Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Digester Pressure Monitoring
Early detection of abnormal gas production or dome stress
Pressure
Quick Overview
| Problem | Pressure inside anaerobic digesters is not always continuously monitored, limiting visibility on gas accumulation and process imbalance. |
| Solution | SENSAiO pressure sensors provide continuous monitoring of digester internal pressure. |
| Value | Improved detection of abnormal pressure behavior, supporting earlier identification of gas buildup, restriction, or imbalance. |
| ATEX | Designed for biogas environments, compliant with ATEX / IECEx requirements for explosive gas atmospheres. |
The Operational Challenge
Anaerobic digesters produce biogas through biological activity. This gas accumulates in the digester headspace before being:
- Transferred to storage systems
- Sent to upgrading units
- Consumed by engines or flares
From a physical perspective:
- Gas production increases internal pressure
- Pressure depends on gas generation rate and extraction capacity
- Any imbalance between production and removal affects pressure levels
Typical operational conditions include:
- Continuous gas generation
- Variable extraction rates
- Influence of temperature and substrate characteristics
Common issues include:
- Gas accumulation due to insufficient withdrawal
- Restriction in gas lines leading out of the digester
- Malfunction of downstream equipment
- Overpressure or underpressure conditions
Detection challenges include:
- Limited instrumentation within or on digesters
- Reliance on local indicators or periodic checks
- Difficulty identifying gradual pressure changes
- Lack of continuous monitoring data
As a result, pressure deviations may not be detected early.
Why Pressure Monitoring Matters
Pressure is a direct indicator of gas behavior within the digester.
By continuously monitoring pressure:
- Gas production and extraction balance can be assessed
- Deviations from normal operation can be identified
- Trends indicating buildup or drop can be observed
Typical interpretations include:
- Increasing pressure may indicate gas accumulation
- Decreasing pressure may indicate excessive withdrawal or leakage
- Fluctuating pressure may correlate with process instability
Pressure data reflects the dynamic interaction between biological production and gas handling systems.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors installed on:
- Digester headspace points
- Gas exit lines
- Associated piping systems
Sensors measure pressure and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous pressure monitoring
- Trend analysis over time
- Alerts on abnormal pressure deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control gas extraction or process conditions
- It does not regulate pressure inside the digester
- It does not replace safety systems such as pressure relief devices
The system supports operational awareness and earlier investigation.
Results and ROI
ATEX Compliance and Safety
Digesters operate in explosive biogas atmospheres.SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Are suitable for hazardous gas environments
- Are designed for industrial classified zones
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace pressure relief systems, gas safety systems, or regulatory requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with biogas monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing digesters and gas 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.
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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
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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
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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.
