valve interlocks, emergency shutdown systems, 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 LNG operation and maintenance platforms |
| Deployment | Suitable for retrofit on existing cryogenic valves |
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.
