Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Dust Collector Differential Pressure Monitoring (ATEX)
Dust loading trend tracking
Differential Pressure (ΔP)
Quick Overview
| Problem | Dust collectors are critical for air quality and explosion risk management, but filter condition is not always continuously monitored. |
| Solution | SENSAiO differential pressure sensors monitor pressure drop across dust filtration systems. |
| Value | Improved visibility on filter loading and airflow restriction, supporting earlier identification of abnormal filtration conditions. |
| ATEX | Designed for explosive dust environments (Zone 20/21/22), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Dust collectors are widely used in mining and metals operations to:
- Capture airborne particulate matter
- Maintain air quality
- Reduce explosion risks associated with combustible dust
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These systems rely on filters (e.g., bag filters, cartridges) to separate dust from airflow.
From a physical perspective:
- Air passing through a clean filter creates a baseline pressure drop
- As dust accumulates, resistance increases, leading to higher differential pressure
- Excessive loading may reduce airflow and affect system efficiency
Typical issues include:
- Progressive filter clogging
- Filter damage or rupture
- Ineffective cleaning cycles (e.g., pulse-jet malfunction)
- Uneven dust distribution across filter banks
Detection challenges include:
- Limited continuous instrumentation on distributed collectors
- Reliance on periodic inspection or manual gauges
- Difficulty identifying early-stage clogging or localized failures
- Lack of centralized visibility across multiple units
As a result, filtration performance degradation may remain undetected until it impacts operations.
Why Differential Pressure Monitoring Matters
Differential pressure across the filter is a direct indicator of filtration condition.
By continuously monitoring differential pressure:
- Filter loading trends can be tracked
- Cleaning efficiency can be evaluated
- Abnormal conditions can be detected earlier
Typical interpretations include:
- Increasing differential pressure may indicate filter clogging or ineffective cleaning
- Sudden decrease in differential pressure may indicate filter rupture or bypass
- Fluctuating pressure may correlate with unstable cleaning cycles
Differential pressure reflects the physical resistance to airflow through the filter media.
Sensa.io Solution
SENSAiO deploys wireless differential pressure sensors installed across:
- Filter inlet and outlet points
- Individual filter sections or entire collector units
Sensors measure pressure difference and transmit data via LoRaWAN to a centralized platform.
The system provides:
- Continuous differential pressure monitoring
- Trend analysis of filter condition
- Alerts on abnormal pressure deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control cleaning cycles or airflow
- It does not regulate dust collection systems
- It does not replace explosion protection systems or safety controls
The system supports maintenance planning and operational awareness.
Results and ROI
ATEX Compliance and Safety
Dust collectors often operate in explosive dust atmospheres. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 20/21/22
- Are designed for operation in combustible dust environments
- Can be installed on filtration systems and ducting
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace explosion protection measures such as venting, suppression, or isolation systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with environmental and maintenance monitoring platforms |
| Deployment | Suitable for retrofit on existing dust collectors |
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
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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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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.
