Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Dust Filtration Differential Pressure Monitoring (ATEX)
Dust loading trend visibility and maintenance optimization
Differential Pressure (ΔP)
Quick Overview
| Problem | Dust filtration systems can progressively clog, but differential pressure is not always continuously monitored at all critical نقاط. |
| Solution | SENSAiO differential pressure sensors monitor pressure drop across dust filters in real time. |
| Value | Improved visibility on filter loading conditions, supporting earlier detection of clogging or abnormal behavior. |
| ATEX | Designed for explosive dust environments (Zone 20/21/22), compliant with ATEX / IECEx requirements. |
The Operational Challenge
In chemical and petrochemical facilities, dust filtration systems are used to:
- Capture fine particles from process air or gas streams
- Prevent dust release into equipment or atmosphere
- Reduce explosion risks associated with combustible dust
Over time, filters accumulate particles, leading to:
- Increased resistance to flow
- Progressive pressure drop across the filter media
- Reduced filtration efficiency or flow capacity
From a physical standpoint:
- Differential pressure (ΔP) represents the resistance to flow across the filter
- As dust accumulates, ΔP increases
- Sudden drops in ΔP may indicate filter rupture or bypass
Key operational risks include:
- Excessive clogging leading to reduced airflow
- Structural stress on filter elements
- Inefficient cleaning cycles
- Undetected filter failure
Detection challenges include:
- Filters distributed across large installations
- Limited instrumentation on secondary units
- Manual inspection intervals
- Lack of continuous trend visibility
As a result, filter degradation or failure may not be detected early.
Why Differential Pressure Monitoring Matters
Differential pressure is the primary indicator of filter condition.
By continuously monitoring ΔP:
- Baseline clean filter conditions can be established
- Progressive clogging can be tracked over time
- Abnormal behavior can be detected
Typical interpretations include:
- Gradual ΔP increase may indicate normal dust accumulation
- Accelerated ΔP rise may correlate with process upset or high dust load
- Sudden ΔP drop may indicate filter damage or bypass
Differential pressure provides a direct measurement of filtration performance.
SENSAiO Solution
SENSAiO deploys wireless differential pressure sensors installed across dust filtration units.
Sensors measure pressure upstream and downstream of the filter and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous ΔP trend monitoring
- Detection of abnormal pressure behavior
- Alerts based on thresholds or deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control cleaning cycles or filtration systems
- It does not automatically diagnose filter condition
- It does not replace safety or explosion protection systems
The system supports condition visibility and maintenance planning.
Results and ROI
ATEX Compliance and Safety
Dust filtration systems often operate in explosive dust atmospheres. SENSAiO sensors:
- Are available with ATEX / IECEx certification for dust zones (20/21/22)
- Are suitable for installation in hazardous dust environments
- Are designed for industrial filtration applications
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 plant monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing filtration systems |
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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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.
